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Details on Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20

[2011]

The construction industry in India has witnessed high growth rates in the recent years. With
increasing demand for built-up dwelling units and pressure of urbanization, the growth rate is expected to increase. 72% of India's power plants are coal based. These power stations generate nearly 150 160 million tones of fly ash annually. Fly ash causes severe pollution of air and water, and its disposal gobbles up large tracts of land. Proper management of fly ash is thereby necessitated so that our already perilously imbalanced environment can be protected. Biltech Building Elements Limited, with a twofold aim to utilize bulk quantities of flyash and help bridge the huge shortfall of bricks and other building materials required by the constantly rising construction activity, undertook the mechanized manufacture of flyash based Aerated Autoclaved Concrete Blocks .The conventional practice of firing clay bricks in Bulls Trench Kilns (BTK) and rural country clamps consumes huge quantities of energy in terms of coal, firewood and other fuels and erode a lot of top soil. Biltech Building Elements Limited, an Avantha Group Company ( formerly The Thapar Group), is in the business of manufacturing and marketing Autoclaved Aerated Concrete building material using Fly-ash (55%-60%) as the basic raw material. First Plant is located at Palwal has a manufacturing capacity Two lac fifty thousand cubic meter per annum Second Plant is located at Bhigwan, near Pune having capacity of one Lac cubic meter per annum and third under erection in Kolkata.

Autoclaved aerated concrete (AAC) is a building material which consists of various sized elements that form a complete building system. In most cases, every portion of the structural and insulation requirements of a building are satisfied with the one material.

AAC Products have found prominence in various projects all over the country. Through its unique and inherent properties, these products are being widely appreciated and extensively used in Northern, Central and Western states.

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20

[2011]

BILTEC Block:

Technical Specifications:

TYPE Block

Length 625 mm

Height/ Width 250 mm

Thickness 100 , 125 ,150,200,225,250 & 300 mm

Properties of AAC material PROPERTIES Density (Oven Dry) Compressive Strength Thermal Conductivity ( K Value) Resistant to Fire Drying Shrinkage Design Gross Density Relevant B.I.S Standards: BIS - 2185 (III) - 1984: Autoclaved Aerated Concrete Block. BIS - 6041 - 1985: Construction of Autoclaved Aerated Concrete Block Masonry. BIS - 6441 - 1972: Methods of Test for Autoclaved Cellular Concrete Product. VALUES 551-650 Kg/Cum Minimum 30 Kg/cm2 0.162 W/mK (avg) 2 - 6 hrs depending upon Thickness 0.1 % 850 Kg/Cum. (appx.)

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20

[2011]

The Manufacturing Process: Various raw materials fly-ash, quicklime, cement, gypsum, and aluminium powder are tested, graded and stored in their respective silos. These are then metered and conveyed in a programmed sequence into the batch mixer. This mixture is poured into moulds, allowed to rise and set, trimmed and cut to shape and size and loaded into autoclaves. In the autoclaves they are steamed, as per the process requirements, for up to 12 hours, unloaded, palletised and sent for dispatch. Pulverised fly-ash is obtained from the NTPC power plant at Badarpur Thermal Power Station (BTPS).

Basic material Thanks to its characteristic structure comprising millions of tiny pores, it offers optimum solidity at low weight. As air has a low heat conductivity, aerated concrete provides excellent thermal protection. It protects from cold and heat, allowing for single-shell constructions which provide more space, save time and reduce cost aspects which are of considerable importance.

Flyash +

Cement +

Lime +

Water +

Aerating agent

= AAC

Raw material composition in AAC ( Appx. by weight): Fly Ash 55-60% Gypsum 2-3% Cement 10-12% Lime 12-14% Aluminum Powder 0.03% Balance Slurry solids generated during process

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20

[2011]

Physical properties of AAC Block:Thermal Insulation & Energy Savings: Buildings constructed of Biltec-AAC provide substantial energy savings in both hot and cold climates. The tiny air pores within the unique structure of AAC and the thermal mass both contribute to provide excellent insulation. Fire Resistance: Biltec-AAC is a non-combustible and fire resistant material (up to 6 hours of direct exposure). Fusion temperature of AAC is equal to other cement products at approximately 1600C. Acoustic Performance: Biltec- AAC Blocks have superior sound absorption properties in comparison with other construction materials

Workability: Biltec- AAC products can be easily cut, drilled and grooved with manual or power tools. This provides higher productivity in hydro-sanitary and electrical installations such as pipes or ducts which can be placed after the structure has been built Sustainable: Biltec- AAC products do not degrade with time, resulting in superior properties compared to other construction materials. As an alkaline material with a pH between 9.0 and 10.5, it does not cause any corrosion to building materials. AAC does not have any toxic substances nor emit odours.

Easy to Install: Biltec -AAC products are ready to use, so their placement is faster and represent less labour time. Also, Biltec- AAC products don't require setting, hardening or waiting time before proceeding with the finishes

Less Weight: Biltec- AAC is up to 3-4 times lighter than traditional concrete, representing great advantages in transportation and material handling

Precision: Exact dimensions of Biltec- AAC pieces result in smooth walls with a perfect contact among the different elements, enabling builders to save in finishes and achieve optimal structural performance. Dimension tolerances are +/- 5 mm.

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20

[2011]

AAC Products can provide benefits in the form of: Structural saving: Depending on the structure , there will be a benefit in cost of minimum 3% for AAC based systems over conventional systems purely on savings on account of structural costs. Speed in construction: AAC based systems shall provide a time benefit of over 20% vis--vis conventional construction due to reduction in number of joints in the wall masonry because of its big size. Operation & Maintenance Benefits: AAC based systems shall provide a major 30% saving in energy costs (depending on design) , due to reduced Air-conditioning load vis--vis conventional construction as AAC based systems provide high insulation properties. Properties to counter seismic sensitivity: AAC material provides excellent insulation and fire resistance properties, apart from the fact that it is lightweight and reduces the impact of earthquake forces on fixed structures. The provisions of amended IS-1893 are very stringent in respect of control of impact and earthquake forces on fixed structures and therefore the use of lightweight material is recommended. This is a unique feature which gives it an edge over the conventional system keeping in mind the seismic sensitivity of your region. Green Building Material: As AAC offers reduced environmental impact during manufacturing, construction and renovation, it is fast emerging as a Green Building Material and is being recommended for all green buildings.. AAC as Green Building Material:

Environmentally friendly - uses fly ash Energy conscious manufacturing process No pollutants generated in production No waste of raw materials Energy conservation

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20
Benefits of Green Building Material: 30% to 40% reduction in operational cost Green Corporate image Health Safety & comfort of building occupants

[2011]

Speed of construction, saving in jointing mortar, attractive appearance, design versatility, good and strong binding are some of the merits of AAC block masonry. Green Building Attributes AAC has wide usage in Europe over the past 90 years and also in India for last 40 years in various applications and conditions. Its use has expanded over the past decades to India and other markets across the globe. Autoclaved Aerated Concrete (AAC) is an environment friendly building material that is used to save energy and enhance the quality of the built environment. The environmentally friendly attributes of AAC provide distinct advantages to building designs when it is used to address green or sustainable building concerns. Many of these beneficial attributes are recognized by Green rating agencies like IGBC LEEDTM (Leadership in Energy & Environmental Design) & TERI- Griha. Any environmentally conscious building owner or developer may choose to design and construct a building to minimize environmental impact using LEED / GRIHA rating system as a guide.

Specification of AAC Block work: Providing and laying of Autoclaved Aerated Concrete (AAC ) block masonry using blocks having dimensions of 625 mm x 250 mm. thickness ranging from 100 mm to 300 mm conforming to I.S. :2185(part-III) .The jointing cement sand mortar in the composition of 1: 6 (Cement: sand) shall be used with suitable plasticizer(optional). The horizontal and vertical joint thickness shall be approximately 10 mm. In case of partition walls (100 mm /125 mm thk.) the joint reinforcement i.e. 2 number of 6-8 mm diameter bars shall be placed at every alternate course to be anchored properly with the main structure. All other structural requirements like stiffening of masonry , joint reinforcement etc. in the AAC masonry work strictly be carried out as per instructions laid down in .I.S 6041 1985, I.S -1905. Laying of AAC Masonry (Useful Tips):

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20
1) LAYING OF AAC BLOCK MASONRY

[2011]

The jointing mortar shall be leaner i.e. 1:6. The mortar shall not be spread so much ahead of the actual laying of the units that it tends to stiffen and lose its plasticity there by resulting in poor bond. Consistency as per requirement of site must be maintained at the point of laying . Laying of AAC block masonry shall be in accordance with the recommendations of IS 6041 of 1985 and IS 1905 of 1987. The maximum joint thickness (Vertical and Horizontal) shall be 10-12 mm. The laying of block may be started either at the corners first or it may be started from one end and proceed to the other direction. Lay 10 mm thick cement mortar uniformly over bed. Wet the blocks on all sides by using a tray filled with 20/25 mm water and place them one by one and press it firmly to have proper bond. Ensure proper spread of mortar in the joints between the blocks. The first course of the cellular block masonry shall be laid with great care, making sure that it is properly aligned, leveled and plumbed, as this may assist the mason in laying succeeding courses to obtain a straight and truly vertical wall. Ensure all the surfaces of the block which comes in contact with cement mortar are wet to have proper bonding. To maintain proper cement mortar filling at the sill level, please check the height of masonry and distribute the same along the joints and if the gap is more same can be adjusted in the bedding mortar. Later the joint shall be ideally filled up with jute strips dipped in cement slurry so that flexible joint can be maintained at that level. Before laying the mortar, two 10 mm square rods can be placed on both the sides of the block to obtain uniform joint. The mortar joint shall be struck off flush with wall surface and when the mortar stiffening, it shall be compressed tightly. Once the masonry erected the curing shall be minimum unlike brick masonry. The curing requires more at the joints. Before plastering, cement slurry may be applied on the walls and only leaner mix shall be applied. The thickness shall be 10-12 mm in the external walls and in the internal application in case of dry walls plastering can be avoided. In such case directly P.O.P / Gypsum plaster can also be applied. Maximum erection of 5-6 courses is desirable in a day.

2) Chasing and cutting Blocks shall be cut with a saw. Where ever chasing to be done in AAC Blocks, rotary cutters to be used. The chases shall be refilled with leaner mortar and chicken mesh (as per Consultants recommendation) shall be applied on the area.

All other structural requirements like placing of joint reinforcement, nominal band beams etc. Is to be considered in accordance with the recommendations laid down in I.S. Codes6041 & 1905

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20
F.A.Qs. ON AAC BLOCK Q: Is AAC a new building material?

[2011]

A: No, AAC was invented over 70 years ago in Sweden. Since then, AAC has gained acceptance around the world. M/s Siporex India Ltd. in Pune, M/s Biltech Building Elements Ltd. in Palwal and Bhigwan and M/s Hyderabad Industries Ltd. in Chennai are some of major organizations in this business of manufacturing AAC in India. Q: What materials are used to make AAC? A: Fly ash, Portland Cement, Lime, Water and an expansion agent. The end result is a building material called AAC that is roughly 70% to 80% air in it. Q: What is the k-value for an AAC Block? A: Since in AAC products there are 70% to 80% air, depending on the required density, independent testing has shown that k value for AAC is around 0.16W/Mk. Q: What are the lead-times for AAC? A: AAC blocks are dispatched within 2-3 working days time after confirmation of order and there is no seasonal variation in supplies. Q: What exterior finishes are suitable for AAC? A: AAC can be finished with brick, stone, stucco, wood/vinyl siding ... or any other standard finishing, as per recommendation of the consultant. Q: What interior finishes are suitable for AAC? A: AAC can be finished with sheet rock (directly attached), plaster (directly applied), tile, nonvinyl wallpaper, paint... again, or any other standard finishing Q: What type of mortar is used with AAC? A: 1:6 Cement mortar or 1:1:5 in Cement flyash mortar of 10 mm thick for both vertical and horizontal joints. Q: How durable is AAC in various climates? A: Autoclaved aerated concrete is extremely durable. It does not rot or decay like wood or other organic materials. It does not rust like metal. Termites and other pests do not eat it. AAC will not burn. The millions of tiny cells in AAC cushion buildings from major force, preventing progressive collapse.

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

BILTECH BUILDING ELEMENTS LTD.


232-B, Okhla Industrial Estate , Phase-III, New Delhi-20 Some of our esteemed clients

[2011]

Contact Nos.: 09811076657, 011-49696629; email: rajdeep.chowdhury@bilt.com

Light weight BILTECH ACE - Autoclaved Aerated Concrete Block

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