Manufacturing and Advantages of AAC Blocks

It is produced from 5 natural materials: Fly ash, lime, cement, gypsum and water, combined with aluminum powder. The production process consists of the following steps.

·         Dosing and mixing of fly ash with lime, Ordinary Portland Cement (OPC), gypsum, lime and stabilizers a high dosing speed at very high accuracy.

·         Casting and rising/pre curing of the mixture to enable the fresh mix to rise and harden to a firm green cake with the volume of the mould.

·         Tilting mould cakes with the tilt manipulator on to a cutter machine and oiling to prevent the sticking of the green cakes for reuse.

·         Horizontal and cross cutting the cakes by cutter which are equipped with broken-wire-detection system.

·         Curing with a steam at pressure in autoclave system for 12 hrs period.

·         A post autoclaving, after buffering and de-stacking of hardened cakes from the cooking frames to the packaging line for final packaging.

The special combination of these substances yields a material with excellent construction properties such as structural strength, lightness, thermal insulation and fire resistance.Much of the material used in the manufacturing process is recaptured from non-toxic mine tailings, dramatically reducing the amount of raw materials required for production.  Additionally, waste generated during production is recycled back into the manufacturing process.  AAC Block is compatible with sustainable building practices since it requires fewer raw materials to produce and is completely non-toxic.  Production of AAC Block is designed to minimize waste and maximize recycling of materials. 

Lightweight 

Weighing approximately 1/5th as much as concrete.  This attribute makes the design and construction of AAC buildings easier and less strenuous. The lighter weight doesn't compromise strength as AAC has a compressive strength more than 30 Kg/cm2.

Energy Efficient  

The closed air cell construction of AAC provides superior insulation equivalent to R-values between 20-24 depending on the thickness of blocks.  It is possible to save up to 40% on energy costs. The breathable qualities of AAC allow energy to move through the blocks very slowly, thus ensuring that the interior temperature remains consistent.

Fire Resistant  

AAC is non-combustible and transfers heat slowly.  As per general laboratory testing AAC has a fire rating of 4 hours for a 4" non-load bearing wall.  AAC built structures provide homeowners with added piece of mind in fire prone landscapes.

Versatile  

It is available in different thickness as per requirement. Because it can be shaped by ordinary power tools with ease, AAC Block lends itself to aesthetically pleasing designs like curves, arches and domes.

Easy to Install  

AAC Block can be drilled, cut, cored, shased and shaped on-site.  Plumbing and Electrical lines can be routered directly into the block.

Sound Absorbing  

 In addition to providing thermal insulation, dead air cells within the block reduce the passage of sound this makes AAC Block ideal for projects next to airports, highways, apartments, resorts or high-density neighborhoods.

Cost Advantages  

The installed cost of AAC Block is competitive with other building materials.  Faster construction time, saving in plaster and mortar because of even and smooth surface also reduced cement and sand requirement by up to 35% to 40%, almost zero long-term maintenance.