Autoclaved Aerated Concrete Block

Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

Biltech at glance
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 tonnes 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, an Avantha Group Company ( formerly The

Thappar Group), with a twofold aim to utilize bulk quantities of fly ash and help bridge
the huge shortfall of bricks and other building materials required by the constantly rising
construction activity, undertook the mechanized manufacture of fly ash based Aerated
Autoclaved Concrete Blocks .The conventional practice of firing clay bricks in Bull’s
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 (BBEL) is in the business of manufacturing

and marketing Autoclaved Aerated Concrete building material using Fly-ash
(55%-60%) as the basic raw material. Over the last 17 years BBEL has become
the largest producers of AAC in the Indian Market. BBEL has 7 manufacturing
plants one in Palwal (Haryana), Palghar (Maharashtra), Bhigwan (Maharashtra),
Pune (Maharashtra), Budge Budge (West Bengal), Mangrol ( Gujarat) and Tumkur
(Karanataka).

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 Block

Technical Specifications

TYPE Length Height/ Width Thickness

Block 600 mm 200mm 100 ,125,150,200,225,250 & 300

mm

Properties of Biltech-AAC Material

PROPERTIES
0B VALUES
1B

Density (Oven Dry) 551-650 Kg/Cum

Compressive Strength ≥ 35 Kg/cm2

Thermal Conductivity (K Value) 0.162 W/mK (avg.)

Resistant to Fire 2 - 6 hrs depending upon Thickness

Drying Shrinkage 0.1 %

Design Gross Density 850 Kg/Cum. (appx.)

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.
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

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, palletized and sent for dispatch. Pulverized fly-ash is
obtained from Thermal Power Plants.

Basic raw material

AAC with its characteristic structure comprising millions of tiny pores, 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
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

Raw material composition in AAC ( Approx. 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

Physical properties of AAC Block

Thermal Insulation & Energy Savings: Buildings constructed of

Biltech-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: Biltech-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 1600ºC.

Acoustic Performance: Biltech- AAC Blocks have superior sound

absorption properties in comparison with other construction materials.

Workability: Biltech- 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: Biltech- 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: Biltech -AAC products are ready to use, so their

placement is faster and represent less labour time. Also, Biltech- AAC
products don't require setting, hardening or waiting time before
proceeding with the finishes.
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

Light Weight: Biltech- AAC is up to 3-4 times lighter than traditional

concrete, representing great advantages in transportation and material
handling.

Precision: Exact dimensions of Biltech- 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.

AAC Benefits

• Structural saving:
Depending on the structure, there will be a benefit in cost for AAC based system over
conventional systems purely on account of AAC’s light weight / density.

• Speed in construction:
AAC based systems shall provide a time benefit of over 20% vis-à-vis conventional
construction due to reduction in number of joints in the wall masonry (because of its
bigger size ).

• Operation & Maintenance Benefits:

AAC based system shall provide substantial saving in energy costs (depending on
design) , due to reduced Air-conditioning load vis-à-vis conventional construction as
AAC based systems provide high thermal 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.

• 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 green buildings.
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

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 LEED (Leadership in Energy & Environmental Design)
& TERI- GRIHA ( Green rating for Integrated Habitat Assessment )

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.

AAC as Green Building Material:

• Utilizes Industrial waste ( fly ash )

• Resource efficient manufacturing process
• No pollutants generated during production
• Conforms to the requirements of IGBC –LEED & TERI-GRIHA
• Energy Efficient

Benefits of Green Building Material

• Reduction of operational cost

• Green Corporate image
• Health Safety & comfort of building occupants
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

Comparison of AAC material with conventional clay brick

Sl No Parameters Aerated Autoclaved (AAC) Burnt Clay Bricks

1 Basic raw materials and Flyash, Cement, lime, sand, Top agricultural soil
other inputs Aeration compound
2 Production process and set- Produced in plant equipped with Processed in specially
up steam boiler and high pressure erected or central brick
auto-claves kilns
3
3 Oven Dry Density Kg/m 550-650 551-650 1900
4 Compressive Strength 30 40 50-100
Kg/cm2
5 Usage Non load bearing Reinforced Load Bearing &
blocks panels Non-load bearing

6 Pre cast block size 600 x 200 x 100mm to 300mm in 229x114x70mm

variation of 25mm
7 Aging No No
8 Thermal Conductivity 0.142-0.161 0.7
(W/m.k)
9 Sound Insulation Superior Normal
10 Ease of Working Can be cut, sawn, nailed, drilled Normal

11 Eco Friendliness - Green Building material -Process creates smoke

- Less energy requirement - Uses high energy and
-Wastes agricultural land
12 Water Absorption Due to its material matrix, very low Being a solid mass, a
water absorption takes place by very high degree of water
capillary action. The macro pores absorption takes place
and micro pores are not due to capillary action
interconnected in AAC and hence
very low level of water absorption
takes place.
Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block
Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

Laying of AAC Blocks

Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

Laying of AAC BLOCK Masonry

• In case of conventional cement mortar, 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 it’s plasticity there by resulting in poor bond.
Consistency as per requirement of site must be maintained at the point of laying.
• The blocks can also be jointed with polymer based premixed mortar. Here the
advantage is that the mortar thickness shall be of 3-4 mm only and the same
can be applied on the vertical side of the block very smoothly which is otherwise
requires extra precaution as the vertical dimension of AAC block is 240/ 250 mm
and in brick masonry its only 75 mm so while sand based mortar applied to
ensure an even spread is difficult.
• 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 in case of sand cement mortar and only 3-4
mm in case of Thin bed Polymer Mortar ( TBPM) .
• 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.
• Before laying of blocks, all the four side of the wall shall be made wet. Ensure
proper spread of mortar in the joints between the blocks.
• The first course of the block masonry shall be laid with great care, making sure
that it is properly aligned, levelled 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 can be filled up with jute
strips dipped
in cement slurry for easy spread of mortar along the width of Block or can be
packed with any other resilient material or lean mortar.
• The mortar joint shall be struck off flush with wall surface and when the mortar
stiffening, it shall be compressed tightly. The joints of the block may be pointed
which may work as key to the plaster. Maximum erection of 5-6 courses is
desirable in a day specifically in case of cement sand mortar.

• At the joints of any dissimilar material, chicken / Fibre mesh need to be applied
before plastering.
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

• Depending on the panel size , height of the building , thickness of the masonry
etc. the external walls required to be stiffened suitably by use of joint
reinforcement , nominal bond beams for improving the strength and stiffness in
the masonry in high lateral loading situation. Bond beam preferably shall be
provided below window sill or any opening. All the internal wall shall be stiffened
with joint reinforcements in the form of either single rod of 8 mm or MS Flat in
every alternate course or as per recommendation of consulting Engineer.
• 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 ready- made Gypsum plaster can also be applied which will
minimize substantially the post curing activity and also the polymer used in the
Gypsum plaster shall also improves the resistance to drying shrinkage which is
very common factor in Cement Sand plaster.

Chasing and cutting

• For smaller dimension, AAC Blocks shall be cut with a normal carpenter saw or
any power saw.
• Where ever chasing to be done in AAC Blocks masonry, 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 cutting area.

AAC Masonry Tools

• Plastic or nylon made Anchors or any standard make. (HILTI/FISCHER).

• Carbide tipped handsaw/Rotary Cutters
• Safety glasses
• Notched Trowel to suit block thickness
• Rubber Mallet
• Sanding float.

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. Codes- 6041 & 1905.

Speed of construction, saving in jointing mortar, attractive appearance, design

versatility, good and strong binding are some of the merits of AAC block masonry.
 Light Weight BILTECH- ACE Autoclaved Aerated Concrete Block

Esteemed clientele

Feel free to contact us at +91-9818348394/+91-7760970771 or send us e-mail at

suresh.sharma@biltechindia.com/manish.tumkur@biltechindia.com.