[Type text]

Affiliated to Purbanchal University

Khwopa Engineering College

(Undertaking of bhaktapur municipality)

Libali, bhaktapur

Nepal

Repot on:

Field visit

Lab sheet no:

Manufacture of ACC Block and Brick

Summited by submitted by:

Name: Mansoon Khajum ER. Ramesh Bala

Roll no: 790236 Department of Civil Engineering

Submission date: 2080-01-18

[Type text]

ACKNOWLedgement

I would like to express my special thanks of gratitude to my teacher Mr.Ramesh

Bela , who gave me the golden opportunity to do this wonderful project of Civil
Engineering on “MANUFACTURE OF ACC BLOCK AND BRICKS”, Who also
helped me in completing my project. I came to know about so many new things I
am really thankful to them

I came to know about so many new things I am really thankful to them

.

 INTRODUCTION:

AAC blocks specifications – (Autoclaved

aerated concrete), Composition
Autoclaved aerated concrete (AAC) block is a building material made of
Portland cement, fine aggregates (fly ash or sand), water and an expansion
agent in an autoclaving process heated under pressure which results in the
production of air voids in the material, making it less dense, easy to cut/mould
and better insulating.AAC block is a special type of concrete block made up of
fine aggregates, Portland cement, water, and another expansion agent
(Aluminum powder).AAC block was developed in 1924 by a Swedish
architect. AAC block is alternate materials for building materials that have
similar properties as wood. As we know, wood has good thermal insulation,
solid structure, and easy to work, combustible, decay, and termite damage.
But AAC blocks minimize the disadvantage of using timber as a construction
material. The combustible, decay, and termite damage can be totally removed
using this block.

The AAC products not only include AAC block, but they also include wall
panels, floor and roof panels, lintels, etc.
Uses of AAC Block
 Used in commercial, industrial and residential applications
[Type text]

 AAC is well suited for high-rise buildings and those with high-
temperature variations,
 Suitable for use in areas with extreme temperatures.
 It reduces the weight of the superstructure, so used in light construction.
AAC blocks specifications

Properties of AAC Block Specifications

General Size 625 mm * 240 mm * (75-300) mm

Thickness 50,75,100,125,150,200,225

Minimum Compressive Strength 3 to 4.5 N/mm2 (IS 2185)

Minimum Dry density 450 to 650 Kg/m3

Thermal Resistance 0.8-1.25 per inch of thickness

Allowable Shear Stress 8-22 psi

Fire Resistance 4* Hours

Thermal Conductivity 0.16 to 0.18 W/Mk

Drying Shrinkage 0.04% of the size of AAC block

AAC Block Specifications

Composition
1. Fly-ash – 59%
[Type text]

2. Cement (usually OPC grade 53) -33%

3. Lime – 8%

4. Aluminum powder – 0.07%

Manufacturing Process of AAC Block

 First a fall, autoclaved aerated concrete is produced by mixing silica or
sand or fly ash with cement, lime, water, and expansion agents such as
aluminum powder.
 After mixing, this concrete is poured into the mould of standard size.
(For structurally reinforced AAC product, steel rebar or mesh is also placed in
mould.)

 When we mix the aluminum powder with silica or other material

containing silica, there is the formation of hydrogen gas. As a result, the
concrete gets expand five times its original volume. Such a process is
called aeration. So it is renamed as aerated.
 Then, the hydrogen gas escape by leaving voids in between concrete,
and this mould is removed and cut into small pieces (Waste during cut
can be recycled).
 Then, pass these pieces into the autoclave. The temperature of
autoclave has reached about 190° Celsius and pressure about 8 bars to
12 bars.
 Under such steam and pressure, sand reacts with calcium hydroxide to
form calcium silicate hydrate, which gives high strength to the AAC
block.
 Then, curing is done and removed AAC block is ready for use in the
construction site.
[Type text]

Step-1: Preparation Of Raw Materials

[Type text]

Raw materials or Ingredients for AAC blocks manufacturing process are

cement, sand, lime, fly ash, Gypsum, and Aluminum
Raw material preparation is an important part of any manufacturing process.

Cement-53-grade Ordinary Portland Cement (OPC) from

the manufacturer is required for manufacturing AAC Blocks.
Fly ash or sand: Fly ash is mixed with water to form fly ash
slurry. The slurry thus formed is mixed with other ingredients
like lime powder, cement, gypsum, and Aluminum powder
in proportionate quality to form blocks.
Limestone powder: Lime powder required for AAC
production is acquired by crushing limestone to fine
powder at AAC factory or purchasing it directly from other companies.
Gypsum: Gypsum is reSadily available in the market.

-2: Mixing And Dosing

Some Limitations are:
 FLY ASH OR SAND : LIME:CEMENT: GYPSUM = 69:20:8:3,
 Aluminum is mixed about 0.08% of total dry materials in the mix,
 water ratio = 0.60 – 0.6
The cycle of mixing and pouring is 5.5 minutes and first all the
ingredients are poured into different containers according to mix
proportions.

Then control system pours into a mixing drum and once the mixture
is ready to set then using the dosing unit, concrete is poured into
molds.

For AAC blocks manufacturing process, entire dosing and mixing operation
is completely automated and requires minimum human
intervention.

Step-3: Casting, Rising, Pre-Curing, Demolding, And Cutting

Based on installation capacity molds size is fixed and generally it will be 4.2m x 1.2m
x 0.65m in size

While slurry is mixed and poured into greased molds, Aluminum

reacts with Calcium Hydroxide and water and releases hydrogen gas.
[Type text]

Chemical reaction ( 2Al + 3Ca(OH)2 + 6H2O → 3CaO.Al2O3.6H2O + 3 H2 )

This leads to the formation of tiny cells causing the slurry mix to expand and it takes
about 1-2hrs. This is known as the pre-curing process. Such expansion may be thrice
its original volume.

 pre-curing

 cutting

After rising and getting enough strength to withstand its own weight then Demolding
and cutting is done with required dimensions

Step-4: Curing And Transporting

Using Autoclave AAC is cured–a large pressure vessel An autoclave is normally a
steel tube of 3m diameter and 45 meters long.

steam curing autoclave

Steam is fed into the autoclaved at high pressure, typically reaching a pressure
of 800kPa to 1200 KPa and a temperature of 180°C for at least 5hrs.

Properties of blocks mainly depend on steam curing and raw material proportions.

When the blocks attain required properties are stored in

an area and transported.

Dimensions And Applications Of The Block

Based on thickness different sizes are available in the market;

 4 Inch

 6 Inch

 8 Inch

 9 Inch
[Type text]

Advantage of AAC Block

 Due to lightweight, it
 Save cost and energy in transportation
 Save labor expenses
 Increase the chance of survival during seismic activity
 Lower Environmental Impact (Use of fly ash)
 Improve thermal efficiency reduces the heating and cooling load in the
building.
 Increases workability, allows accurate cutting,
 The generated solid waste can be reused.
 Termite resistant (does not affected by termite like in timber)
 Cost-effective
 Earthquake resistant and design flexibility
 Thermally insulated and Energy efficient
 Fire-resistant and ecofriendly
 The size of the AAC block is generally large which leads to faster masonry
work.
 Reduces a dead load of building on the foundation .
Disadvantage of AAC Block
 Higher initial cost
 Scarcity of manufacturing plants
 Brittle nature, so handled and transported carefully.
 Installation during rainy season leads to crack after installation.
 For the partition wall, the thickness of the AAC block will be more. So, clay
brick is preferred.

 Brick:
A brick is a rectangular building material made from clay, sand, lime, or
concrete materials. It has been used in construction for thousands of
years and is one of the oldest and most enduring building materials in
[Type text]

the world. Bricks come in a range of sizes and shapes and can be used in
a variety of building projects, from simple walls to complex
architectural designs. They are prized for their durability, fire
resistance, and ability to withstand weathering, making them a popular
choice for building homes, buildings, and other structures. Additionally,
bricks can be used for decorative purposes, such as creating patterns or
designs on walls, adding a timeless and classic aesthetic to any building.

Manufacturing Brick ;
Preparation of clay for brick manufacturing:
[Type text]

The manufacture of brick and structural clay products involves mining, grinding,
screening and blending of the raw materials followed by forming, cutting or
shaping, drying, firing, cooling, storage, and shipping of the final product. The raw
materials used in the manufacture of brick and structural clay products include
surface clays and shales, which are mined in open pits. The moisture content of
the raw materials ranges from a low of about 3 percent at some plants to a high
of about 15 percent at other plants. Some facilities have onsite mining operations,
while others bring in raw material by truck or rail. The raw material is typically
loaded by truck or front-end loader into a primary crusher for initial size
reduction. The material is then conveyed to a grinding room, which houses
several grinding mills and banks of screens that produce a fine material that is
suitable for forming brick or other products. Types of grinding mills typically used
include dry pan grinders, roller mills, and hammermills. From the grinding room,
the material is conveyed to storage silos or piles, which typically are enclosed. The
material is then either conveyed to the mill room for brick forming or conveyed to
a storage area. Most brick are formed by the stiff mud extrusion process,
although brick are also formed using the soft mud and dry press processes (there
may be no plants in the U.S. currently using the dry press process). A typical stiff
mud extrusion line begins with a pug mill, which mixes the ground material with
water and discharges the mixture into a vacuum chamber. Some facilities mix
additives such as barium carbonate, which prevents sulfates from rising to the
surface of the brick, with the raw material prior to extrusion. The moisture
content of the material entering the vacuum chamber is typically between 14 and
18 percent. The vacuum chamber removes air from the material, which is then
continuously augered or extruded through dies. The resulting continuous
"column" is lubricated with oil or other lubricant to reduce friction during
extrusion. If specified, various surface treatments, such as manganese dioxide,
iron oxide, and iron chromite can be applied at this point. These treatments are
used to add color or texture to the product. A wire-cutting machine is used to cut
the column into individual bricks, and then the bricks are mechanically or hand
set onto kiln cars. All structural tile and most brick are formed by this process.
Prior to stacking, some facilities mechanically process the unfired bricks to create
rounded imperfect edges that give the appearance of older worn brick. The soft
mud process is usually used with clay that is too wet for stiff mud extrusion. In a
pug mill, the clay is mixed with water to a moisture content of 15 to 28 percent,
and the bricks are formed in molds and are dried before being mechanically
[Type text]

stacked onto kiln cars. In the dry press process, clay is mixed with a small amount
of water and formed in steel molds by applying pressure of 500 to 1,500 pounds
per square inch (3.43 to 10.28 megapascals)
 Finding:
 AAC Factory:

The AAC factory utilized advanced machinery and technology to produce

high-quality blocks. The blocks were made by mixing cement, lime, fly ash,
water, and aluminum powder in a precise ratio. The mixture was then poured
into molds and placed in an autoclave, where they were subjected to high-
pressure steam for several hours. This process resulted in the production of
lightweight, durable, and high-strength blocks with excellent insulation
properties.

 : Brick Factory

The brick factory produced traditional clay bricks using manual and semi-
automatic techniques. The bricks were made by mixing clay, sand, and water
in a specific ratio. The mixture was then molded into bricks and dried in the
sun for several days. The bricks were then fired in a kiln at high temperatures
to make them durable and strong.
 DISCUSSION:
AAC Factory:
The AAC factory is a modern manufacturing plant that produces high-
quality, lightweight concrete blocks. The autoclave applies high
pressure steam and heat, resulting in the formation of a chemical
reaction that expands the mixture and forms the blocks.The production
process starts with the mixing of cement, lime, fly ash, water, and
aluminum powder in a specific ratio. The mixture is then poured into
molds, which are then placed in an autoclave.. The blocks are then cut to
size and cured in a chamber, which hardens and strengthens them
further. The result is a lightweight, durable block that has excellent
insulation properties, making them ideal for building modern
structures. Additionally, the factory uses cutting edge technology, such
as computer-controlled machines and automated processes, to ensure
that production is efficient and consistent.

Brick Factory:
[Type text]

The brick factory is a more traditional manufacturing plant that

produces clay bricks. The production process starts with the mixing of
clay, sand, and water in a specific ratio. The mixture is then molded into
bricks and dried in the sun for several days. After drying, the bricks are
stacked in a kiln and fired at high temperatures to make them strong
and durable. The firing process can take several days, and the resulting
bricks are then sorted and packaged for sale. While the process is more
manual, the result is a classic, timeless building material that is still
widely used in construction.

 RECOMMENDATION:
Based on the findings of the field visit, it is recommended that the Brick
factory implement measures to ensure safety and environmental
sustainability. This could help improving ventilation, installing a
wastewater treatment system, and exploring the use of cleaner fuels.
Additionally, the factory could explore ways to automate certain parts of
the production process to improve efficiency. Furthermore, it is
recommended that the both factories work towards increasing their use of
renewable sources of energy, such as solar or wind power, to reduce their
reliance on non-renewable sources of energy. This could help to reduce
their carbon footprint and contribute to environmental sustainability.
Finally, it is recommended that the government should provide support to
factories to help them implement measures to ensure safety and
environmental sustain ability. This could include providing training and
resources to help factories improve their operations and offering
incentives for factories that prioritize safety and environmental
sustainability.

‘ THANK YOU’
[Type text]