INTRODUCTION -AAC

• AAC means autoclaved aerated concrete, a new generation walling material

• Invented by a Sweden Architect -Johan Axel Eriksson-mid 1920
AAC BLOCKS • AAC is made with major materials such as fly ash, cement, lime and an aerated agent.
VS • AAC replaces clay bricks which are environmentally unsustainable
CONVENTIONAL BLOCKS • Being aerated , it contains 50 - 60 % of air, leading to light weight and low thermal conductivity
• AAC has properties such as light weight, high strength and high thermal and sound insulation

What makes them Greener? • AAC can withstand up to 4 hours of direct fire exposure.
• AAC panel design offers buildings a protection up to 8 on a Richter’s scale.
6th September 2014 • AAC blocks are dimensionally accurate

Dr. Satyanarayana The above characteristics of AAC is helpful in green housings and
Head - R&D saves fertile lands and a solution for fly ash disposal
HIL Limited
(formerly Hyderabad Industries Ltd.,)
www.hil.in

ATTRIBUTES OF AAC WHY AAC BLOCKS ARE GREENER

ATTRIBUTES BENEFITS

§ Moisture resistant § Lasts long

§ Improved interiors with reduced noise pollution.
§ Sound reduction
37-42 db.
Resource
§ Comfortable interiors & improved energy efficiency. efficiency
§ Thermal conductivity
0.12 W/m-K
§ Dimensionally accurate & easy workability. Factory finished with Affordability
Affordability Indoor Air
§ Dimensional stability Quality
superb surface finish; easily accepts renders & plasters
§ Termite resistance § No threat from any microbes. AAC
Blocks
§ Fire resistance § Ensures safe interior space - 4 hrs
§ Easy workability § Use of standard tools to cut, saw, chisel, drill & shape Water Energy
conservation efficiency
§ Good adhesion § Can take all type of finishes
Material
efficiency
§ Reduces foundation load of the building up to 30%. Reduces
§ Guaranteed Savings
power consumption by 27%.

WHY AAC BLOCKS ARE GREENER WHY AAC BLOCKS ARE GREENER

RESOURCE EFFICIENCY RESOURCE EFFICIENCY

AAC uses fly ash about 60 to 75% (fly ash is a waste product
1 Recycled content 5 Durable • Cementitious material –lasts life long
generated from thermal power stations)

6 Repair , maintenance • Minimal ware and tear over prolonged use

Resource efficient •AAC Blocks uses less power (reduces power consumption by
and finishing • AAC blocks requires substantially less of plaster or surface
2 manufacturing 27%)
treatment (consumption of cement is 52% per CuM
process • Zero waste(All the recycled material is used in the process)
compared to clay bricks)
• Minimal maintenance due to resistance to weathering and
•Fly ash –From power plants and cement plants located better surface level/ smoothness
raw materials nearby- 100-150km
3 • Can take all types of surface finishes and economizes on
sourcing
• Reduced transportation costs - saves fuel their consumption

•AAC Blocks –Broken blocks can be reusable

4 Reusable
• Actual wastage at site less than 2%
 WHY AAC BLOCKS ARE GREENER WHY AAC BLOCKS ARE GREENER

ENERGY EFFICIENCY
INDOOR AIR QUALITY
THERMAL INSULATION
• AAC blocks does not emit fumes Depends upon thermal conductivity, K value
1 Non- Toxic • No irritants during manufacture, installation and while in - Measure of the ability of the material to transmit heat
use
- Lower the value higher the thermal insulation
• Zero VOC
Minimal chemical - Higher thermal insulation makes interiors comfortable
2 • No petrochemical derivatives
emission
• Less CO2 emission
THERMAL INERTIA
Inhibit growth of
3 • do not absorb moisture from atmosphere •Depends on the material characteristics
microbes
- combination of thermal conductivity, specific heat and mass
• Delays the rise of temperature by 2 to 3 hours
4 Better air quality • Good working atmosphere
• Reduces the effect of peak outside temperatures

Higher insulation characteristics leads to less or no usage of cooling or

heating systems. Hence energy efficient.

WHY AAC BLOCKS ARE GREENER WHY AAC BLOCKS ARE GREENER

ENERGY EFFICIENCY MATERIAL EFFICIENCY

LIGHT WEIGHT •Reduced use of cement mortar, plaster for application
•K value of Blocks is 0.12w/m-k • Reduced Steel(18%) and Cement(12%)
Energy efficient 1 Resource conservation
1 •Indoors remain cooler during summer and warm during winter • Faster construction – saves money and labor (rapid
building shell/walls construction by 30%)
• K value of Clay Bricks is 0.84 and Concrete is 2.0
Reuse and minimal
2
Minimise electric
• Reduces AC loads due to low K value 2 • Breakages/ Wastages are minimal
loads wastage

Energy efficient •Product installation, tools, surface finish, maintenance all uses
3
systems minimal energy

WATER CONSERVATION

• Consumption of water within the process

• Efficient use of water and water recycling
• AAC Blocks need less water for curing due to less no of joints —
reduction around 50%

WHY AAC BLOCKS ARE GREENER Specification for AAC blocks – IS 2185 part 3

AFFORDABLITY Specification : Autoclaved, Aerated Concrete Blocks – IS 2185 Part 3

Physical Properties of Autoclaved cellular concrete blocks
(Clauses 4.1, 8.3, 8.4, 8.5, 11.2, 11.3 and 11.4)
• AAC Blocks –Overall wall system costs are not higher than
conventional systems
Density in Oven dry Compressive Strength, Min Thermal Conductivity in Air
• AAC blocks offers more carpet area S. No
condition Dry Condition
Grade 1 Grade 2
• Faster construction – faster returns on investment (Speed up
(1) (2) (3) (4) (5)
construction by up to 30%) Kg/m3 N/mm2 N/mm2 W/ m. K
• Life time living costs are lower – due to energy saving, lower i) 451 to 550 2.0 1.5 0.21
maintenance etc.,(Reduces power consumption by 27%, Steel & ii) 551 to 650 4.0 3.0 0.24
iii) 651 to 750 5.0 4.0 0.30
Cement savings by 18% & 12% respectively, eliminates termites, iv) 751 to 850 6.0 5.0 0.37
rodents, pests & fungal growth ) v) 851 to 1000 7.0 6.0 0.42

Note:
1. Fly ash: Confirming to IS 3812-1981 with loss of ignition not more than 6 per cent
2. Use of fly ash confirming to IS 3812-1980 may be permitted to a limit of 20 per cent in cement confirming to
IS:269-1976
3. The drying shrinkage shall be not more than 0.05% for Grade 1 blocks and 0.10 percent for Grade 2 blocks
 Manufacturing of conventional clay bricks Manufacturing of conventional clay bricks

Drying Burning

Burning

Emission Manufacturing process of AAC Blocks

1 kg coal = + 3800 kcal

C 42%
1.5 kg CO2
Storage silos Batch mixing

= + 10500 kcal
1 kg fuel oil
C 84%
3 kg CO2
Control system(PLC) Dosing

Manufacturing process of AAC Blocks Need of the AAC product

Energy and Environment:

The product helps towards the energy and environment in the following ways.

•Utilization of fly ash in the product helps to solve the disposal problems and save
the fertile lands used for clay brick manufacturing.
Cutting
•Utilization of fly ash leads to the reduction in the cement consumption in the
product. 1MT of cement – 1 MT of CO2. Hence leading to the reduction of green

Pre curing house gases.

•The reduced consumption of cement implies the preservation of coal (natural
resource) and the same can be made available for producing energy.
•The blocks require less than 1/ 3 times energy compared to conventional clay
Stacking bricks.

Autoclaving
 Comparison of AAC blocks with clay bricks Comparison of AAC blocks with clay bricks

S. S.
Parameter AAC BLOCKS CLAY BRICKS Parameter AAC BLOCKS CLAY BRICKS
No No
Soil Uses fly ash which is a thermal One sq ft of carpet area with clay Compressive
1 consumptio power plant waste product & thus brick walling will consume 25.5 kg 6 Not less than 3 N/mm 2 3-5 N/mm2
strength
n no consumption of top soil of top soil
Fuel
One sq ft of carpet area with AAC One sq ft of carpet area with clay 7 Dry density 551-600 kg/m3 1920 Kg/m3
2 consumptio
blocks will consume 1 kg of coal bricks will consume 8 kg of coal
n
One sq ft of carpet area will emit One sq ft of carpet area will emit Consumption of 1.44 bags of cement/
3 Co2 emission 8 0.77 bags of cement / CuM
1.5 kg of CO2 12.0kg of CO2 cement mortar CuM
Production Unhealthy working conditions due Thermal
4 State-of-the-art factory facility 9 0.12 w/m-k 0.8 w/m-k
facility to toxic gases conductivity
190(L)x90(W)x90/40mm(H) Approximately 30% for heating and cooling
10 Energy saving None
600 x 200 x75,100,125,150,175,200, (modular) because of low thermal conductivity value.
225 mm 230(L)x110(W)x70/30mm(H) (non-
5 Sizes
Dimension variation are within modular). Dimensionally not Reduction in dead weight leading to savings
+/- 1.5mm accurate 11 Cost benefits None
in steel and concrete.
As per IS 1077-1992

Comparative Properties among Various Products Walling & Ceiling Solutions

S. Product key Solid Concrete Hollow Concrete CLC Light
AAC Blocks Clay Bricks Fly Ash Bricks
No Features Blocks Blocks Weight Blocks
1 Density 550kg/cum 1800kg/cum 1700kg/cum 2500kg/cum 1500kg/cum 800kg/cum
Thermal Good
2 Very Good Average Average Average Good
Insulation
Noise
3 Very Good Average Average Average Good Good
Insulation
Compressive
4 3 Mpa Quality can vary . 4 Mpa 8 Mpa 6Mpa 3 Mpa
Strength
Environmental
5 Ultra Positive Very negative positive Negative Negative Very Positive
Impact
Low strength- Easy
to break ;
Difficult to Difficult to Breaking into
high strength-
Easy to cut, break; break; sizes is very Easy to cut,
6 Usability Difficult to cut;
Easy to handle Not easy to Not easy to difficult; Easy to handle
Easy to handle but
handle handle Easy to handle
time consuming and
tedious
Availability
Availability Available with Availability
7 Availability decreasing in urban Easily available Easily available
increasing less suppliers increasing
areas
8 Efflorescence Absent Generally present Absent Absent Absent Present
Less High structural High structural High structural Avg. structural
Structural High structural
9 reinforcement reinforcement reinforcement reinforcement reinforcement
savings reinforcement req.
req. req. req. req. req.

Insulation Solutions

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