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Autoclaved Aerated

Concrete

Introduction

Formed as a result of reaction of Aluminum on a proportionate blend of lime, cement & Fly ash, the hydrogen gas that escapes creates millions of tiny air cells giving it a strong Cellular structure which is further strengthened by high pressure steam curing in Autoclaves known as AUTOCLAVED AERATED CONCRETE .

AAC –Light Weight Product

600

1200

1800 19202400

0

500

1000

1500

2000

2500

AAC Hollow Block

Cement Concrete

Block

Clay Bricks

concrete

Density (Kg/Cum ) of Various materials

Density (Kg/Cum ) of Various materials

• Fire rating of 4 hours

AAC has excellent acoustic properties with an STC (Sound Transmission class) rating of 44.

Acoustics

Pest Resistant

AAC Blocks being made of inorganic minerals are Termite resistant. They also prevents growth of fungus, algae and mosses.

Comparison between AAC, Concrete & Brick

Sr. No

Parameter AAC Block Concrete Block Brick

1 Size (600x200x75-300) mm

(400x200x100-200) mm

(230x115x75) mm

2 Variation in dimensions

+/-1mm +/-3mm +/-5mm

3 Compressive strength

35-40 kg/cm2 (As per IS : 2185)

40-50 kg/cm2 (As per IS : 2185)

25-30 kg/cm2(As per IS : 1077)

4 Dry Density 550-600 kg/m3 (Oven dry)

1800 kg/m3 1950 Kg/m3

5 Fire Resistance 4-6 Hour depending on thickness

4 hours 2 hour

6 Sound Reduction Index (dB)

60 for 200 mm thick wall

40 for 230 mm thick wall

7 Thermal Conductivity W/(K-m)

0.16 0.51 0.81

8 Colour availability Greyish white Grey Red

A Green Building Material …

Autoclaved Aerated Concrete Block (AAC) Plant at Hyderabad

Fully Automatic, State of Art Plant from HESS, Netherlands

Aerated Autoclave Concrete Blocks

CLAY BRICKS AAC BLOCKS

Environmental Impact

One clay brick consumes 3.2 kgs of top soil

No top soil consumed

One sq ft of carpet area with clay brick walling will consume 25.5 kgs of top soil

Uses fly ash which is a thermal power plant waste product & thus no consumption of top soil

One sq ft of carpet area with clay bricks will consume 8 kgs of coal

One sq ft of carpet area with AAC blocks will consume 0.9677 kgs of coal

One sq ft of carpet area will emit 17.6 kgs of CO2

One sq ft of carpet area will emit 2.13 kgs of CO2

Social Impact

Unorganised sector (child labour rampant in unorganised sector)

Organised sector. Nation building through Corporate Governance, Statutory Labour and HR practices

Does not contribute to government exchequer (taxes)

Contributes to government taxes in form of Central Excise, VAT & Octroi

Unhealthy working conditions, a major health hazard due to toxic gases

Organised sector with state-of-the-art factory facility

Autoclaved Aerated Concrete Blocks

Autoclaved Aerated Concrete Blocks

Walls Internal/External

Load Bearing in low and medium rise Buildings

Non Load Bearing walls in framed construction

Partitions Walls

Thermal Insulation Tiles

Applications

Dry Mix Products

Dry Mix Plant at Wada, MumbaiDry Mix Plant at Wada, Mumbai

Wada, MumbaiFully Automatic Plant from M-Tec, Germany

FixoblockFixoblock

• Jointing Mortar is to create Thin (2-3 mm) Mortar Joints in Block work.

• The application results in faster, cleaner and accurate system for construction particularly with AAC blocks of close dimensional tolerances.

• High Quality, greater productivity, air tightness and waste reduction.

• No water curing is required.

• Higher thickness of conventional mortar joints, results in shrinkage, leading to separation cracks at beams soffits resulting in water percolation.

• Very less chances of water percolation through the joints due to denseness and water repellent properties.

• Economical and hassle free application with improved line and level in walls.

Jointing Mortar

The The final strength……final strength……

UltraTech “Fixoblock”

AAC BLOCKS Fixed on the Wall at Site with Cement : Sand Mortar (1:6) & FIXOBLOCK

Load Applied on the Blocks fixed at site Cement - Sand Mortar (1:6)

Failed under the Load of 28.32 kg.

Load applied on the Blocks fixed with “FIXOBLOCK” Sustained the Load of 87.5 Kg &

No Failure was observed.

Load Applied on the Blocks Fixed on the Ceiling with Fixoblock

Load

Sustained the Load of 55.80 KG & NO FAILURE WAS OBSERVED

Load Applied on the Blocks Fixed on the Ceiling with Fixoblock

Load

Sustained the Load of 55.80 KG & NO FAILURE WAS OBSERVED

Seal & DrySeal & Dry

• Single component grey cement based elastomeric water proofing coating applied by brush over mortar and concrete surfaces.

• User friendly product.

• Reliable water proofing solution over terraces, plastered surfaces, roofs, etc.

Features

Impermeable coating withstanding capacity of 5-7 Bars on positive side.

Capable of handling 1.5 Bar when applied on negative side.

Extremely Good adhesion with cementitious surfaces, Abrasion Resistance as measured by wear out is only 75 micron against limit of 1000 micron.

Flexible.

No Water curing required after application.

Easily Brush applied.

Durable & economical.

Advantages

No. Properties Results1 Appearance Free flowing powder2 Colour Light Grey3 Water demand, % 324 Applicability Can be applied by brush5 Touch dry, minutes 30 - 406 Chalking Not observed

7 Self curing Yes8 Coverage (2 coats on concrete) 1.24 m2/ Kg

9 Tensile Adhesion test (28 days) 1.35 N/ mm2 (Req. 0.5 N/mm2 )10 Water absorption, ( Karsten Tube) 0.2 ml in 24 hours11 Water impermeability Passes 7 Bar pressure(Req. 1.5 Bar )

The Product has been Tested at CFTRI , Mysore and Conforms to 21 CFR 175-300 of US-FDA for the intended use for Packaging of Aqueous foods and storing.

(CFR- Code of Federal Regulations)

• Water proofing is important in all types of Buildings, Multiplexes, Swimming Pools, Water Reservoirs, basements, etc.

• Considering seepages/ leakages through walls/roofs especially in high rain fall areas like Mumbai - Pune, Goa, Konkan belt, Southern Gujarat, etc., Seal & Dry can be used as original construction material to be applied over plaster/ RCC slabs directly.

• Repairs of shrinkage cracks, dampness in walls, pools, water retaining structures, wet areas like kitchens, bathrooms, etc.

Applications

Seal & Dry Coating

Before Application

Cracks in China Mosaic

Seal & Dry 1st Coat

Super StuccoSuper Stucco

• Base coat product over plaster for interiors and final finish for exteriors.

• Super Stucco coat can be applied directly on Concrete surfaces. Thickness of stucco coat is about 3-5mm against conventional plaster of 10 to 12mm.

• Excellent Crack Filling Material.

• Finish much superior to any existing products.

• Self curing material.Features

Residential buildings

Commercial complexes

Basements

Parking areas

Renovation Segment, etc.

Applications

An alternative add-on ……..An alternative add-on ……..

Beam / Column / Slab with Chiseling / Hacking

Cost of Hacking

(Tools + Labour) is = Rs.0.50 per sqft

Rough Plaster

Cost of Rough Plaster

Sand + Cement + Water + Tools + Scaffoldings + Labour = Rs. 7 per sqft

Smooth Plaster over Rough

Cost of Smooth Plaster

Sand + Cement + Water + Tools + Scaffoldings + Labor = Rs.11 per sqft

Curing the Plaster

Cost of Curing

Water + Labour = Rs.0.30 per sqft

Chiseling / Hacking

Rough Plaster

Finishing Rough Plaster

Curing

Cost of Plastering over RCC

Rs.18.80 per sqft approx.

Putty CostingPutty Costing

Cost on Mala Finish Plaster

Material Cost = Rs. 2.50 per sqftLabour Cost = Rs. 2.50 per sqft

Total Cost = Rs. 5 per sqft

Painting CostPainting Cost

Cost of Painting

Emery Paper + Tools + Labour = Rs. 5 per sqft

1.Cost of Hacking = Rs.0.50

2.Cost of Rough Plaster = Rs.7.00

3.Cost of Smooth Plaster = Rs.11.00

4.Cost of Curing = Rs.0.30

5.Cost of Putty = Rs.5.00

6.Cost of Painting = Rs.5.00

Total= Rs. 27.80 approx.

Summary 1Summary 1

Over RCCOver RCC

Beam /Slab and Column (No Hacking)Beam /Slab and Column (No Hacking)

Saving

Saving of chiseling cost = Rs.0.50 per sqft

No plaster required on RCCNo plaster required on RCC

Saving

Saving of plaster = Rs.18.80 per sqft

Application of Application of Superstucco on RCCSuperstucco on RCC

Cost of SuperstuccoLevelling of RCC joints + Cleaning the surface + Scaffoldings + Tools + Emery Paper + 2 Coats of Superstucco(Material + Labour) = Rs. 12 per sqft (Thickness: 5-7mm)

Putty over SuperstuccoPutty over Superstucco

Cost of Putty

Scaffoldings + Tools + 2 Coats of Putty(Material + Labour) = Rs. 5 per sqft

No curing required over the surface

Saving

Saving of Curing Cost = Rs.0.30 per sqft

1. Cost of 2 coats of

Superstucco

over RCC = Rs. 12.00 per sqft

2. Cost of 2 coats of Putty

over Superstucco = Rs. 5.00 per sqft

Total = Rs.17.00 per sqft

Summary 2Summary 2

SavingsSavings

There is a saving of Rs.10.80/- per sqft if costing compared with Summary 1

Time of application reduces to 50 % as compared with Plastering

AdvantagesAdvantages

You can avoid painting over final Putty finish.

If more line and leveling required, then

Birla White LevelPlast or Conventional

Putty can be applied.

No Properties Stucco Render

1 AppearanceFree flowing

powderNot so Free

Flowing2 Colour Light Grey Grey3 Water demand, % 27 25-354 Workability Very Good Not so Good5 Touch dry, minutes 30 - 40 60

6 Self curing YesMin 7 Days

Curing7 Thickness, mm 2 – 6 12-28

8Tensile Adhesion test (15

days)0.43 N/ mm2

0.15 N/ mm2

9Tensile Adhesion test (28

days)0.8 N/ mm2

(Req. 0.3 N/mm2 )0.25-0.3 N/ mm2

10Water absorption, ( Karsten

Tube) 0.2 ml in 24 hours > 1 ml in 24 Hrs

Test report of Super Stucco : Wacker laboratory, India & Singapore.

No hacking of concrete is required.

No water curing is required.

It can be applied over moist surfaces

No primer is required over stucco coat before

application of paint.

The surface after application will be water resistant.

Advantages

PowergroutPowergrout

• Powergrout is a cement -based material consisting of OPC cement, additives and graded sand. It is a ready to use dry powder, grey in colour and free flowing. It gives high-early strength in very short span of time.

Features

• Insulator segment, Repairs to roads, Airstrips, Floors, etc.

Crack filling, Repairs to bridges / bridge decks, Defense establishments.

Applications

Very high strength development at very short span of time.

No water curing required

Excellent material for repair of Honey combed concrete.

Fixing of bolts, fasteners etc.

Non-expansive.

Gives non-bleeding homogeneous mass.

Self compacting obviates the need of vibration.

Advantages

ReadiplastReadiplast

Features

Readiplast is a ready mix cement plaster / render with a high quality polymer additives. It can be used on inner and outer walls.

It can be used on brick, block, stone walls as well as concrete surfaces.

It is water resistant with high quality and sustainability.

Rendering with Readiplast have lesser chances of developing cracks.

Made with graded sand which enhances the durability.

Advantages

Smooth plaster

Less curing

Least rebound

Time saving

Light coloured plastered walls with uniform quality

Durable plaster

Thank You!