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CHAPTER 1

INTRODUCTION

AAC was invented in mid-1923 in Sweden. It is also known as Autoclaved Cellular

Concrete (ACC) or Autoclaved Ligtweigt Concrete (ALC). !roduction "rocess o#

AAC is #airl$ sim"le. It is made wit made wit a mi%ture o# #l$ as& lime& cement&

g$"sum& an aeration agent and water. Aeration "rocess& im"arts it a cellular ligt-weigt

structure. AAC "roducts are "recast in various si'es and "rovide structure& insulation&

and #ire and mold resistance.

AAC "roducts are o##ered in various sa"es and si'es including ut not limited to

locks& wall "anels& #loor and roo# "anels& and lintels. se o# Autoclaved Aerated

Concrete (AAC) locks in construction industr$ in India o##ers interesting "ro"osition

#or various segments in te societ$. *or a "ro+ect develo"er it means #aster and lower

cost construction. *or environmentall$ conscious it means eco-#riendl$ "roducts and #or

tose wo occu"$ uildings uilt wit AAC locks it means etter sa#et$ and lower

energ$ costs #or cooling or eating. !rimar$ raw material #or AAC is #l$ as.

,ousands o# tonnes o# #l$ as is generated $ termal "ower "lants ever$da$

and its dis"osal is a cause o# concern. oreover& using #l$ as does not arm te

environment at all. In #act using #l$ as takes care o# issues related to dis"osal o# #l$ as.

,ere#ore $ using #l$ as to "roduce AAC "roducts "rovides a sustainale& economic

and environment #riendl$ o"tion. At te end it all translates to a etter world #or #uture

generations.

1

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Types of Aerocon bricks

ne interesting as"ect o# Aerocon rick is tat it lets te user uild te walls o# wit te

tickness o# is coice. Contrar$ to te wall made $ traditional ricks& walls made

wit Aerocon ricks are tinner ut are still sustainale.

/owever& de"ending on di##erent various needs o# internal and e%ternal walls&

Aerocon ricks are availale in di##erent si'es and varied tickness as #ollows. Aerocon

ricks are currentl$ availale in tree si'es0 In#ill& umo& and ,ermal locks

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Infill blocks

,e si'e o# te In#ill Aerocon rick is 4 mm and te tickness varies in te

ranges o# 56&1&126&16&2 mm. ,e main advantage o# In#ill locks is tat te$ caneasil$ re"lace 7 o# te concrete in roo# slas and tus el" in saving signi#icant

amounts o# concrete& steel& laor& water& "laster etc. ,ese locks are es"eciall$ suitale

#or uilding roo#s in large column-#ree constructions.

Jumbo blocks

umo locks are t$"icall$ in te si'e o# 43 mm& and tickness ranges #rom

56&1&126&16& to 2 mm. ,e uni8ue large si'e o# umo Aerocon ricks results in

te usage o# muc #ewer ricks and ence less mortar is re8uired. ,ese ricks are more

suitale #or non-load earing walls& multi-storeid uildings etc.

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Therml blocks

,ese locks are also called as Aerocool termal locks wose si'e and tickness is342 mm and 6 mm res"ectivel$. ,ese locks are ideal #or roo#ing since te$

dela$ te transmission o# eat #low and also el" interiors remain warm during winters

and cool during summers.

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CHAPTER !

CO"PARI#ION $ET%EEN AEROCON $RIC AND

C'A( $RIC

Comprison be)*een Prme)er AAC $locks Cly $ricks

Au)ocl+e, Aer)e,

Concre)e -AAC.

blocks n, cly

bricks #eril

1 Soil Consum"tion ses #l$ as wic is a ne s8 #t o# car"ettermal "ower "lant area wit cla$ rick

waste "roduct tus walling will consume

no consum"tion o# to" 26.6 kg o# to" soil

soil

2 *uel Consum"tion ne s8 #t o# car"et ne s8 #t o# car"et

area wit AAC locks area wit cla$ rickswill consume 1 kg o# will consume : kg o#

coal coal

3 C2 ;mission ne s8 #t o# car"et ne s8 #t o# car"etarea will emit 2.2 kg o# area will emit 15. kg

C2 o# C2

< Laour rgani'ed sector wit norgani'ed sector

"ro"er /= "ractices wit ram"ant use o#

cild laour

6 !roduction *acilit$ State-o#-te-art #actor$ nealt$ working

#acilit$ conditions due to

to%ic gases

,a% Contriution Contriutes to >oes not contriute

government ta%es in to government

#orm o# Central e%ce8uer ;%cise& ?A, and

ctroi

5 Si'e 26 mm % 2

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weigt leading to

savings in steel and

concrete

13 ;nerg$ Saving A""ro%.37 eating Bone

and cooling

The ,+n)/es of Aerocon blocks o+er con+en)ionl clybricks

1 Aerocon Dlocks are an innovative "roduct in te green uilding revolution.

2 Aerocon locks are te new locks in walling materials&sustituting conventional and environmentall$ unsustainale materialslike cla$ ricks& concrete and ollow locks.

3 ,e raw materials used in te manu#acture o# tese locks areenvironmentall$ #riendl$ and are certi#ied green "roducts. ,e asic rawmaterials used in "roduction o# Aerocon locks are Cement& *l$ as& lime andwater.

4

Aerocon locks can e "lastered& "ainted& and dr$ lined or tiled.

5 Aerocon lock is e%tremel$ ligt& +ust one-tird te weigt o# cla$ ricksor one-#ourt te densit$ o# =.C.C. ,e$ are muc easier to andle on te site.

6 ,e$ are eas$ to install and can com"lete te construction "rocedure in asorter s"an in case o# scarcit$ o# laour and in te usage o# mortars. ,ere8uired time to com"lete a uilding wit aerocon locks is 13 lesser tan tato# te conventional uilding materials.

7 ,e edges o# te locks are suc tat te$ allow eas$ workailit$ andaccurate dimensioning and are eas$ to cut& drill& nail& sa"e and case usingordinar$ wood working tools. !ower tools can e used #or ra"id casing #oremedding service lines.

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1 Aerocon locks can e cut virtuall$ in an$ sa"e or angle making teme%tremel$ ada"tale.

2Aerocon lock covers te same area as tat 1< cla$ ricks do enaling a#aster construction results in saving o# laour& time and material.

3 Aerated concrete is "er#ect uilding material #or an$ climate. It is used touild all kinds o# walls0 e%terior and interior earing and non-earing wallsoundation walls& "artition walls as #illing agent in #ramework structures& wall"artitions& #ire division walls& etc.

4 Aerocon e%cellent termal "ro"erties el"s in saving recurring energ$ costs

o# eating and cooling. ,e termal resistance comined wit te ene#its o#termal mass inertia and wole wall coverage eliminates te need #oradditional insulation.

5 Aerocon locks are availale in various si'es and sa"es.,e$ are availale in

tree t$"esE In#ill locks& umo locks and ,ermal locks. ,e$ are includedinto te categor$ o# Freen Duilding materials ecause te$ don t emit ?C

(?olatile rganic Com"ounds) wic cause environmental "ollution.

6 A"art #rom eing eco-#riendl$ tese locks are also ligt weigt wit igtermal insulation& #ire resistance& sound insulation& ave strengt and durailit$&ave consistent 8ualit$ control and gives a "er#ect #inis wit dimensional

stailit$. Duildings constructed out o# tese locks ensure long term

sustainailit$ and save a lot o# water during te construction.

7 ;%cluding te eco-#riendl$ caracteristics o# tese locks& te$ are also used

in construction #or various oter reasons. ,ere are a numer o# "rolems

involved in ac8uiring te sand and ricks and also te "rices o# tese asic

materials are iking u". As te traditional construction materials ave a iger

"rice te initiation o# Aerocon locks acts as etter sustitutes wit a##ordale

"rices. >ue to tese reasons te Aerocon locks are in great demand.

8 /ence& it is one o# te revolutionar$ materials tat can e used to make teworld a etter& greener and cleaner "lace to live in. It is a revolutionar$ materialtat

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comines te uni8ue "ro"erties suc as durailit$ and strengt& low weigt& ver$sim"le construction tecnolog$ and e%cellent environmental "er#ormance.

CHAPTER 0

DE#IN CON#IDERATION#

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8

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enerl consi,er)ions

AAC masonr$ com"onents(lock units) can e used to uild load earing or non loadearing walls.

1 -lock units used to uild "ilasters.

2

-lock units used to uild ond eams and lintels.3 Control +oints on AAC rein#orced walls must e "laced at ma%imum 1 #t.

o.c.

Ins)ll)ion ui,e1 Ceck #oundation.2 =eceiving and distriution o# AAC wall units.

Ins)ll)ion re2uiremen)s1 ,ools2 ;8ui"ment3 ter materials4 Installing -lock #or "ilasters in #irst course

'yin/ )he firs) course -le+ellin/ course.1 La$ te #irst course over a semi-dr$ cement mortar levelling ed- GH to 2H

tick.

2 Corner locks are laid #irst and te #irst course sould e com"leted

e#ore second course installation.3 nce corner locks are "laced a""l$ tin ed mortar& to te vertical +oints

#or oter locks.4 ,in ed mortar 11H inc to 1:H

Cu))in/ blocks -,3us)men)s n, chses.1 A and saw or and saw to cut te locks to s"eci#ic lengts.

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Plcin/ con)rol 3oin)s in firs) course

1 ,ese are vertical +oints taken troug te #ull wall tickness& and #romottom to to".

2 3:H to GH tick.3 a%imum s"acing etween control +oints sould e 16 #t.

'yin/ )he subse2uen) courses

1 *or suse8uent courses use onl$ tin ed mortaring on all +oints etweenAAC locks.

2 inimum overla""ing o# vertical +oints etween la$ers sould e

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U)ili)ies ins)ll)ion f)er )he *lls re buil)

1 *or electrical conduits and "i"ing installation& a case is cut using anelectrical router or a casing tool.

2 Jen re8uired de"t o# case is igger tan ma%imum de"t recommended&additional -locks are used to lodge te "i"es or interru"t wall continuit$.

3

A#ter installation& te case are #illed wit re"air mortar or cement sand mortar.

Ren,ers1 Sur#ace "atcing0

=as" lock +oints and oter areas were AAC sur#ace is out o# "lane.

1 Sur#ace must e cleaned using a scru rus and an$ loose or damagedmaterial e removed.

2 A ruer #loat is commonl$ used to smoot te wall sur#ace.

3 *ier glass mes0

,is sould e installed directl$ over one la$er o# render in all control

+oints& around windows& doors and utilit$ locations.

6inishes

1 AAC masonr$ walls can e #inised wit stucco & acr$lic te%ture coats& or acomination o# ot& also laminated stones& ceramic or cla$ tiles& concrete"ieces and ornamental "roducts5

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R* ")eril

6ly Ash or #n,

Ke$ ingredient #or manu#acturing AAC locks is silica ric material like #l$ as or sand.

ost o# te AAC com"anies in India use #l$ as to manu#acture AAC locks. *l$ as is

mi%ed wit water to #orm #l$ as slurr$. Slurr$ tus #ormed is mi%ed wit oter

ingredients like lime "owder& cement& g$"sum and Aluminum "owder in 8uantities

consistent wit te reci"e. Alternatel$ sand can also e used to manu#acture AAClocks. A wet all mill #inel$ grinds sand wit water converting it into sand slurr$.

Sand slurr$ is mi%ed wit oter ingredients +ust like #l$ as slurr$.

'ime Po*,er

Lime "owder re8uired #or AAC "roduction is otained eiter $ crusing limestone to

#ine "owder at AAC #actor$ or $ directl$ "urcasing it in "owder #orm. Altoug

"urcasing lime "owder migt e little costl$& man$ manu#acturers o"t #or it rater tan

investing in lime crusing e8ui"ment like all mill& +aw cruser& ucket elevators& etc.

Lime "owder is stored in silos #aricated #rom mild steel (S) or uilt using rick and

mortar de"ending o# individual "re#erences.

Cemen)

63-grade rdinar$ !ortland Cement (!C) #rom re"uted manu#acturer is re8uired #or

manu#acturing AAC locks. Cement su""lied $ mini "lants is not recommended due to

drastic variations in 8ualit$ over di##erent atces. Some AAC #actories migt "lan teir

ca"tive cement "rocessing units as suc an unit can "roduce cement as well as

"rocess lime. Suc #actories can o"t #or ma+or "lant clinker and manu#acture teir own

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cement #or AAC "roduction. Cement is usuall$ stored in silos.

ypsum

F$"sum is easil$ availale in te market and is used in "owder #orm. It is stored in silos.

Aluminum Po*,er7Ps)e

Aluminum "owder"aste is easil$ availale #rom various manu#acturers. As ver$ small

8uantit$ o# Aluminum "owder"aste is re8uired to e added to te mi%ture& it is usuall$

weiged manuall$ and added to te mi%ing unit.

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CHAPTER 8

PRODUCTION PROCE##

R* ")eril Prepr)ion n, #)or/e

,e #irst ste" o# AAC "roduction is grinding o# silica ric material (sand& #l$ as& etc) in

all mills. *or di##erent materials& di##erent "rocessing is ado"ted& suc as dr$ grinding

(into "owder)& wet grinding (into slurr$) or mi%ed grinding wit 8uicklime (Ca).

,ere are two metods #or mi%ed milling.

ne is dr$ mi%ing to "roduce inding material& and te oter metod is wet

mi%ing. Since most 8uicklime is agglomerate& it sould e crused and ten grinded.

F$"sum is normall$ not all milled se"aratel$. It is grinded wit #l$ as or wit

8uicklime& or it could e grinded wit te same miller #or 8uicklime in turn. ter

su""lementar$ and cemicals are also ave to e "re"ared. =aw material storage assures

te continuous "roduction and material stailit$.

,e continuous "roduction guarantees te non-sto" on-time su""l$& and te

material stailit$ guarantees te 8ualit$ o# "roducts& since te raw material migt come

#rom di##erent sources& wit di##erent 8ualities. =aw material "re"aration storage is

te "re-ste" #or "ro"ortioning atcing. ,is "re-ste" guarantees te raw material meette standard #or AAC "roduction& and it is also #inises te storage& omogeni'ation and

aging "rocess. It is te asic "rocess tat assures te smoot "roduction and "roduction

8ualit$.

Dosin/ n, mi9in/

aintaining ratio o# all ingredients as "er te selected reci"e is critical to ensure

consistent 8ualit$ o# "roduction. ,is is accom"lised $ using various control s$stems

to measure and release te re8uired 8uantit$ o# various raw materials. A dosing and

mi%ing unit is used to #orm te correct mi% to "roduce Autoclaved Aerated Concrete

(AAC) locks. *l$ assand slurr$ is "um"ed into a se"arate container.

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nce te desired weigt is "oured in& "um"ing is sto""ed. Similarl$ lime "owder&

cement and g$"sum are "oured into individual containers using screw conve$ers. nce

re8uired amount o# eac ingredient is #illed into teir individual containers control

s$stem releases all ingredients into mi%ing drum.

i%ing drum is like a giant owl wit a stirrer rotating inside to ensure "ro"er mi%ing

o# ingredients. Steam migt also e #ed to te unit to maintain tem"erature in range o#

osing unit releases tis mi%ture as "er

set 8uantities into molds #or #oaming.

>osing and mi%ing "rocess is carried out continuousl$ ecause i# tere is along ga" etween carging and discarging o# ingredients& residual mi%ture migt start

ardening and coke u" te entire unit. In modern "lants& entire dosing and mi%ing

o"eration is com"letel$ automated and re8uires minimum uman intervention.

,is entire o"eration is monitored using control s$stems integrated wit

com"uter and CC,? cameras. As wit an$ industrial o"eration& tere is "rovision #or

uman intervention and emergenc$ actions integrated inside te control s$stem.

Cs)in/: 6omin/ n, Pre4curin/

nce te desired mi% is read$& it is "oured into moulds. ,ese moulds can e o# various

si'es de"ending on te "roduction ca"acit$ o# a manu#acturing unit. nce mi% is

"oured into moulds& it is read$ #or "re-curing. A#ter casting& te slurr$ in molds will e

in te "re-curing camer to #inis #oaming and ardening. *oaming and ardening

actuall$ starts wen te slurr$ is #ed into molds& wic includes gas-#orming e%"ansion

and "er#orm& curing to acieve certain strengt& wic is enoug #or cutting. !re-curing

is alwa$s done under set tem"erature.

/ence it is also called as M/eating-room-"re-curing.H !re-curing as not a

com"licated "rocess& ut sould avoid viration. "erations must kee" e$es to monitor$ te

slur$ cange during #oaming and "rovide #eedack to dosing& mi%ing and casting "rocess.

!re-#orm de#ects (cracking& sinking& etc.&) mainl$ occur during te "rocess.

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Cu))in/

>uring tis "rocess& te "re-cured lock goes troug cutting and sa"ing& into di##erent

si'e sa"es as "er re8uirements. ,e ig workailit$ and large variet$ o# si'es make

AAC "roduction more suitale #or massive "roduction wit iger mecani'ation.

Cutting can e done mecanicall$ or manuall$. Jit a cutting macine& te "roduction

e##icienc$ and dimensional accurac$ is easil$ acieved.

Au)ocl+e, Curin/

A#ter cutting into te desired si'es sa"es& green AAC locks are trans#erred into

autoclaves. Autoclaves are used #or steam curing under "ressure. AAC must e "re-curedand steam cured to #inis te "$sical and cemical canges& and ten to acieve enoug

strengt #or desired usage. A atc o# AAC locks is steam cured #or 1-12 ours at a

"ressure o# 12 ar and tem"erature o# 19NC. In ot and umid conditions& AAC locks

undergo last stages o# $dro-termal s$ntesis reaction to trans#orm into a new "roduct

wit re8uired strengt and various "$sical "er#ormances. Autoclaved curing im"arts

inerent "ro"erties and "er#ormance o# AAC.

roupin/

Frou"ing could e te last ste" o# AAC "roduction (in some AAC "lant& te AAC will e

#urter "rocessed into "anels a#ter leaving autoclaves). A#ter te cured AAC leaves te

autoclaves& ins"ection and "ackaging is done.

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16

Process 6lo* Chr)5

6ly Ash ypsum 'ime OPC

Jater

*l$as Jeigt Jeigt Datced

Slurr$ Datced

Datced

!ouring

i%ture

to mi% ingredients

Dricks Casting on ould

>e-molding and Jire Cutting

/i!re

ssu

reSteam

Cur

ing#or

:

/ours

;c

o-

Dric

ks

=ead

$

#o

rSa

le

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"in

R* m)eril

Ouantit$

Aluminum

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CHAPTER ;

ANA'(#I#

"rke)

Selter is tird skin& according to a Ferman Conce"t& wic im"lies its im"ortance ne%t

to uman Skin and Cloting. ,is also sows te attacment o# uman race to tis

#undamental re8uirement.

Duilding aterial accounts #or ma+or com"onent o# te construction cost. >e"ending

on te location te$ can contriute to - 5 7 o# te cost o# construction. Jit te

ever increasing "o"ulation& te demand #or ousing increases. ,is directl$ creates

demand #or tis "rime commodit$ o# uilding.

Add to te aove #act te near$ area o# tis "ro+ect site is undergoing a ma+or

in#rastructure revolution. As =esidential& Commercial& I, com"anies& and Industrial

estalisments are coming in& we can conclude tat te Dlocks unit will "ros"er and

#louris in tis environment.

,ere is a central government gadget noti#ication mandating government

de"artments and C!J> to use 17 *l$ As ased Dricks in teir all constructions-

directl$ o# troug contractors. ,is #actor will el" te marketailit$ o# tis "roduct

immensel$.

*l$ As "olic$ o# te Fovernment also mandates tat 27 o# *l$ as Fenerated $ a

"ower "lant must e given #ree o# cost to S; sector on a "riorit$ asis.

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Crbon Cre,i)s Es)im)es

AAC locks are eing seriousl$ considered #or C> "ro+ects in India #or earning

Caron Credits. As te C;= Fenerated is also relativel$ less& #our or #ive suc unitscan e undled togeter to make a Frou" C> in te same sactors.

,is "ro+ect is likel$ to generate 1 C;= "er eac 5 or : Cuic eter o# Dlocks

"roduction& de"ending on& and su+ect to te C> metodolog$ ado"ted& and te

inter"retation o# additionalit$ and aseline "arameters $ te validating autorit$.

ust #or a roug estimate o# C;=S& #or an annual "roduction o# average si'e AAC

"lant& tat is 1CAnnum& we are likel$ to get around 126 C;=s on #ull

ca"acit$ !roduction. At "resent market rate o# 11.6 ;uros "er C;= and P =s. "er

;uro& we can e%"ect to get additional revenue on C;=. Dut we must e%"ect to take a

cut o# around 2 to 37 o# C;=s& i# we want to #orward sell te C;=s and get te

C> "art s"onsored $ te u$er

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R* ")eril #ui)bili)y

Almost 967 o# te raw materials can e made suitale #or AAC line troug "ro"er mi%

design. Also we can ave man$ di##erent mi% designs #or te same denicit$Qsame

strengt o# Dlocks. Je will el" $ou to get te Dest 8ualit$ locks at o"timal cost $

means o# designing "ro"er i% as "er $our in"ut raw materials.

,e #ollowing are asic guidelines (certainl$ not te #inal call) on te suitailit$ o#

asic raw materials #or AAC.

156ly sh -?.

In,e9 I)em r,e -?.

r4I r4II

(.egree o# amount) R 3

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20

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!5 'ime -@4!;?.

I)em r,e

#uper r5 1s)r5 !

n,r

A(Ca@g)Oualit$ *raction 7 9 56 6

g Oualit$ *raction 7 R 2 6 :

Si2 Oualit$ *raction 7 R 2 6 :

>igestion

s"eed 6-16&min R

>igestion tem"erature & -9

ndigested residue 8ualit$ #raction &7 R 6 13 16

*ineness (.: s8uare ole sieve le#t amount)7 R 1 16 2

C2 Oualit$ *raction 7 R 2 6 5

05 Cemen) -

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85 ypsum7Pls)er -04;?.

CaS< 57

g 27

Cloride .67

!re#eral$ ground residue 9Tm 1-167

;5 Aluminum Po*er -bou) >5>@?.

,$"e and recommendation #or su""l$ de"end on raw materials and mi% #ormula

etal Content A""ro%. UV67 !owder

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CHAPTER ue to ig #ire resistance o##ered $ AAC& structures made #rom AAC ave iger rate

o# survivailit$ in case o# #ire.

#oun, Insul)ion

Sound asor"tion "ro"erties o# AAC make it ideal material #or reducing amient noi

se.AAC is well-suited #or estalisments like os"itals and o##ices situated in nois$

areas.

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Con)ribu)ion )o N)ion

AAC #actories create man$ +os directl$ and indirectl$ creating a social im"act.

Along wit tat te$ "a

%e)her Resis)nceAAC does not deca$& rust& deteriorate or urn. AAC as een #ound to e eart8uake

resistant. AAC structures are known to maintain structural integrit$ in eav$ rains&

e%tremel$ low tem"erature and salt$ air.

Pes) Resis)nce

!rimar$ raw material used to manu#acture AAC is #l$ as. *l$ as (or "ond as) is an

inert material and does not allow termites or oter "ests to survive.

;%cise >ut$ and ?A, contriuting to national econom$

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Pro,uc) Dis,+n)/es

,e ma+or disadvantages o# autoclaved aerated concrete are listed elow.

1 ,e "roduction cost "er unit #or ACC is iger tan oter ordinar$concrete.

2 Bumer o# manu#acturer is limited. So& cost will drasticall$ increase in"laces #ar #rom te manu#acturer and need to travel a long distance.

3 It is not as strong as conventional concrete.

4 ?er$ #ew contractors wo are #amiliar wit ACC.

5 Construction wit autoclaved aerated concrete ma$ will need s"ecial

"ermission.

6 ;nvironmentall$ #riendl$

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CHAPTER @

CONC'U#ION

As a construction s$stem& AAC "rovide signi#icant environment and oterene#its #or te uilding owner. ,e sort and long term e##ect o# using AACcom"ared to man$ oter materials results in lower energ$ consum"tion&reduced o"erating costs& greater sa#et$ and com#ort& and a ealtier and moretroule #ree uilding. ,ese #eatures "rovide a etter investment #or uildingowner and #or environment.

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RE6ERNCE#

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