AUTOCLAVED AERATED CONCRETE BLOCK (AAC)

INTRODUCTION: Chapter 1

Autoclaved aerated concrete (AAC), also known as autoclaved cellular concrete (AAC), autoclaved
lightweight concrete (ALC), autoclaved concrete, cellular concrete, porous concrete, it is a lightweight,
precast, foam concrete building material that simultaneously provides structure, insulation, and fire and
mould resistance. AAC products include blocks, wall panels, floor and roof panels and lintel.
AAC was invented in 1920s by Sweden (Swedish architect), Autoclaved lightweight concrete (ACC), the
production process of AAC is fairly simple, it is made with a mixture of fly ash, lime, cement, sand, gypsum,
an aeration agent and water, Aeration process imparts it a cellular light weight structure. ACC products
precast and offered by various shapes and sizes for structure. ACC products are cured under heat and
pressure in an autoclave.
Use of Autoclaved Aerated Concrete (AAC) blocks in construction industry in India offers interesting
proposition for various segments in the society. AAC products are used for both interior and exterior
construction. For a project developer it means faster and lower cost construction, in addition to their quick
and easy installation, for environmentally conscious it means eco-friendly products and for those who
occupy buildings built with AAC blocks it means better safety and lower energy costs for cooling or heating.
AAC is well suited for urban areas with high rise buildings and those with high temperature variations. Due
to its lower density, high rise buildings constructed using AAC require less steel and concrete for structural
members. The requirements for mortar for laying of AAC blocks are reduced due to the lower number of
joints. Similarly, the material required for rendering is also lower due to the dimensional accuracy of AAC.
The increased thermal efficiency of AAC makes it suitable for use in areas with extreme temperature, as it
eliminates the need for separate materials for construction and insulation, leading to faster construction and
cost savings.

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 Autoclaved Aerated Concrete Blocks

Primary raw material for ACC is fly ash. Thousands of tonnes of fly ash are generated by thermal power
plants everyday and its disposal is a cause of concern. Moreover, using fly ash does not harm the
environment at all. In fact using fly ash takes care of issues related to disposal of fly ash. Therefore by using
fly ash to produce AAC products provides a sustainable, economic friendly option. At the end it all translates
to a better world for future generation.
Autoclaved cellular concrete blocks can be used for both load bearing and non load bearing internal walls,
partition walls. AAC is to be conforming to IS Code 2185-1984 the sample shall be prepared as per and
compressive strength. AAC extensively used in Europe and Asia it comprises over as been 40% of all
construction in the United Kingdom and 60% in Germany.

TABLE (1): TECHNICAL SPECIFICATION

PROPERTY UNITS AAC BLOCKS

Size mm 600x250x150
Size tolerance mm ± 1.5
Compressive Strength N/mm2 3 - 4.5 (IS 2185 Part 3)
Normal Dry Density Kg/m3 550 – 650
Sound Reduction Index Db 45
Fire Resistance Hrs 2-6(depending on thickness)
Thermal Conductivity ”K” W/m-k 0.16-0.18

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ADVANTAGES
 High fire insulation.
 Lightweight saves cost & energy in transportation, labour expenses, and high strength.

 Durable with good resistance to sulphate attack.

 ACC is very environmentally and Eco friendly.

 Easily workable & it can easily cut to any required shape can be sawed, nailed, & drilled easily even
than wood.

 Long lasting the life of this material is extended because it is not affected by harsh climates or extreme
weather changes. It will not degrade under normal climate changes.

 Economic, no curing is required.

 Larger size of AAC block (6 times larger than brick) leads to faster masonry work & less mortar
requirement.

 Attractive Finishing.

 Reduces project cost.

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OBJECTIVE:
 To construct economical buildings (cost comparison) by replacing clay bricks by AAC blocks.

 To make productive use of recycled industrial waste (fly ash).

 To cast standard AAC blocks in the laboratory and conduct various tests to check the strength and
capacity of blocks.

 To conduct experimentation on modified AAC blocks by adding materials such as paddy husk, quarry
dust, M-sand and super plasticizer to increase the efficiency of AAC blocks.

 To create a sustainable environment for AAC blocks industry.

 To propose to the government to eliminate excise and create a same level playing field between AAC
block and red clay brick.

 To have special railway tariffs so that AAC block can be supplied via rail to distant locations.

 To propose State Government to remove VAT on AAC block, as its green building material.

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LITERATURE REVIEW: Chapter 2

AAC is being used for bearing walls in low to medium rise building, and for use as floor and roof structure
in the form of roof structure in the form of factory made reinforced panels. AAC blocks are being used in
construction works in all major cities in India – Kolkata, Mumbai, Bangalore and Chennai. In some
European countries 60% of new home constructions are being done with autoclaved aerated concrete (AAC)
block or panels. AAC is widely used as a building material in the Middle East, Australia, and South America
and now due to its workability, flexibility and durability it use has started in the United States of America.
New AAC manufacturing plants are coming up in USA and since the cost of a plant to produce AAC blocks
and panels is between $30 and $40 million, it represents a serious commitment.

1. Compressive Strength

Ali J. Hamad (2014)

Ali J. Hamad (2014) tested and found that increase in percentage of Aluminium
Powder decreased the compressive strength of AAC blocks due to increase in void ratio. The findings
suggest the use of Aluminium be restricted to 0.2% by weight of cement to get the compressive strength of
1431 Kg/m3. SassanSomi (2011) studied the effect of humidity on strength and found out that increase in
absorbed water content reduces the compressive strength of AAC blocks. Work done by RA Caroll et al.
(2006) tells us that there is a direct relation between the compressive strength and density of the AAC
Blocks, whereas in standard concrete at the same density the compressive strength can be increased or
decreased by adding admixtures .Work done by Y.A. Daou (2001) is a comparison of Actual Compressive
strength and the values given in the European and British standards. Both the Codes give low values of
compressive strength at higher block strength, the difference is less at lower Block strength. He further
demonstrated that the size of units had an effect on their compressive strength. N.Narayan et al. (April 2000)
found out that the compressive strength is dependent on the pore size inside the AAC blocks. The smaller the
pore size greater is the strength. Again greater pressure, temperature and time period inside Autoclave had
good effect on the strength, i.e. the strength increases as the block dries.

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2. Environmental Benefits

Stefan Schnitzler (2006) & J. Hamad (2014)

J. Hamad (2014) researched and found AAC blocks to be economical and environment friendly due to use of
by products of other industries. Work done by RA Caroll et al. (2006) tells us that by replacing ordinary
grounded sand by fly ash in the manufacturing of AAC Blocks, we can increase the eco-points per ton from
1.9 to 2.4. This is due to big saving on our ground resources and using a waste by-product of blast furnace.
Applied Research paper of Stefan Schnitzler (2006) confirms that AAC blocks reduce material use and
minimize waste and pollution. Secondly they consume approximately 50 % less energy in manufacturing.
The paper stresses on AA high thermal efficiency, reduction in noise pollution (due to millions of pores),
and improvement in indoor air quality (as it is mold resistant). It has better performance during natural
disasters &fire. Last but not the least they are cheaper than the conventional masonry system.

3. Aerated autoclaved concrete (AAC) block

Mallampalli. Ch, et al

Aerated autoclaved concrete (AAC) blocks a revolution building material in construction industry. Have
discussed about the reactions undergone while casting the block. They use gypsum for filter.

4. Materials, Production, Properties sand Application of Aerated Lightweight

Concrete.
Ali J. Hamad

Have discussed about the AAC block production in industry. The ratios are explained in this literature on
what stage aluminium powder should be mix.

5. Structure and properties of Aerated concrete.

N. Narayanan, et al,

It explains about the strength parameters and durability. It has discussed about the various strength
properties under certain condition.

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6. Hygric, thermal and durability properties of Autoclaved Aerated Concrete.
Milos Jerman, et al

It explains about the hygric, thermal and durability properties of AAC. They have compared 3AAC block
with different densities and tested results of thermal property and durability.

7. A Review of Autoclaved Aerated Concrete Products.

Robert G, et al,

Has discussed the various property and reaction taking place while producing AAC block. This also tells
about the autoclaved process in detailed about in pressure and temperature.

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METHODOLOGY Chapter 3

1) Material used
2) Mould preparation
3) Tests conducted on AAC
4) Casting & Curing
5) Comparison of Results
6) AAC block quality & benefits

MATERIALS USED:

Cement : Cement is a binder, a substance used in construction industry that sets and hardens and can
bind other materials together.

Fly ash : Fly ash is waste industrial product used for reduction of construction cost. The density of fly ash
ranges from 400-1800kg/m3. It provides thermal insulation, fire resistance and sound absorption. The type
of fly ash used is of Class C with contains 20% lime (CaO) and loss of ignition not be more than 6%, refer
figure 4 for powdered fly ash.

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Sand : Fine aggregate are basically sand consists of crushed stone with maximum particles passing
through a 4.75mm sieve, refer figure 5 for fine sand. As per code IS 383:1970; the silica content shall not
be less than 80%.

Limestone : Limestone is made up of calcite aragonite. Limestone is obtained either by crushing to fine
powder at AAC factory or by directly purchasing it in powder form from a merchant.

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Aluminium powder : Aluminium is an expansion agent. When the raw material reacts with
aluminium powder, air bubble introduced due to reaction between calcium hydroxide, aluminium and water
and hydrogen gas is released.

2 3 2

TABLE (2): PERCENT PROPORTION OF RAW MATERIALS

SI. Material % of proportion for AAC

No. Blocks with Fly ash / with
Sand
1. Fly ash / Sand 65-70 / 55-65 %
2. Cement - 53 GRADE OPC 6-15 / 10-20 %
3. Lime 18-25 / 20-30 %
4. Gypsum 3–5/2–3%
5. Aluminium powder paste (600 kg / m3) 8 %
6. Water 0.6 – 0.65 %
7. Casting system 36-40 ° C / 35-38 ° C

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 MANUFACTURING PROCESS: Chapter 4

Fly ash Gypsum Lime OPC

POURING MIXTURE ADDING Aluminium

popo

pp

B LOCKS CASTING ON MOULD

DEMOULDING AND WIRE CUTTING

HIGH PRESSURE STEAM

CURING FOR 12 HOURS

AAC BLOCKS READY FOR SALE

FLOW CHART OF MANUFACTURING POCESS OF AAC BLOCK

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PREPARATION PROCESS OF AAC BLOCKS: Chapter 5

1) Raw Material Preparation and storage

The first step of AAC production is grinding of silica rich material (sand, fly ash, etc) in ball mills. Gypsum
is normally not ball mixed separately. It is grinded with fly ash or with quicklime or it could be grinded with
the same miller for quicklime in turn. Other supplementary and chemicals are also have to be prepared.

Raw material storage assumes the continuous production and material stability. The continuous production
guarantees the non-stop and on time supply and the material stability guarantees the quality of products,
since the raw material might come from different sources, with different qualities. Raw material preparation
and storage is the pre-step for proportioning batching. This pre-step guarantees the raw material meet the
standard for AAC production, and it is also finishes the storage, homogenization and aging process. It is the
basic process that assumes the smooth production and production quality.

2) Dosing and mixing

A dosing and mixing unit is used to form the correct mix to produce AAC blocks. Fly ash or sand slurry is
pumped into a separate container. Once the desired weight is poured in, pumping is stopped. Similarly lime
powder, cement and gypsum are poured into individual containers using screw conveyers. Once required
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amount of each ingredient is filled into their individual containers, control system releases all ingredients
into mixing drum. Mixing drum is like a giant bowl with a stirrer rotating inside to ensure proper mixing of
ingredients.

3) Casting, Foaming and Pre-curing

Once the desired mix is ready, it is poured into moulds and it is ready for pre-curing. After casting, the slurry
in moulds will be in the pre-curing chamber to finish foaming and hardening. Foaming and hardening
actually starts when the slurry is fed into moulds.

4) Cutting

During this process, the pre-cured block goes through cutting and shaping into different size and shapes as
per requirements. The high workability and large variety of sizes make AAC production more suitable for
massive production with higher mechanization. Cutting can be done mechanically or manually.

5) Autoclaved curing

After cutting into the desired sizes and shapes, “green” AAC blocks are transferred into autoclaves.
Autoclaved used for steam curing under pressure. AAC blocks are steam cured for 10-12 hours at a pressure
of 12 bars and temperature of 190 degree Celsius. In hot and humid condition, AAC blocks undergo last
stages of hydrothermal synthesis reaction to transform into a new product with required strength and various
physical performances.

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REFERENCE:

1. Trivedi Manoj S, Patel Harsh M, Chauhan Ritin K, Prof. JigarZala. (2015)

Comparison of Compressive Strength In Between Conventional Clay Bricks and
Cellular Light-weight Concrete Blocks, International Journal of Advance Engineering and Research
Development, Vol. 02, Issue. 03 March.

2. Stefan Schnitzler (2006), Applied Research Paper: Autoclaved Aerated Concrete as a Green Building
Material.
3. Ali J Hamad (2014), Materials, Production, Properties and Application of Aerated Lightweight Concrete:
Review, International Journal of Materials
Science and Engineering, Vol. 2, No. 2December.

4. Narayanan N, Ramamurthy K (2000), Structure and Properties of Aerated Concrete: A Review Received
in 7 January 1999; Accepted 13 April 2000.

5. Ahsan Habib, HosneAra Begum, Eng. RubaiyetHafiza, (2015), International Journal of Innovative
Science, Engineering and Technology, Vol.2 Issue 3, ISSN 2348-796.

6. IS 2572:2005 Construction of hollow and solid concrete block masonry-code of practice.

7. IS 6041:1985 Construction of autoclaved cellular concrete block masonry

8. Ali J. Hamad, (2014), International Journal of Materials Science and Engineering Vol. 2.
9. IS 2185 (part 1):2005 concrete masonry units – specification part 1 hollow and solid concrete blocks.

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