AAC blocks are made by mixing natural elements like sand, cement, lime, gypsum, and water. This mixture is then placed into moulds and allowed to solidify, and then wire-cutting machines are used to cut the material into the appropriate size and shape. The blocks are cured at high temperatures and pressures in an autoclave to provide the appropriate strength and durability.
ACC blocks are manufactured using a combination of lime, cement, sand, gypsum and aluminium powder. They are carefully measured and mixed in appropriate proportions.
AAC (Autoclaved Aerated Concrete) blocks are an environmentally benign, long-lasting, and adaptable building material utilised in construction applications. AAC blocks are produced by a multi-step process guaranteeing the creation of high-quality blocks with exceptional characteristics.
In this article, you’ll learn how AAC blocks are manufactured. Some key ingredients, equipment, and steps are required to produce high-quality AAC blocks for various construction applications.
Did you know?
Swedish architect and inventor Dr Johan Axel Eriksson developed AAC in the middle of the 20th century while collaborating with Professor Henrik Kreüger at the Royal Institute of Technology. In 1924, the method was granted a patent, and production began in the Swedish city of Yxhult in 1929.
The Process for Manufacturing AAC Blocks
Fly ash, cement, lime, gypsum, aluminium powder, and water are combined to create a slurry for AAC (Autoclaved Aerated Concrete) blocks. Then, after being poured into moulds of various sizes and shapes, the slurry is dried in an autoclave.
During the curing process, the blocks are heated to high pressure within the autoclave. This causes the aluminium powder to react with the other materials and create gas bubbles. These gas bubbles form millions of tiny air pockets inside the blocks, giving them a cellular structure and making them lightweight.
After curing, the blocks are removed from the moulds and cut using a wire-cutting machine into the required sizes. After that, the blocks are packaged and stacked for delivery.
AAC blocks are advantageous over conventional building materials like clay bricks and concrete blocks.
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They are strong, lightweight, and have great insulating qualities.
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They provide significant time, cost, and energy savings during construction.
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They are also more environmentally friendly because they are produced from recycled materials with less energy.
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AAC block manufacture is largely mechanised, guaranteeing uniform quality and dimensions.
Steps to Manufacture AAC Blocks
The following steps are involved in the production of AAC (Autoclaved Aerated Concrete) blocks:
1. Preparation of Raw Materials
Cement, lime, sand, gypsum, water, and an expansion agent are the basic materials required to construct AAC blocks. According to the instructions, the ingredients are precisely proportioned to achieve the necessary strength and density of the blocks.
2. Mixing
The basic components are combined in a slurry mixer to create a homogeneous mixture. The slurry is then poured into various-sized and shaped moulds.
3. Setting and Hardening
Depending on the temperature and humidity levels, the mixture can be set and hardened for many hours after the moulds have been filled with the slurry. The combination goes through a chemical reaction at this point that results in hydrogen gas, which distributes countless tiny air pockets throughout the mixture, producing a light and porous substance.
4. Auto Claving
After the blocks have hardened and set, they are placed in an autoclave, a high-pressure, steam-cured vessel, for many hours at a high temperature and pressure. The process of steam curing encourages additional chemical reactions that build a crystalline structure and give the blocks great strength and endurance.
5. Cutting and Finishing
Following autoclaving, the blocks are removed from the moulds and cut with a wire saw into the required sizes. The surface of the cut blocks is then completed using a grinding machine.
6. Drying And Packaging
After the blocks have finished drying in a drying chamber, they are prepared for packaging and transportation.AAC blocks are produced by an automated method that guarantees uniformity in quality and shortens production time. Because of their strength, lightweight, and durability, the resulting blocks are perfect for use in various building applications.
AAC blocks are produced using a highly automated method that guarantees consistency in quality and speeds up production. The resulting blocks are an excellent option for sustainable building because they are energy-efficient, environmentally benign, and good thermal insulators.
What Benefits Do AAC Blocks Offer?
As the importance of environmental conservation is recognised globally, the building industry has also seen technological advancements, including the use of cutting-edge and environmentally friendly construction materials.
A few advantages of AAC bricks are accelerated construction and better usefulness.
1. Lightweight
AAC blocks are 50% lighter and ten times larger than regular bricks. This unique characteristic facilitates installation and offers flexibility, simplifying modifications, cutting, shaping, etc. Since AAC blocks have fewer joints and are of a constant size, they are quicker to make and easier to lay. Last but not least, the lightweight blocks are easy to move, which lowers total logistics and shipping costs compared to the expenditures involved with transporting conventional blocks.
2. Fire-resistant
Compared to other building materials, AAC blocks are non-combustible and provide fire resistance for up to six hours and up to 1,200 degrees Celsius, depending on the block thickness. Because of this, it is also crucial for fire safety.
3. Energy-efficient
AAC blocks are constructed from natural, non-toxic raw materials and produce the least amount of waste during manufacturing, making them sustainable and economical. Micron-sized air pockets in the substance and using hydrogen to foam the concrete provide outstanding heat insulation capabilities that enable mild winter and cool summer temperatures.
Thus, it can significantly lower your air conditioning expenses by 25%. AAC blocks are more energy-efficient since they need less energy to produce them.
4. Pest-resistant
Since organic materials are used to create pest-resistant AAC blocks, which aid in defending the building against mice, termites, and other pests.
5. Soundproof
AAC blocks provide high sound suppression because of their lightweight and porous nature. Because of this, AAC blocks are frequently utilised in the construction of studios, hotels, hospitals, and other buildings.
6. Moisture-proof
Moisture has the potential to ruin a structure seriously. The internal macropores of the AAC blocks guarantee little water absorption, and as a result, they provide better moisture protection.
For smaller-scale construction projects, red bricks could still be crucial. However, AAC blocks provide more benefits and are essential in reducing environmental damage caused by using outdated building materials in large-scale residential, commercial, and infrastructure projects.
Drawbacks of AAC Blocks: Why Aren't They Used in Foundations?
Here are a few drawbacks of using AAC blocks in the foundation.
1. Limited Load-Bearing Capacity: AAC blocks are sturdy and long-lasting, although they have a smaller load-bearing capability than other common foundation materials like concrete or brick. As a result, they might not be able to withstand large loads and might need additional support, which would raise the cost.
2. Water Absorption: AAC blocks absorb much water because of their porous structure. When used in foundations, mould growth, water damage, and structural deterioration are possible.
3. Durability: While AAC blocks resist fire, they can be damaged by freeze-thaw cycles, impact, and erosion. The resilience of AAC blocks may be a problem in foundation walls where they are exposed to dampness, soil, and other factors.
4. Limited Availability: AAC blocks may not be easily accessible in some areas, which makes them more expensive and less accessible than alternative foundation materials.
5. Compliance Issues: Building rules and regulations may not allow the use of AAC blocks in foundations due to concerns about their poor durability, water absorption, and limited load-bearing capacity.
Conclusion
Blocks made of AAC (Autoclaved Aerated Concrete), a versatile and eco-friendly building material, can be used in various construction projects. Preparing the raw materials, mixing, pouring into moulds, setting, hardening, autoclaving, cutting, finishing, and drying are all steps in producing AAC blocks.
Air pockets are distributed throughout the raw material mixture due to a chemical reaction that occurs throughout the production process. This creates a lightweight and porous material. AAC blocks become even more sturdy, long-lasting, and pest- and fire-resistant after autoclaving.
AAC blocks are produced using a highly automated method that guarantees quality consistency and speeds up production. The resulting blocks are an excellent option for sustainable building because they are energy-efficient, environmentally benign, and good thermal insulators.
In conclusion, AAC blocks are an effective and environmentally friendly method that provides a high-quality building material with several benefits.
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