AUTOCLAVED AERATED CONCRETE (AAC) BLOCK MASONRY

GUDLINES FOR AAC BLOCK MASONRY

Laying Of Block Masonry
Ø Do not soak the blocks during laying. All surfaces of the blocks are to be moistened,
using wet brush or sponge, to prevent absorption of water from mortar. Best way to dip
and remove the blocks. (Refer IS6041-1985 Para 6, 6.1)
Ø Masonry work on RCC elements such as RCC beams should not be started till a minimum
of two weeks after striking off the shuttering.
Ø Before laying the first course, the alignment of the wall shall be marked on the damp-
proof course/ plinth beam. The blocks for this course shall first be laid dry, that is,
without mortar along a string stretched between properly located corners of the wall in
order to determine the correct position of the blocks including those of the cross walls
jointing it and also adjust their spacing. When the blocks are set in proper position, the
two corner blocks shall be removed, a mortar bed spread and these blocks laid back in
place truly level and plumb. The string shall then be stretched tightly along the faces of
two corner blocks and the faces of the intermediate ones adjusted to coincide with the
line. Thereafter, each block shall be removed and re-laid over a bed of mortar. After
every three or four blocks have been laid, their correct alignment, level and verticality
shall be carefully checked.
Ø The first course of the block work should be laid on a conventional 10-15mm thick 1:6
cement sand mortar.
Ø The first layer of cellular concrete block masonry on plinth should preferably have
groove/offset outside so that rain water coming down the wall falls out.
Ø The construction of walls may be started either at the corners first or started from one
end proceeding in the other direction. If the corners of the wall are built first, they shall
be built four or five courses higher than the centre of the wall. As each course is laid at
the corner, it shall be checked for alignment and level and for being plumb. Each block
1
 shall be carefully checked with a level or straight-edge to make certain that the faces of
the blocks are all in the same plane. This precaution is necessary to ensure truly straight
and vertical walls.
Ø At least 10mm gap must be provided between a concrete column and AAC wall and gap
must be filled with lean mortar.
Ø At least 15 to 20mm space be provided in between the beam and uppermost course and
gap must be filled with flexible backing rod and lean mortar.
Ø Closure Block -When installing the closure block, all edges of the opening and all four
edges of the closure block shall be buttered with mortar. The closure block shall be
carefully lowered into place. If any mortar falls leaving an open joint, the closure block
shall be removed, fresh mortar applied and the operation repeated.
Ø Maintain a regular bond pattern, based on minimum overlap of 100 mm or quarter
block, whichever is more.
Ø Once the masonry erected the curing shall be done for one week, brick masonry, unlike
brick masonry AAC blocks require curing mortar joints.
Mortar For Masonry
Ø The blocks shall be embedded with a mortar, the strength of which is relatively lower
than that of the mix used for making blocks in order to avoid the formation of cracks. A
1:6 cement – sand mortar may be used. (Refer IS 6041-1985 Para 3, 3.9.2)
Ø Preferably use PPC cement for best results.
Ø Mortar thickness
Cement sand mortar : 10 to 12 mm
Ready mix mortar : 3 to 4mm
(Refer IS 6041-1985 Para 7, 7.1)

2
Coping Beam
Ø Horizontal coping at sill level (at 900mm height) : 100mm thick
Reinforcement : Two no’s of 8 mm dia rods and 6 mm stirrups at 200 mm c/c
Concrete : M20 (1:1.5:3) concrete.
Ø Horizontal coping at lintel level or on the sides of lintel beam if throughout lintel beam is
not provided. : 100mm thick
Reinforcement : Two no’s of 8 mm dia rods and 6 mm stirrups at 200 mm c/c
Concrete : M20 (1:1.5:3) concrete.
Ø Vertical coping in centre if wall length is more than 3 m without break.
(Refer IS 6041-1985 Para 4, 4.6.5.1 & 2)
Storage
Ø The blocks shall be stored in such a way as to avoid any contact with moisture on the
site. They shall be stock piled on planks or other supports free from contact with the
ground and covered to protect against wetting. (Refer IS 6041-1985 Para 5, 5.1)
Plaster
Ø Plastering shall not be applied to the walls when wall is wet or in monsoon. The wall
shall be plastered only after they are fully dried (Refer IS 6041-1985 Para 12.1.1)
Ø It is recommended to use cement mortar 1:6 for internal & external plastering works
and preferably use PPC cement for masonry and plastering works to minimize shrinkage
cracks
Ø Plaster thickness required
Internal : 12mm
External : 15mm
(Refer IS 6041-1985 Para 12)
Lintels
Ø Precast or cast –in-situ concrete lintels can be used in block masonry, over all openings.
Ø Lintels shall always rest on full block with minimum bearing as under.

3
 Opening Size Upto 900 to 2000 2000 to 3000 Above 3000
900 mm mm mm mm
Minimum 150 mm 200 mm 300 mm To design
bearing
(each side)

Electric & Sanitary Chases

Ø Chase to be grooved before plaster of wall and use electric wall chasing machine for
zero vibration & good quality work, do not chase on joints. Depths of vertical chases
should be Limited to one-third of the wall thickness and horizontal chases to one-sixth
of the wall thickness. Holes in block wall can be made with a standard hand or electric
drill.
Beam & Column joints
Ø Use chicken wire mesh/fiber mesh for RCC-Masonry joints & coping.
Electric & Sanitary Chases
Ø Chase to be grooved before plaster of wall and use electric wall chasing machine for
zero vibration & good quality work, do not chase on joints. Depths of vertical chases
should be Limited to one-third of the wall thickness and horizontal chases to one-sixth
of the wall thickness. Holes in block wall can be made with a standard hand or electric
drill.

Precautions To Be Taken For Laying Of AAC Masonry:

The cracks occurring in block masonry and in plastering are of any structural problem
involving stability and safety to the structure. But it is advised to minimize the same to have
good appearance and maintenance free.
Ø Do not store the blocks on un leveled surface
Ø Do not use wet blocks for masonry construction
Ø Do not make the holes on block masonry for scaffolding supports
4
 Ø Do not soak the blocks before use
Ø Do not hammer the block masonry for service lines, chases etc
Ø Do not completely wet the block masonry before plastering works
Ø Do not chase the blocks back to back for lesser thickness blocks.
TESTING OF BLOCK

Ø Block Density : The block density shall be determined in the manner described in IS :
6441( Part 1 )- 1972*.
Ø Compressive Strength: The compressive strength shall be determined in accordance
with IS : 6441( Part 5 )-1972*.
Ø Thermal Conductivity: The thermal Conductivity shall be determined in accordance with
IS :3346-1980.
Ø Drying Shrinkage: The drying shrinkage shall be determined in the manner described in
IS : 6441 ( Part 2 )-I992.
SAMPLING
Ø Lot : In any consignment, all the blocks of the same size and from the same batch of
manufacture shall be grouped together into a minimum number of groups of 10 000
blocks or less. Each such group shall constitute a lot.
Ø From each lot a sample of 24 blocks shall be selected at random. In order to ensure
randomness of selection, all the blocks in the lot may be arranged in a serial order.
Starting from any random block every rth block may be selected till the requisite number
is obtained, r being the integral part of N/24, where N is the lot size.
Ø The required number of blocks shall be taken at regular intervals during the loading of
the vehicle or the unloading of the vehicle depending on whether sample is to be taken
before delivery or after delivery. When this is not practicable, the sample shall be taken
from the stack in which case the required number of blocks shall be taken at random

5
 from across the top of the stacks, the sides accessible and from the interior of the stacks
by opening trenches from the top.
Ø The sample of blocks shall be marked for future identification of the consignment it
represents. The blocks shall be kept under cover and protected from extreme conditions
of temperature, relative humidity and wind until. they are required for test. The tests
shall be undertaken as soon as practicable after the sample has been taken.
Number of tests
Ø All the 24 blocks shall be checked for dimensions and inspected for visual defects.
Ø Out of the 24 blocks, 12 blocks shall be subjected to the test for compressive strength, 3
blocks to the test for thermal conductivity, and 3 blocks to the test for drying shrinkage.
The remaining 3 blocks shall be reserved for re-test for drying shrinkage if a need arises.
Criteria for Conformity
Dimensions:
Ø The nominal dimensions of the concrete block shall be as follows:
Length - 400,500 or 600mm
Height - 200,250 or 360 mm
Width - 100,150,200 or 250 mm
In addition, block shall be manufactured in half lengths of 200,250 or 300 mm to
correspond to the full lengths.
Ø The maximum variation in the length of the units shall not be more than +/- 5 mm and
the maximum variation in the height and width of unit, not more than +/- 3 mm .
Ø Subject to the tolerances specified in above the faces of masonry units shall be flat and
rectangular, opposite faces shall be parallel, and all arises shall be square. The bedding
surface shall be at right angles to the faces of the blocks.
Block Density
Ø The mean value shall be within the range specified in Table 1.

6
Compressive Strength
Ø The mean value, say X shall be determined. The test results shall be grouped into groups
of 4 and individual values of ranges shall be determined and the average range a
calculated from these values and shall satisfy the following condition:
X - 0.6 R > minimum value specified in Table 1.
Thermal Conductivity:
Ø The mean value shall be equal to or less than the value specified in Table 1.
Table 1
Sr. Density In Oven Compressive Strength Thermal Conductivity
No dry Condition Min In Air dry Condition
Kg/m3 Grade 1 Grade 2 W/m.k
N/mm2 N/mm2

1 451 to 550 2.0 1.5 0.21

2 551 to 650 4.0 3.0 0.24
3 651 to 750 5.0 4.0 0.30
4 751 to 850 6.0 5.0 0.37
5 851 to 1000 7.0 6.0 0.42

Drying Shrinkage –
Ø The drying shrinkage shall be not more than 0.05 percent for Grade 1 blocks and 0.10
percent for Grade 2 blocks.
Ø All the test specimens shall satisfy the requirements of the test. If one or more
specimens fail to satisfy the requirements, the remaining 3 blocks shall be subjected to
these tests.