#Aerocon Bricks #Types #Advantages of AAC block over Clay bricks #Cost Analysis #Advancement in Cement Technology

1. AEROCON BRICKS
GREATER NOIDA INSTITUTE OF TECHNOLOGY
SEMINAR ON
SUBMITTED BY:-
RITIK RAJ
DEPARTMENT OF CIVIL ENGINEERING

2. AEROCON BRICKS
 Autoclaved aerated concrete brick was invented in mid-1923 in
Sweden by a Swedish architect Dr. Johan Errikson, who was
looking for a alternate building material having quality of :-
Wood i.e good thermal insulation, solid structure and easy to
work.Without the disadvantage of combustibility and decay.
 It is now considered as a new generation brick also known as
Autoclaved Cellular Concrete (ACC) bricks or Autoclaved
Lightweight.
 Concrete (ALC) bricks or, autoclaved aerated concrete bricks(AAC).
These AAC bricks are made with a mixture of cement, fly ash,
lime,aluminium and water involving an aeration process that gives it
the unique cellular structure.
INTRODUCTION

3. CHARACTERISTICS OF
AEROCON BRICKS
 Light weight : Their weight is only one-third densities of clay bricks.
 Fire Resistance: walls build by means of aerocon bricks,with a minimum
thickness of 100mm can resist fire for upto Four hours.
 Sound Insulation : A good quality aerocon bricks can reduce the sound
transmission upto 42 decibels.
 Thermal Insulation
 Strength and Durability
 Perfect Finish and Dimensional Stability

4. TYPES OF AEROCON BRICKS
1. Infill bricks:
 Size :- 600X600 mm.
 Thickness :- 75,100,125,150,200 mm.
Importance:
 Easily replace 60% of the concrete in roof
slabs.
 Saving significant amounts of concrete, steel,
labor, water, plaster etc.

5. 2. Jumbo blocks:-
 Size:- 600X200 mm.
 Thickness:- 75,100,125,150, to 200 mm
Importance:
 Because of large size less mortar is required.
 These bricks are more suitable for multi-
storied buildings etc.

6. 3.Thermal blocks:-
 Size:- 300X200 mm.
 Thickness:- 50 mm.
Importance:
 Delay the transmission of heat
flow. So, help interiors remain
warm during winters and cool
during summers.
 Good for roofing.

7. Steps Involved in
manufacturing process.
1.Raw Material Preparation:
 Fly ash :-
 Fly ash is mixed with water to form fly ash slurry.
 Fly Ash is usually a by-product of thermal power plants and is an
important raw material in the manufacture of AAC Blocks.
 Slurry thus formed is mixed with other ingredients like lime powder,
cement, gypsum and Aluminum powder in quantities consistent with the
recipe.

8. Limestone powder:-
Lime powder required for AAC production
is obtained either by crushing limestone to
fine powder at AAC factory or by directly
purchasing it in powder form from a
vendor.
Crusher for grinding lime stone

9. Cement :-
53-grade Ordinary Portland Cement (OPC) from reputed manufacturer
is required for manufacturing AAC blocks.
Gypsum :-
Gypsum is easily available in the market and is used in powder form.
Aluminum powder/paste :-
A small quantity of Aluminum powder/paste is required to be added to the
mixture, it is usually weighed manually and added to the mixing unit.

10. 2. Dosing and Mixing: -
Fly ash slurry is pumped into a separate container. Once the desired
weight is poured in, pumping is stopped.
Lime powder, cement and gypsum are poured into individual containers
using screw conveyors.
 Mixing drum is like a giant bowl with a stirrer rotating inside to ensure
proper mixing of ingredients. Steam might also be fed to the unit to
maintain temperature in range of 40-42oC.
 Dosing and mixing process is carried out continuously because if there is
a long gap between charging and discharging of ingredients, residual
mixture might start hardening and choke up the entire unit.

11. 3. Casting and Rising : -
Before casting, the moulds are coated with a thin layer of oil. Done in order
to ensure that cake does not stick to the mould.
 While slurry is mixed and poured into greased moulds, Aluminium reacts
with Calcium Hydroxide and water to form Hydrogen.
 Millions of tiny Hydrogen bubbles are released due to this reaction. This
leads to formation of tiny unconnected cells causing slurry mix to expand.
 These cells are the reason behind light weight and insulating properties of
AAC blocks.

12. 4. Demoulding and Cutting:-
Once a mould is out of pre-curing room, it
is lifted by a crane or rolled on tracks for the
demoulding operation.
Cutting operation is achieved by moving
green cake through horizontal cutting
machine.
 Horizontal or Vertical cuttings are made
through cake using stationary steel wires.
These wires can be adjusted offline to get
desired height of AAC blocks or panels.

13. Comparison Between AAC
Bricks and Clay Bricks
S.no Parameters AAC Bricks Clay Bricks
1. Soil Consumption. Zero soil consumption. 1 square ft. of area with clay brick
walling will consume 25.5 kg of top soil.
2. Labour Organized sector with proper HR
practices.
Unorganized sector with rampant use
of child Labour.
3. Production Facility. State-of-the-art factory facility. Unhealthy working conditions due to
toxic gases.
4. Compressive Strength. 3-4 N/m2 2.5-3 N/m2
5. Fire Resistance (8″ wall). Up to 7 hours. Around 2 hours
6. Cost Benefit. Reduction in dead weight leading to
savings in steel and concrete.
None
7. Thermal Resistance. Approximately 30% for heating and
cooling.
None
8. Speed of manufacturing HIGH LOW

14. COST ANALYSIS
MM.DD.20XX
Cost of building materials vary from region to region.
For Instance, one cubic meter comprises of 600 bricks, which
costs around Rs.3000-4000/- cubic meter.
However, AAC blocks are available at the range of Rs.2800-
4000/- per m3.

15. AAC Manufacturing in India
MM.DD.20XXADD A FOOTER15

16. ITS IMPORTANCE IN NEXT
GENERATION CONSTRUCTION
Use of waste Product:-
Fly Ash is usually a by-product of thermal power plants and is an important
raw material in the manufacture of AAC Blocks.
Water Conservation :-
AAC blocks don’t need curing, as water used in other ordinary Clay Bricks.
Durability:- AAC has a very porous structure filled by Air Bubbles which
arrests water absorption into the AAC material is minimum. So, It leads to
Low maintenance and increased durability.
 Recycle / Reuse :-Waste from the cutting process is recycled back with raw
materials and used again.
AAC blocks can be reused into base preparation of roads.

17. CONCLUSION
However it is difficult to replace the old materials with new one.
Comparative Analysis indicates that in almost all the parameters, the AAC
blocks have a superior edge over burnt clay bricks.
The use of AAC blocks leads to savings in overall project cost; enables to
speed up the construction process reduced environmental and social
impact.
Therefore we can conclude that use of ACC blocks over burnt clay
bricks is recommended. It is advisable to developers, contractors, and
individuals to encourage this product as its use is in national interest.

18. THANK YOU!
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