Grű𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧AAC Blocks : Technical Guide

Part I : Typical Block Size Details

Nos/brass
Size in mm Size in m3 Nos/m3 (per 100 sqft) Weight/block
1 625 x 240 x 75 0.01125 m3 88.89 nos 62 nos 7.31 kg
1 625 x 240 x 100 0.015 m3 66.67 nos 62 nos 9.75 kg
2 625 x 240 x 125 0.01875 m3 53.33 nos 62 nos 12.19 kg
3 625 x 240 x 150 0.0225 m3 44.44 nos 62 nos 14.63 kg
4 625 x 240 x 200 0.03 m3 33.33 nos 62 nos 19.50 kg
5 625 x 240 x 225 0.03375 m3 29.63 nos 62 nos 21.94 kg

Part II : Requirements of IS 2185 (Part 3) : 1984-2005 : Grade 1

1 Compressive Strength 4MPa

2 Tolerance in Length 5mm
3 Tolerance in Width 3mm
4 Tolerance in Height 3mm
5 Density 650 kg/m3
6 Thermal Conductivity 0.24 W/m.k
7 Drying Shrinkage 0.05%
8 Allowable Breakage 5.0%
Part III : Work Instructions

How to lay a masonry wall with Grű𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧Blocks

1.0 Please make sure that the starter bed is in zero tolerance level. Spread slight mortar to take care of
unevenness. The first layer of AAC blocks masonry is thus fixed in cement : Sand mortar.

2.0 For each upper layer, fix the blocks by uniformly applying a thin layer of 3 to 4mm jointing mortar on
the course. Spread the mortar as you go along. Do not spread the mortar far ahead which will result
in earlier setting.

3.0 It is not required to soak the AAC blocks completely in water. Only slight wetting of surface is
enough.

4.0 Use a tray filled with 30 to 40mm of water. Before laying each block, immerse it in the tray from all
sides and make it slightly wet on four sides. Then place the block firmly in position to have proper
bond.

5.0 The first course of the masonry shall be laid with proper attention and should beuniformly aligned,
levelled and plumbed. This ensures that the upper layers remain in true plumb and uniform level.

6.0 Apply the mortar on the side of a block as you move ahead. Ensure that mortar is uniformly spread
over the block. None of the joints shall be left with a gap.

7.0 It has been observed that when the joints are not filled fully with mortar, it leads to cracking of
blocks or gypsum plaster due to movement in blocks.

8.0 Fill the top 10mm of the wall with coarse aggregates.This packs the masonry and takes care of the
unevenness of the beam bottom. The top slab gets uniform bearing with the masonry avoiding
any stress concentration on the wall. This ensures that cracks do not develop in AAC blocks from
vibration of loads of the upper slab.

9.0 We can apply the gypsum plaster on the inner wall surfaces and then paint the walls.

10.0 You can drill a screw or carve an electrical conduit in an AAC wall. The AAC blocks have excellent
workability. Just use proper tools for the work. Avoid using hammer and chisel – instead use
mechanised cutting tools or saw for shaping the blocks.
How to apply External Plaster on a masonry wall of AAC Blocks

1.0 Rake the joints.

2.0 The beam-masonry joint and the column-masonry joint must be treated with chicken mesh and
polymer adhesive. Apply a bonding coat of polymer adhesive over the entire length of the joint.

3.0 Do the wetting of the wall with water for 2 hours only before you begin the plaster. If you do the
wetting for longer period, it may result in weaker bond of plaster.

4.0 Use a properly sieved river sand that is free of silt and any impurities.

5.0 You have an option to finish the external plaster in one or two layers. But the total thickness of
plaster should not be more than 12mm in case of single layer or 20mm in case of 2 layers.

6.0 A continuous curing for 10 days is very essential for a high quality bonding of plaster free of cracks.
It has been seen on numerous sites that this last step is ignored and all the good work done before
goes in vain.

How to do curing for the external plaster

1.0 The most ideal way for curing the external plaster is by the way of sprinklers
2.0 Use the top down method with sprinklers for curing the plaster.
3.0 Run the sprinklers from the terrace to the ground floor.
4.0 The sprinklers should have holes facing the wall.
5.0 Connect the water source to the sprinklers – run the water through the sprinklers.
6.0 Keep the water running at very low pressure. The idea is to do a continuous curing whole day.
Part IV :Frequently Asked Questions and Answers

1.0 My Gypsum plaster is cracking – what is the reason?

The most common reason for cracking of gypsum plaster is the inferior quality of gypsum used that
contains adulteration.

The next common reason is the joints of AAC block wall are not filled properly with mortar leaving
gaps in between. Ensure that all vertical and horizontal joints are filled 100% with thin bed jointing
mortar.

2.0 The AAC block has cracked at some places in the wall. What is the reason?

There could be several reasons for cracking of the blocks.

1. If the joints are not properly filled, it leads to unevensettlement. It may lead to stress
concentration and cracking.
2. Take care to use only mechanised cutting tools to cut the blocks – do not use chisel and
hammer. Because cutting the block in perfect right angle is important.
3. Packing of coarse aggregates below the top beam is essential as it fixes the wall in place and
does not allow vibration from loads of the upper slabin the blocks.

3.0 My gypsum plaster shows a moist surface at the bottom of the wall. How to prevent it?

Begin the block masonry with a starter bed of 3 to 4 inch at the bottom of the wall.
Begin the AAC masonry work on this starter bed.
Part V : Comparison Between AAC Blocks and Bricks

Technically what is the difference between masonry in AAC blocks and inconventional bricks

Difference in Weight

1.0 For similar size, Weight of One Brick (1500 kg/m3) = Weight of Two and Half AAC Blocks (650 kg/m3)
This means AAC blocks are very very light in weight
2.0 This helps to make a much bigger size of AAC blocks = about 8 bricks in one AAC block
3.0 This results into huge saving in cement and sand as the number of joints get reduced by 6 times!!
4.0 This also means that a mason can do the masonry much faster – almost 50% more output in a day.

Difference in Heat Transfer

1.0 AAC blocks have very lowrate of heat transfer compared to burnt clay bricks –less than 1/3rd.
AAC Blocks = 0.24 w/m’K against 0.81 w/m’K
2.0 This results in massive savings in air conditioning costs – by more than 25% in AAC block homes

Difference in Water Seepage

1.0 The pores in AAC blocks are not connected to each other. Therefore AAC blocks do not allow
seepage of water through them by capillary reaction.
2.0 Whereas the pores in burnt clay bricks are connected to each other. Therefore they have a high rate
of seepage of water due to capillary reaction.

Perfection in Size

1.0 AAC blocks have a maximum deviation in height and width of 3mm. This ensures a much thinner
plaster and thinner joints.
2.0 This results in substantial saving in sand and cement.
3.0 The block work looks aesthetically pleasing with neat and clean joints.