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Building Smart with AAC Blocks

"Challenging A Century Of Convention With 3 Decades Of Innovation"

It’s the era of globalization, the era of growth and rapid infrastructural development. It’s the period of growing skylines and exceeding urban boundaries. While cities are evolving into smart cities, infrastructural growth is undergoing a mammoth change in terms of planning, amenities and construction quality. However, growing concern over ecological sustainability pose on the future.

This is the very reason why AAC blocks forward as strong contender for fly ash bricks and clay bricks. Produced all year long, these blocks are perennially available and easily accessible. The block dimensions are pre-fixed and constant which cuts down correction time. To add to it, these blocks take lesser time and space to build saving time and money in the process.

AAC blocks are slowly becoming a norm for Indians and after a number of monumental buildings in India were made from AAC block, people’s faith in the product has gone up considerably.


What is AAC?

Autoclaved Aerated Concrete (AAC) block is a newly-adopted green building material in India which is used as a friendly substitute of the conventional red clay bricks in making walls in residential, commercial and industrial construction activities. AAC block is a light weight precast building material that offers a unique combination of strength, low weight, cost effectiveness, speed and durability. It is also an environment friendly product, as it is manufactured using 60-65% of fly ash (by weight), an unavoidable waste from coal/lignite-based thermal power plants.


Features & Advantages

Use of AAC block in construction activities offers interesting proposition for various segments of the society. For a project developer, an AAC block means faster construction along with cost saving; for an environmentally conscious peoples, it means eco-friendly product and for those who occupy buildings built with AAC block, it means better safety and lower energy costs for cooling or heating.

Light Weight

Light Weight

  • Usage of AAC substantially reduces the total dead load of a building, reducing structural steel consumption resulting in noticeable savings in overall project cost.
  • The light weight nature of blocks make construction easier and quicker reducing construction time by 20 %.
  • 3times lighter than traditional red clay & fly-ash bricks, therefore, easier and cheaper to transfer from one point to another within a construction site.
  • Lighter weight reduces mass of a structure, thus lowering the impact of an earthquake on a building.

Porous in Nature

Porous in Nature

  • Discontinuous 'macro' pores block capillary action and penetration of water in AAC blocks is minimal which prevents seepage ensuring damp-proof building.
  • Tiny air pores and thermal mass of blocks provide excellent thermal insulation, thus reducing air conditioning costs of a building, thus saves on electricity bill.
  • Non-combustible and fire resistant up to 1600° C. Can withstand up to 6 hours of direct exposure.
  • Superior sound absorption offering sound attenuation of about 60 to 200 mm dB, blocking out all major sounds and disturbances.

Bigger in size

Bigger in size

  • AAC block covers greater area for the same mass of brick used thus saves on transportation costs and conserves precious fuel.
  • Reduces construction time and labor cost by 20%
  • Larger sizes of blocks help reduce the number of joints in wall masonry and fewer joints result in considerable saving in mortar.
  • Reduces overall construction cost by 2.5% as it requires less jointing and reduces need for cement and steel.

Environment Friendly

Environment Friendly

  • Non-polluting manufacturing process – the only by-product is steam
  • Does not exude gases.
  • No water required for curingas well as during application.
  • Autoclaved Aerated Concrete products do not contain any toxic gas substances. The product does not harbour or encourage vermin.





Technical Data

  • Dimensions: L-600/625/300 | H-200 | B-75-250 mm
  • Dry Density (Oven Dry): 550 - 650 kg/m3
  • Compressive Strength: > 3 N/mm2 (MPascal)
  • Shear Strength: 0.6
  • Modulus of Elasticity: 2040 MPascal
  • Coefficient of Thermal Expansion: 8.1 x 10-6 K-1
  • Water Absorption (at equilibrium): 8%
  • Thermal Conductivity: 0.16 W/m-k
  • Thermal Resistance (R Value): 0.46 m2-k/w
  • Drying Shrinkage: 0.04%
  • Fire Rating: 4 Hrs.(for 200 mm wall)
  • Sound Transmission Class Rating: 44
  • Contribution To Carpet Area: Increases by 2-3%
  • Sound Reduction (db): 45 for 200 mm Thick Wall

Product Related Queries

Autoclaved Aerated Concrete (AAC) block is a precast, lightweight and insulating green building product which is used as walling material and as replacement for any building bricks, CLC Blocks etc. Due to strong thermal insulation, AAC blocks also find use in specialty applications such as fire walls, sound walls, roof tiling etc. EcorexBuildtech manufactures these products at its state-of-the art plant with latest innovations under German technology in Raipur, Chhattisgarh under the Brand name "Ecorex AAC Blocks".
Cement, Fly ash and Lime are the key ingredients for making AAC Blocks. They are cured under steam, known as Autoclave. Due to sustainable material envelope, these products are certified under green rating system and helps builder to get credit points.
Yes.Theseblocks are environmental-friendly construction material.They conserve and protect earth's precious natural resources, unlike bricks, which consume the top soil. Manufactured from fly ash, an industrial waste from thermal power plant. During manufacturing
EcorexAAC Blocks are manufactured at state-of-the-art plant with mostly automatic process under German Technology. The plant is equipped with latest innovations, such as horizontal curing and green separation. This ensures that users are able to get an accurate and consistent product. There is additional feature of Tongue & Groove and Hand Grips, which ensures faster work, accurate alignment and savings of joining mortar.
AAC blocks are in use for more than 90 years across the globe. Structures built over 85 years ago are still standing today. However for India, this is an evolving product.
AAC was developed in 1924 in Sweden by an architectural science lecturer who was looking for an alternate building material with properties similar to that of wood such as good thermal insulation, solid structure and easy to work etc. and also having resistance against fire and termite.
Durability of AAC has been proven in every type of climate in the world-from Northern Finland to the deserts of the Mid-East. AAC Blocks have excellent resistance to fire, moisture, termite and seismic attacks. They have very high shelf life and do not decay like wood or bricks. Termites and other pests do not eat them. Millions of tiny cells in AAC Blocks make them moisture resistant and also help increasing chance of survival during seismic attack.
K value for AAC Blocks is around 0.16W/Mk and this result in strong thermal insulation of walls with energy saving upto 20%.
Yes, being lightweight it reduces the impact of earthquake forces on fixed structure and increases chances of survival.
Hand Grips help in better handling and placing of blocks which result in reducing wastage and faster completion of work. Tongue & Groove provides automatic alignment of wall thus eliminating need to check plumb. It also reduces mortar consumption and provides accurate wall with savings of time and money.
Being lightweight (1/3rd weight of clay bricks), AAC Blocks are highly recommended for high rise buildings and help in reduction of total dead load of structure which directly helps in structural savings upto 20%.
Strength of AAC Blocks is as per IS:2185:1984 (Part III), which is absolutely safe and strong enough to use for any non-load bearing walling applications.

Application Related Queries

All kind of paints and putty can be applied onAAC Blocks. Dimensional accuracy of AAC Blocks helps to reduce thickness of Plaster by 50%. AAC Blocks require natural pre-curing. All kind of cladding is possible on it.
Inside, the Blocks can be finished with plaster, POP or any other interior finish. They can be easily cut, chased, sawed and sanded. Hence there are unlimited design possibilities with AAC Blocks.
Regular masons and labor can work on AAC Blocks with minimal training. Normal masonry practices, which adheres to IS:1905 (for Brick masonry) and IS:6041 (for AAC Block masonry), are applied in AAC Blocks masonry work. Care should be taken to ensure savings on mortar and plaster. *Please refer to best practices guide for further explanation. It is important to use right tools to get maximum productivity and quality. Please refer to tools section in our website (www.ecorex.in).
To get maximum benefit and have modern walls, it is important to use the right tools to get maximum productivity and quality. (You may refer to tools section for explanation on right tools).
Yes, AACBlocks can be easily worked upon and can be cut to required dimensions with a saw having carbide tips. *Please refer to smart tools section for further explanation.
Yes, it is possible. Chasing lines can be done with proper hand or machine tools.
Normal tools used in daily routine masonry can be used. For effective results and better productivity, special tools are highly recommended. *Please refer to smart tools section.
AAC Blocks offers large number of Smart Benefits. AAC Blocks should be considered right from design stage to get maximum benefits. One gets better quality wall with AAC Blocks. Depending on the cost of resources, life cycle cost can even be lower with these Blocks when compared with clay bricks or CLC blocks.
AAC Blocks are very light weight for example, 600 X 200 X 100 mm block will have around 7.2 Kgs of weight in comparison to brick with dimension of 230 x 115 X 75 mm which weighs around 3.57 Kgs.
AAC Blocks is not recommended for load bearing walls.
AAC Blocks need not be wetted before or during the laying of walls. In case the climatic conditions desire so, the top and the sides of the block may be moistened so as to prevent absorption of water from the mortar and ensure the development of the required bond with the mortar.
In rainy season, blocks should be covered to avoid extra absorption of water.
Walls exposed constantly to water require water proofing, else there is no need.
Water absorption coefficient of Ecorex Blocks is very less, hence it is recommended to cure at the masonry joints only.

Manufacturing Process

Ecorex Buildtech is first of its kind AAC Blocks manufacturer in Chhattisgarh with state-of-the-art production facilities. We are the largest unit in the state with an installed capacity of 1,55,000 cum per annum. Located at Kharora- Tilda Road, Raipur, the plant is well-equipped with calibrated laboratory for testing of raw materials and the finished product. Our team of experienced engineers and experts ensure processing process is smooth at every level. The manufacturing process in Ecorex Buildtech strictly adheres to IS 2185(PART3):1984 and the only company having ISI License in Central India. The Testing & Sampling for the same is done as per the BIS norms as stated in the article. The process can be described in following steps



Raw Material Preparation

Raw materials received is inspected before it enters the plant, once the quality is confirmed it is moved forward for the next process. Cement and Lime is stored to prevent from moisture entering in. There is a separate pneumatic based unloading system for raw materials being used.



Batching

The basic composition of Ecorex AAC Blocks consists of fly-ash slurry, ordinary Portland cement, quick lime, gypsum (pop) and aluminum powder. The desired volumes of each raw materials mixed by a highly precise batching system that ensures the consistency of each batch. The material is batched according to their respective test results which eliminates the variation in the batch quality.



Mixing and Pouring

All the raw materials are accurately and uniformly poured into big sized mould boxes by an automated mobile mixer. Once the batches are poured into moulds they are monitored by our highly skilled & dedicated quality team ensuring its quality matches the desired parameters.



Cutting

The porous green cake is then cut into desired size by high tensile of very low thickness wires that provide sharp and precise edges to the blocks. The system separately cuts the block vertically as well as horizontally, bringing accuracy in the dimensions of the blocks.



Autoclaving

After cutting, the porous green cake it undergoes the steam curing process in autoclaves for 10-12 hours cycle which provides 12 bars of steam pressure at a temp of 190-210. The Autoclaving process is responsible for the physical as well as chemical properties of AAC blocks.



Dispatch

Finally each of the blocks are separated with the help of Grab & Shift assembly process which is automated and involve least human intervention. From here, the final product is transferred to the stock yard with the help of a chain conveyor system and is all set for dispatch