GUBBI ENTERPRISES

ADVANCE AREATED CONCRETE (AAC) / AREATED LIGHT WEIGHT CONCRETE (ALC)

MANUFACTURING PLANT

Sr.

No.

Density In Ovendry

Condition

Compressive

Strength

Thermal Conductivity

In Air Dry Condition

Grade I Grade 2

Kg/m2 N/mm2 N/mm3 W/m.k

i 451 to 550 2-0 1-5 0-21

ii 551 to 650 4-0 3-0 0-24

iii 651 to 750 5-0 4-0 0-30

iv 751 to 850 6-0 5-0 0-37

v 851 to 1000 7-0 6-0 0-42

Physical Properties of

AAC/ ALC Blocks

As per IS: 2185 (Part 3)

What is AAC/ ALC Blocks ?

AAC is called as Advance Aerated Concrete block or ALC is called Aerated lightweight concrete.

The blocks are made to aerate by creating a reaction between

silica in base material such as fly ash, active lime, and aluminium powder. The block hardness is being achieved by cement strength, and instant curing. Gypsum acts as a long term strength gainer.

The finished product is a 2.5 times lighter Block compared to conventional Bricks, while providing the similar strengths. The specific gravity stays around 0.6 to 0.65. This is one single most USP of the AAC / ALC.

This unit is proposed to manufacturer AAC/ ALC Block by consuming the Fly ash as one of the prime raw material..

AAC Blocks are largely used in various constructions, such as load bearing and pillar structure Buildings, Boundary walls, Roads, Culverts, Pavements, and wherever conventional bricks can be used.

Using these blocks in structural buildings, the builder saves around 25 to 35% of structural steel and concrete.

These green bricks can attain very regular & uniform shapes. As no burning is involved, so the shapes also remains unchanged.

Workability Energy Saving Thermal Insulation

Cost Saving

Fire Resistance

Less Weight

Water Barrier High Strength Easy to Install

Versatile Faster Construction Earthquake Resistant

Long Lasting Future Product Eco- Friendly

Light in Weight

One fifth weight of concrete and

are produced in easily

handled sizes.

Eco friendly Reduce at least 30%

of environmental

waste, decrease over

50% of greenhouse

radiation and over

60% integrated

energy on the

surface of the bricks.

Material Saving

AAC blocks are

bigger in size

then conventional

bricks, resulting in

lesser number of

joints. So, result

in Saving of

mortar

Long life products are not

affected by harsh

climatic conditions

and will not

degrade under

normal

atmospheric

conditions

Energy saving Pleasant interior

environment is

achieved. In most

cases the need for

supplementary

insulation can be

avoided.

Ventilation Very airy thus allowing more

diffusion of water, reducing humidity of the

building

Thermal Insulation

Very Low Thermal Conductivity &

therefore very high thermal energy

efficiency is achieved

Fire Resistance

Extremely high fire rating of at least 4 hours and more

Uniform Block can be

produced in large variety of size, from standard blocks to

large reinforced panels.

Accuracy panels and blocks are

always produced to

size as they leave the

factory. This results in

less on-site trimming

and reduced quantities

of mortar and finishing

materials use

Workability Excellent size/ weight

ratio, constructing with

AAC is very rapid. It

can be cut, sawn,

drilled, nailed & mailed

like wood, making it an

extremely workable

product

Lime: Active powered lime is a requirement for giving the real aeration to the product. In phase 1 we can aim to buy the active lime directly. In phase -2 we can think of having backward integration and making a lime powering unit at site to have a more competitive advantage, Different qualities of lime are available, and depending on the raw materials, the mix design can be chosen to get the optimal quality of production.

Cement: This Project aims to utilize OPC cement as main binder material. It will give faster strength to the bricks, besides giving improved consistent quality. It also ensures a better cost effectiveness for the same. Using OPC will be a standardized practice. The other prime advantages of using OPC (compared to other binders) is it’s easy availability locally through nationwide Retail Network of Cement Companies.

Gypsum: This too is an industrial waste. This is available as an industrial by product of Fertilizer Plant. Gypsum is responsible to give long term strength to the Blocks.

Aluminium Power. Finely ground Aluminium power is used in very limited quantity ( less than 0.5%), so that it reacts with active lime, and silica in base material to make the aeration, and swell the product, making it very light weight product.

Chemical:

This is solely supplied by M/s Gubbi enterprises.

Fly-Ash: This Raw material is freely available in Thermal Power plants. There are no taxes on this item whatsoever. Transportation charges are only to be attended by the entrepreneur.

Parameter AAC Block Clay Brick

Size

600 x 200 x 100-300mm

230 x 115 x 75mm

Variation in dimensions

+/-1mm

+/-5mm

Compressive Strength

30 -40 kg/cm2

25 -30 kg/cm2

Dry Density

550-700 kg/m3

1950 kg/m3

Wet Density 800 – 850kg /m3 (Approx) 2400 kg / m3

Fire Resistance 4-6 hour depending on thickness

2 hours

Sound Reduction Index (dB)

45 for 200mm thick wall

50 for 230mm thick wall

Energy Saving 32 % (App.) Air-Condition

Load Both Both Heating And

Cooling Will Come Down

No Saving

Thermal Conductivity

0.16 – 0.17 (approx) 0.81 approx

Mortar Consumption 0.018 Per M3 With 1:6 / 0.5

Bag Of Cement

0.1 Per M3 With 1:6 / 1.35 Bag

Of Cement

Particulars AAC Blocks Conventional Red Bricks

Strength 35-40 kg/ cm2 30 -40 kg/ cm2

Shape & Size Uniform & Regular Non Uniform & Irregular

Plaster Thickness 10 – 12 mm 15 – 20 mm

Density 550- 650 kg/ cm3 1500 – 1700 Kg/ cm3

Water Absorption 15 – 20% 40 – 45%

Mortar Consumption Less High

Mortar Joint Thickness 8 – 10 mm 15 – 18 mm

Breakage/ Wastage Nil – 0.5% 8 - 10%

TECHNICAL COMPARISON

Comparison Between AAC Block & Bricks

Fly Ash is mixed with water, and made slurry in a slurry mixture. If sand is used

as base material, we need a ball mill to grind the sand to fine power.

After that, weigh batcher weighs the slurry in preset quantities and lime, OPC,

Gypsum and aluminum powder mixes thoroughly. The mixture also pours the

mix into the mould carried in the mould cart. The full pouring of the mixture is

just enough to fill around 60% to 70% of the mould.

.

After that, chemical reaction takes place for aeration and the light initial setting

takes place.

Next process is de-moulding process of the big block, in which a sophisticated

overhead hoist takes the mould, de-moulds the block.

Next process is the level wire cutting of the Block, while the block passes on the

cutting trolley through the series of wires. This process follows a vertical wire

cutting where as the block remains stationary, and the cutter cuts the block

vertically.

The final cut blocks are Steam cured for 10 hours at 12 KG/Sq cm pressure,

and 100D C. Hence, the product is ready to go into the market for commercial

purpose.

Procedure for

Making AAC / ALC

Block

Fly Ash Gypsum Lime Cement

Slurry, Water,

Fly ash

Pouring Mixture to mix

ingredients

Bricks casting on mould

De- moulding and wire cutting

Steam curing for 10 Hours

Blocks Ready for sale

Process Chart/ Flow Chart

Raw Material

EQUIPMENT

Blender

Cutting Machine

Silo

Steam Curing Machine Slurry Tank

De- Moulder

AAC Mould

AAC / ALC Block AAC / ALC BLOCKWALL

Housing make by AAC /

ALC BLOCK

Application

GUBBI ENTERPRISES 18/26, Dev Prayag CHS Ltd,

Bhakti Mandir Road, Nr. Hari Niwas Circle, Thane (W)-400 605

__________________________________

Tel No: 022- 25387711/ 25383839 Mob No. 9322451475/ 9819901129

Email: clcplant@gmail.com ___________________________________

Web: www.clcplant.com