CORPORATE OFFICE :Sona House, 35/ 75 Punjabi Colony, Katora Talab,Near SBI Zonal Office, Raipur (C.G.)-492001-India
Call : 9300193001 E-mail : [email protected]
WORKS :Ecorex Buildtech Pvt Ltd, Survey No 64/22-28-29-31,
PH. No. 33, Village Bhurwadih Khurd, Post Office: Kharora,Tah: Tilda, Near GMR Power Plant, Raipur (CG)
Follow us on : /ecorexaac
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EconomicallySustainable
ErgonomicallySuperior
EfcientlyRevolutionary
SUSTAINABLE GROWTH,ONE BLOCK AT A TIME
The zeal to feed the nation's growing building material needs while conserving the environment led to astate-of –the-art plant at Kharora, Raipur with a capacity to manufacture 2,50,000 CuM of AAC blocksconsistently throughout the year come rain or shine. The product- Ecorex AAC blocks of superlative quality,tested for all parameters at its in house advanced lab to ensure you get a product that confirms to highestinternational standards.
Ecorex AAC block is a revolutionary construction material that strengthens the foundation of ecologicalbalance while triggering rapid economical and infrastructural growth. The product has changed the scenarioof urban development, all this while helping reduce the carbon footprint and taking a big leap towards asustainable environment.
PCMSM3111204IN
CERTIFICATIONS
ISO 14001:2004ISO 9001:2008 GRIHA Council
VISION
To be a leading producer and supplier of construction material in India in the next 5 years of AAC Blocksas well as ready-mix mortar, plaster, grouts wall and floor tile adhesives, etc.
MISSION
To make Ecorex Buildtech a great work place for all its employees.To make the word ‘Organised’ synonymous with brick and mortar industry in India.To produce top notch AAC blocks and other sustainable green products that consolidate the performancewith value pricing, while making a fruitful, long lasting association with our clients and our suppliers.
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Reference
-IS-2185 (Part-3):1985 for autoclave cellular (aerated) concrete blocks-IS 2212 : 1991-Brick works - code of practice-SP 21 : 2005 summaries of Indian standards for building materials-IS: 6441( Part 1 )- 1972for determining block density-IS: 6441( Part 5)-1972 for determining compressive strength
DESIGN & CONSTRUCTION GUIDELINES
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• B should loadA CA locks be used for internal and external walls which are non- bearing. They shouldnever be used in foundations & masonry below damp-proof course. The thickness of the wall should beas per the provisions of :1905-1980IS .
• Non-load bearing internal walls as well as external walls should be a minimum 10 cms. and externalpanel wall in frame construction should not be less than 20 cm thick. However, 15 cm thick panel wallsmay be used provided they are suitably braced and reinforced by lateral and vertical support anddepending upon the local condition & desired effect of thermal transmission and sound reduction. In caseof parapet walls, the height of the wall should be limited to five times its thickness.
• Modular coordination principles & applications should be preferably be used when planning an AACblock wall to facilitate maximum use of full and half length units. All horizontal dimensions should ideallybe in multiples of 3 M and all vertical dimensions should be in multiples 2 M. This will offer the nominalhalf length in horizontal dimensions and full height of units of vertical dimensions.
• A minimum reinforcement of two 8 mm diameter mild steel bars or two 6 mm diameter high-strengthproviding bars should be used to build bond beams. The area of influence of a bond beam shouldnormally be presumed to extend 600 mm above and below its location in the wall.
• To meet the requirements of unusual stress conditions listed below, reinforced concrete structural bondbeams may be used in block masonry:AACa) in structures in earthquake prone regions.b) in structures in areas where severe wind storms occurs:c) in structures in areas where unfavourable soil movements and soil subsidence occur, and
td) in struc ures where walls are subject to excessive vibration or to very heavy loads.
• Galvanized steel wire conforming to :280-1978 should preferably be used to fabricate jointISreinforcement. Joint reinforcement should be used in conjunction with cement mortar not weaker that a1:2 mix. A minimum mortar cover reinforcement of 15 mm should be provided in walls exposed to theaction of weather.
• Control joints are employed to reduce restraint by accommodating movement of the masonry wall, ormovement of structural elements adjacent to the wall. They are in fact, vertical separations built into thewall at locations where there i a likelihood of excessive horizontal stresses.s
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HISTORY OF AAC
The development in autoclaved aerated concrete history is based on a series of process patents. AAC wasfirst experimented by a German researcher Michaelis in 1880 and was also granted a patent on his steamcuring processes.
This was followed by more experiments in aerating the concrete, using aluminum powder and calciumhydroxide, making aerated mix of limestone and ground slate.
It didn't take long for commercial interest to grow which paved the way for the firstlarge scale manufacturing facility of these artificially-madecrystallized stone blocks in 1929.
AAC Blocks found their place in India's masonry market around 1920swhen it was first introduced. Since then, the use and demand for thesame has been growing considerably. Currently there are around35 AAC blocks manufacturing plants across India with a heavyconcentration near Surat, Gujarat. More and more AAC blocksplants are set up across India as awareness about AAC blocksis growing.
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WORKABILITY AND INSTALLATION
Ecorex blocks offer easy workability and can be easily cut, drilled, nailed, milled and grooved to fit yourrequirements. They are also available in custom sizes to fit your needs. Ecorex blocks are lightweight and ready touse, so their placement is faster and takes less labour time. Also these don’t require much setting, hardening orwaiting time before proceeding with the finishes
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SMART CITY - SMART PRODUCT
Challenging a century of convention with 3 decades of innovation
It's the era of globalization, the era of growth and rapid infrastructural development. It's the period of growingskylines and exceeding urban boundaries. While cities are evolving into smart cities, infrastructural growth isundergoing a mammoth change in terms of planning, amenities and construction quality. However, growingconcerns over ecological sustainability pose a question on the future.
This is the very reason why Ecorex AAC comes forward as a strong contender for fly ash blocks and claybricks. Made from fly ash and other ingredients, Ecorex AAC blocks are convenient to retrieve and use.Produced all year long, these blocks are perennially available and easily accessible. The block dimensionsare pre-fixed and constant which cuts down correction time. To add to it, these blocks take lesser time andspace to build saving time and money in the process.
AAC blocks are slowly becoming a norm for Indians. After a number of monumental buildings in India weremade from Exorex AAC, people's faith in the product has gone up considerably.
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ENVIRONMENTAL BENEFITS OF AAC BLOCKS
1) Fly Ash as the major raw material -We all are aware of current scenario of developinginfrastructure in India. The fly ash being emitted asa result of this growth is hazardous to theenvironment. The major raw material inmanufacturing Ecorex AAC Blocks is fly ash whichcan contribute in keeping the environment cleanand green. The process requires almost 65 to 70%of fly ash.
2) Substitute to clay - The conventional redclay bricks demands soil which is a major issuewhen we discuss environmental challenges. UsingEcorex AAC Blocks cannot only reuse the fly ashbeing produced by the industry, but also saves theprecious land soil
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3) Saves transportation - The manufacturing ofAAC Blocks is such that they are lighter in weightand hence can reduce the transportation costduring supply. The pollution caused by thetransport vehicles is a major problem now a daysthat can be reduced with AAC Blocks.
4) Less water requirement - The process ofmanufacturing AAC Blocks requires very lessamount of water. The application too, needs lesswater than conventional bricks.
Ecorex AAC blocks earned the most ‘green building points’ under LEED/GRIHA rating as Ecorex uses lessnatural resources & energy and lowers pollution.
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WHAT IS ECOREX AAC?
Autoclaved Aerated Concrete blocks are lightweight building blocks manufactured by a precise controlledreaction of aluminum on lime, cement & fly ash which releases hydrogen gas through the millions ofminiscule air cells which result in a very strong cellular structure but that reduces its weight. Curing in underhigh-pressure steam further enhances its strength resulting in a block that has high compressive strength butits own weight being low doesn't add to the dead load of the structure being constructed. This makes it theideal building block.
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Parameter
Size (L x H x B)
Variation in Size
Dry Density
Compressive Strength
Consistency
Cost Benefit Factor
Savings in Mortar
Saving in Labour
Energy Saving
Contribution to CarpetArea
Sound Reduction
Thermal Conductivity
Earth Quake Benefits
Wastage
Quality
Supply
Plant Capacity
Fire Resistance
Basic Raw Material andInputs
Production Process &Set-up
Curing
Eco-friendliness
Sr.No.
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AAC Block
600x200x100-225 mm
1-2mm
451-650 Kg/m3
30-50 Kg/cm2
Always Same
Reduction in dead weightleading to saving in steel &concrete
Leads to savings in materialdue to less number of joints
Reduced by upto 50%compared to clay bricks
32% (App) Air-condition loadboth heating and cooling willcome down
Increases by 2-3 %
45db For 200 Mm Thick Wall
Approx 0.21-0.24 W/m K
Yes
Upto 1%
Consistent
Can supply 24 x 7 x 365 days
750 m3/day
Upto 6 Hours for 200mmthickness
OPC cement, lime, aerationcompound, flyash
Produced only in organizedplant equipped with steamboiler and Autoclaves
Done in controlled way byAutoclaves with high pressuresteam; ready in 12 hours
Pollution free process thatutilize fly ash as major rawmaterial
Fly Ash Bricks
225x100x75mm/200x100x100mm
5-10mm
1800-2000kg/m3
20-25 kg/cm2
various variety
None
None
Increases the time taken toconstruct
No savings
No Saving
Not Applicable
Approx 1.05 W/m K
No
upto 10 %
Inconsistent
Seasonal Effect
Max 10 m3/day
2 Hour
Flyash, gypsum, quarrydust, lime
unorganized plant
Requires huge amount ofwater for curing in open7-10 days
Pollution free process bututilizes lesser percentageof fly ash
Red Clay Bricks
225x100x75mm/200x100x100mm
5-10mm
1800-2000kg/m3
25-30 Kg/cm2
various variety
None
None
Increases the time takento construct
No savings
No Saving
Not Applicable
Approx 1.35 W/m K
No
upto 10 %
Inconsistent
Seasonal Effect
Max 10m3/day
2 Hour
Top soil,sand and lime,water
Can only be producednear river needed hugeamount of water forproduction
Done is chimneypolluting the atmospheredrastically
Pollutes the atmosphereand also removes off thetop soil
Autoclaved Aerated Concrete (AAC) blocks are not Fly Ash Bricks buta completely different advanced product
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Thermal insulation-The tiny air pores within theunique structure of these blocksand their thermal masscontribute to provide excellentinsulation. This reduces airconditioning and heating costsin the building.
Seepage-Ecorex AAC Blocks have astrong water resistant abilitythat keeps seepage andleakage at bay making thebuilding damp-proof.
Energy saving-Houses and commercial spacesmade from Ecorex AAC havebeen found to consume lessenergy to efficiently heat andcool spaces.
Long lasting-Being fire, water, sound, pestand earthquake resistant,Ecorex AAC Blocks slow downthe process of wear and tear,making the building lastlonger and stay strong.
Pest Resistant-Unlike clay bricks, Ecorex AACBlocks do not posses organicingredients. As a result, pestsand insects do not infest thewalls, making the structurestrong and pest resistant.
Noise- With a higher air-voidratio than other materials, ourblock absorbs 60-70% moreair than conventional concreteand offer sound attenuation ofabout 44 dB, which shuts outmajor sounds anddisturbances.
Fire proof- Ecorex AAC beara high heat resistant capacitythat keeps the building safeand unharmed. Non-combustible and fire resistantup to 1600 0C, Ecorex blockscan withstand up to 6 hours ofdirect exposure. A uniqueproperty of AAC is that itcontains water in crystallineform. This allows it to absorbheat and turn it into steam.
Earthquake Resistant-Our building block gives theadvantage of earthquakeresistance to the overallstructure. This adheres to theprovisions of the BIS code“IS-1893' recommendation.
User benets
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ADVANTAGES OF ECOREX AAC
Apart from being a low maintenance building material due to its lighter weight, Ecorex AAC Blocks havenumber of other benefits to both builders and buyers.
Benets for builders
Faster construction-Using Ecorex decreasesconstruction time by 40%. Thesize of the blocks that reducesthe number of joints in the wallmasonry and the light weightmakes this possible.
Time and labour cost-The labour costs involved inconstruction come downconsiderably with EcorexAAC. The faster fix time andlesser dimension errors cutdown labour costs making theproject economicallybeneficial.
More savings in material-Apart from less mortar,plastering and use of steel andother material, Ecorex AACblocks also utilize lesser powerand water making it aneconomically viable option forconstruction.
Enhances the carpet area-AAC Blocks achieve higherwall strength in thinner wallsthan conventional bricksachieve in thick walls. Thisresults in thinner walls beingused all over in theconstruction leaving sell-ableand usable carpet area onevery floor.
MANUFACTURING PROCESS
Ecorex AAC is the largest and the first AAC Blocks manufacturer in Chhattisgarh with a state-of-the-artproduction facility with an installed capacity of 2,50,000 cum per annum situated at Kharora- Tilde Road,Raipur. The plant is well equipped with calibrated laboratory for testing of raw materials and the finishedproduct and a team of skilled and dynamic engineers and professionals.
Ecorex AAC Blocks are manufactured & tested with reference to IS 2185 (PART3):1984.Ecorex AAC Blocks are manufactured in the following stages :
Raw Material Preparation & BatchingThe basic composition of Ecorex AAC Blocks consistsof fly-ash slurry, ordinary Portland cement, quicklime,gypsum and aluminum powder. The desired volume ofall raw materials is mixed by a highly precise batchingsystem that ensures the same quality of each batch.The materials are batched according to theirrespective test results which eliminates the variations inthe batch quality.
Mixing & PouringThe blend of raw materials is accurately and uniformlypoured into mould boxes by an automated mobilemixer. Once poured into moulds, it is monitored by thehighly skilled & dedicated quality team to ensure itsquality matches the desired parameters.
CuttingThe porous green cake is cut into desired size by hightensile wires at the cutting stage. These wires cut theblocks vertically as well as horizontally separately,bringing accuracy in the dimensions of blocks.
AutoclavingAfter cutting, the porous green cake undergoes steamcuring in the autoclave for 10-12 hours at atemperature of 190-210 with saturated steam at a℃pressure of 12 bar. Autoclaving gives Ecorex AACBlocks its physical & chemical properties.
Separation and PackingAfter autoclaving, Ecorex AAC Blocks are separatedwith the help of Grab & Shift assembly with leasthuman intervention. These are further transferred tostock yard with the help of a chain conveyor system.Ecorex AAC Blocks are now ready to dispatch.
Cost saving-Ecorex Blocks dry and setquickly, making them a fasteroption for construction overconventional clay bricks. As aresult, the builder is able tofinish a project faster thanestimated.
Plastering-Ecorex blocks bring about amassive 35% reduction in thecost of plastering as they haveuniform shape and texturegiving a very even surface to thewall needing very littlecoverage.
Less breakage-Ecorex blocks havenegligible breakage anddrastically reduce wastagewith a utilisation increase ofapprox 99.99%
Lighter in weight-Ecorex AAC blocks are Lighteron your Pocket. Being about66% lighter than conventionalbricks means lesser deadweight and hence lowerexcavation for foundation,15% reduction in steel usage,10% reduction in cementusage and also constructiontime and labour resulting inmega savings.
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