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AERATED AUTOCLAVED CONCRETE (AAC) BLOCKS: NOVEL MATERIAL FOR

CONSTRUCTION INDUSTRY

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 AERATED AUTOCLAVED CONCRETE (AAC) BLOCKS:
NOVEL MATERIAL FOR CONSTRUCTION INDUSTRY
Farhana M. Saiyed 1, Ashish H. Makwana2, Jayeshkumar Pitroda3, Chetna M. Vyas4
First Year Student, ME C E & M., BVM Engineering College, Vallabh Vidyanagar, Gujarat, India 1
Assistant professor, Civil Engineering Dept., Marwadi Education Foundation, Rajkot, Gujarat, India 2
Assistant professor, Civil Engineering Dept., BVM Engineering College, Vallabh Vidyanagar, Gujarat, India 3
Assistant professor, Civil Engineering Dept., A.D.Patel Institute of Technology, New Vallabh
Vidyanagar, Gujarat, India 4

Abstract: Autoclaved Aerated Concrete (AAC) is an ultra-light concrete masonry product. It

can weigh as little as 1/5 as much as ordinary concrete due to its distinct cellular structure
featuring millions of tiny pockets of trapped air. This cellular structure gives AAC a number
of exceptional physical characteristics. AAC consists of basic materials that are widely
available. These include sand, cement, lime, fly ash, gypsum, aluminium powder paste, water
and an expansion agent. Silica sand, the raw material used in the greatest volume in AAC, is
one of the world's most abundant natural resources. The finished product is up to five times
the volume of the raw materials used, with an air content of 70% to 80% (depending on the
required strength and density.) Due to this large increase in volume, AAC is very resource
efficient. The high consumption of raw materials by the construction sector, results in chronic
shortage of building materials and the associated environmental damage. In the last decade,
construction industry has been conducting various researches on the utilization of easily
available raw materials in construction. AAC is one of the materials which can cope up with
the shortage of building raw materials and can produce a light weight, energy efficient and
environmentally friendly concrete. This study deals with the introduction to the process of the
autoclaved aerated concrete and its advantages compared to the normal concrete..

Keywords: Autoclave aerated concrete blocks, Aluminium powder paste, Fly ash, Light
weight, Silica sand.

I. INTRODUCTION
. Since Roman times, lightweight aggregates and foaming agents have been employed to
reduce the weight of concrete. However, unlike these foamed or light aggregate mixes, true
aerated concrete relies on the alkaline binder (lime & cement) reacting with an acid to release
gases, which remain entrained in the material.
This is not a "new" innovation. Autoclaved Aerated Concrete has been around for
over 80 years. Invented in 1923, AAC has been used extensively in Europe and Asia. It
comprises over 40% of all construction in the United Kingdom and 60% in Germany.

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Figure 1: AAC Blocks used at Various Construction Sites

Source: https://www.google.co.in/#q=AAC+Blocks+used+at+Various+Construction+Sites+images

The first attempt to produce Powdered Aluminium and In 1917, a Dutch patent was
AAC was done by Mr E. Calcium Hydroxide were registered using yeast as an
Hoffman, in 1889. The used as aeration agents in aerating agent.
aeration was produced by cementitious mixtures by
carbon dioxide generated in Aylsworth & Dyer in the
the reaction between USA in 1914.
Hydrochloric Acid and
limestone.

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 AERATED AUTOCLAVED CONCRETE (AAC) BLOCKS: NOVEL MATERIAL FOR
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The use of metal powders as
a Hydrogen gas forming
agents was developed further
by Grosahe in Berlin in
1919.
The first documented attempt Autoclaved aerated concrete
at autoclaving aerated is a versatile lightweight
concrete was in 1923 in construction material and
Sweden. usually used as blocks

II. AAC BLOCKS – INDIAN SCENARIO

AAC consists of basic materials that are widely available. These include sand, cement,
lime, gypsum, water and an expansion agent. Silica sand, the raw material used in the
greatest volume in AAC, is one of the world's most abundant natural resources.

At present there are 31 manufacturing plants in India are working with heavy
concentration near Surat.

Gujarat: production capacity 2000 m3/day against requirement of 3000 m3/day (Surat has
3-4 plants).

In Ahmedabad, 1 m3 of AAC blocks costs Rs. 3200-3500 while 1 m3 of clay bricks

would cost Rs. 2400-2700.

In spite of the price difference, construction industry wants to use AAC blocks due to
inherent advantages.

It is more used in Mumbai, Banglore, Chennai and Hubli.

III. COMPARISON WITH NORMAL CONCRETE

Sr. No. Autoclaved Aerated Concrete Normal Aggregate Concrete

1. Autoclaved aerated concrete is a versatile Normal concrete has heavy weights compared to the
lightweight construction material and usually AAC.
used as blocks.
1 AAC Block size = 6 * brick size

1 AAC Block weight = 1/2 of aggregate block

weight

2. A low density and excellent insulation High density and lower insulation property
properties due to high porosity.

3. The low density is achieved by the formation The concrete so formed has a high density and
of air voids to produce a cellular structure.

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These voids are typically 1mm - 5mm across compact.
and give the characteristic appearance.

4. Densities range from about 460 to 750 kg/ m3 Medium density concrete blocks have a typical
density range of 1350-1500 kg/m3 and dense
concrete blocks a range of 2300-2500 kg/ m3

5. The finished product is up to five times the The finished product is compact and non-porous.
volume of the raw materials used, with an air
content of 70% to 80% (depending on the
required strength and density.)

6. Easily workable – can be sawed, nailed and Cannot be sawed, nailed or drilled as easy as AAC
drilled easily even than wood. blocks.

7. No curing required – labour cost is saved of Curing is must.

curing.

IV. ADVANTAGES AND DISADVANTAGES OF AAC BLOCKS

A. Advantages of AAC

Lightweight saves cost and energy in transportation as well as labour. (550 kg/m3 - half
of weight of light weight aggregate blocks)

Figure 2: Light weight concrete Blocks of AAC

Source: Discovery channels

Larger size (6 times larger than brick) leads to faster construction and less mortar
requirement for joining.

1) Fire Resistant: It has one of the highest hourly fire resistance ratings per inch of any
building material currently used in homebuilding. This makes it an ideal choice for fire
protection around steel columns and steel beams and in the construction of shaft walls,
stairwells, corridors and firewalls.

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Figure 3: AAC is highly Fire-resistant

Source: Discovery channels

2) AAC very Environmentally Friendly: The process of manufacturing AAC uses only
natural materials and produces no pollutants or by-products. AAC is totally free of toxic
or harmful substances. Low energy is required in production, low raw material
consumption, ease of use in construction, high energy efficiency, better indoor air quality
and recyclability add up to make AAC a very environmentally friendly building material
and system.

Figure 4: This AAC house survived a devastating fire in California while neighbouring homes were
destroyed
Source: www.5caac.utp.edu.pl/

3) Breathable: It does not promote mold growth.

4) Good Sound Insulation Property: Its noise reduction co-efficient is more than twice that
of a standard concrete block wall and over 7 times that of ordinary concrete.
5) Easily Workable: It can easily cut to any required shape, can be sawed, nailed and drilled
easily even than wood.
6) Durable: With good resistance to sulphate attack.
7) Attractive Finishing: Walls can be left exposed without plaster.
8) Economic: No curing is required, labour cost is saved hence.

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B. Disadvantage of AAC

Some disadvantages of AAC blocks and panels are that they do contain Portland cement,
they are made in so few place which means more transportation cost and using gas resources.

Builders must learn how to use them since the mortaring is different, some of the blocks
are made to European standards and have to be cut.

They are porous so must have stucco or cladding on the exterior to keep out water. For
load-bearing, AAC may need rebar reinforcement.

In some states, they have yet to be accepted in building codes due to lack of test results.
What is not green about Portland cement is that it is about 60 percent limestone, or calcium
carbonate, and must be burned at high temperatures in kilns using lots of energy and creating
carbon dioxide (CO2), a greenhouse gas linked to global warming. The newer magnesia-
based cement can be burned at lower temperatures using less energy and creating less CO 2.
Magnesium carbonate and calcium carbonate are both obtained by mining, but lower alkaline
magnesia concrete is able to remain strong when recycled materials are added to the mix and

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 AERATED AUTOCLAVED CONCRETE (AAC) BLOCKS: NOVEL MATERIAL FOR
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can insulate better when organic materials are added. Magnesia concrete can also absorb CO2
through a carbonation process while it is being manufactured and used, reducing the
greenhouse gas.

V. RAW MATERIALS USED IN AAC

https://www.google.co.in/?gws_rd=cr&ei=X6X3UremGIqJrAeJ44CAAg#q=RAW+MATERIALS+USED
+IN+AAC+images

TABLE.1 PERCENT PROPORTION OF RAW MATERIALS

Sr. No. Material % of proportion for AAC Blocks

with Fly ash / with Sand
1. Flyash / 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

VI. FLOW DIAGRAM OF AAC PRODUCTION PROCESS

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VII. PRODUCTION PROCESS

Autoclaved aerated concrete is quite different from dense concrete (ie: “normal concrete”) in
both the way it is produced and in the composition of the final product.

Autoclaved aerated concrete is cured in an autoclave - a large pressure vessel. In aircrete

production the autoclave is normally a steel tube some 3 metres in diameter and 45 metres
long. Steam is fed into the autoclave at high pressure, typically reaching a pressure of 800
kPa and a temperature of 180 °C.
Autoclaved aerated concrete can be produced using a wide range of cementitious materials,
commonly: Portland cement, lime and pulverized fuel ash (PFA) OR Portland cement, lime
and fine silica sand. The sand is usually milled to achieve adequate fineness. A small amount
of anhydrite or gypsum is also often added.

Autoclaved aerated concrete is of much lower density than dense concrete. The chemical
reactions forming the hydration products go virtually to completion during autoclaving and so
when removed from the autoclave and cooled, the blocks are ready for use.

Autoclaved aerated concrete does not contain any aggregate; all the main mix components
are reactive, even milled sand where it is used. The sand, inert when used in dense concrete,
behaves as a pozzolana in the autoclave due to the high temperature and pressure.

The autoclaved aerated concrete production process differs slightly between individual
production plants but the principles are similar. It is a mix that contains cement, lime and
sand; these are mixed to form slurry. Also present in the slurry is fine aluminium powder -
this is added to produce the cellular structure. The density of the final block can be varied by
changing the amount of aluminium powder in the mix.

The slurry is poured into moulds that resemble small railway wagons with drop-down sides.
Over a period of several hours, two processes occur simultaneously:

The cement hydrates normally to produce ettringite and calcium silicate hydrates and the mix
gradually stiffens to form what is termed as "green cake". The green cake rises in the mould
due to the evolution of hydrogen gas formed from the reaction between the fine aluminium
particles and the alkaline liquid. These gas bubbles give the material its cellular structure.

Slurry poured in moulds Green cake rising in mould

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The mix proportions and the initial mix temperature must be correct and the aluminium
powder must be present in the required amount and with the appropriate reactivity an alkaline
environment. All of the materials should be of suitable fineness. A complicating factor is that
the temperature of the green cake increases due to the exothermic reactions as the lime and
the cement hydrate, so the reactions proceed faster.

When the cake has risen to the required height, the mould moves along a track to where the
cake is cut to the required block size. Depending on the actual production process, the cake
may be demoulded entirely onto a trolley before cutting, or it may be cut in the mould after
the sides are removed. The cake is cut by passing through a series of cutting wires.

Green cakes being cut by wires Green cakes being loaded in autoclave

At the cutting stage, the blocks are still green - only a few hours have passed since the mix
was poured into the mould and they are soft and easily damaged. However, if they are too
soft, the cut blocks may either fall apart or stick together; if they are too hard, the wires will
not cut them - here too, the process has to be carefully controlled to achieve the necessary
consistency.

The cut blocks are then loaded into the autoclave. It takes a couple of hours for the autoclave
to reach maximum temperature and pressure, which is held for perhaps 8-10 hours, or longer
for high density/high strength aircrete.

When removed from the autoclave and cooled, the blocks have achieved their full strength
and are packed ready for transport.

TABLE II: SPECIFICATION -AAC BLOCKS

PARAMETERS IN mm

Length 625

Breadth 240

Thickness 90/100/150/200

Tolerance +-1%Z

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 AERATED AUTOCLAVED CONCRETE (AAC) BLOCKS: NOVEL MATERIAL FOR
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TABLE III: SPECIFICATION –AAC BLOCKS

PARAMETERS VALUE

Density 550 – 650 kg/m3

Compressive Strength >3 N/mm2

Modulus of Elasticity 2040 N/mm2

Coefficient of Thermal Expansion 8.1 x10-6 k-1

Water Expansion 8%

Figure 5: layout of AAC production plant

Source: www.blockmachine-henan.com

VIII. CONCLUSION
 AAC block provides Good Avenue for entrepreneurs in Gujarat, India.
 AAC block is Lightweight.
 AAC block saves cost and energy in transportation and labour.
 Larger size of AAC Block leads to faster construction and less mortar requirement for
joining.
 AAC block has good fire resistance.

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 AAC block is less permeable, well suited to withstand fires, earthquakes and other
natural disasters.
 Easily workable – can be sawed, nailed and drilled easily even than wood
 Walls can be left exposed without plaster.
 No curing required – labour cost is saved of curing
 It reduces additional material use and minimizes waste and pollution.
 Process has no waste by-product, recyclable

REFERENCES
[01] Autoclaved Aerated Concrete as a Green Building Material, Stefan Schnitzler ,October 2006
[02] Sustainable use of crushed autoclaved aerated concrete
[03] (CAAC) as a filter medium in wastewater purification, Gunno RENMAN, Agnieszka RENMAN ,KTH
Royal Institute of Technology, Department of Land and Water Resources Engineering, SE-100
44,Stockholm,Sweden
[04] Structure and properties of aerated concrete: a review N. Narayanan, K. Ramamurthy Building
Technology and Construction Management Division, Department of Civil Engineering, Indian Institute
of Technology Madras ,Chennai 600 036, India, Received 7 January 1999; accepted 13 April 2000
[05] http://www.anjaliexim.net/aac-blocks-making-line-1200079.html
[06] www.neopor.com
[07] http://extension.ucdavis.edu/unit/green_building_and_sustainability/pdf/resources/auto_aerated_concre
te.pdf
[08] http://www.magicreteaac.com
[09] http://articles.timesofindia.indiatimes.com/2013-04-04/hubli/38277625_1_aac-blocks-walls
[10] http://www.naldehraindia.com/aac-projects.html
[11] http://www.biltechindia.com/biltech-ace-aac-benefits-advantages.asp?links=b3
[12] http://dearyebrickmachine.blogspot.in/2012/04/two-typical-formula-for-
autoclaved.html#!/2012/04/two-typical-formula-for-autoclaved.html
[13] http://www.naldehraindia.com/aac-projects.html
[14] http://aac-india.com/aac-blocks-and-business-opportunities

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