AAC Industry of India– Scenario

Building green and using eco-friendly materials for construction has been gaining popularity, and a growing number of AAC blocks manufacturers have sprung up to meet the demand. The industry is facing many challenges in terms of costs, but key players remain optimistic.

Challenges for the AAC Industry

Autoclaved Aerated Concrete or AAC blocks have been around in India since 1972, but it wasn’t until 2010 when manufacturing and production started ramping up—around the same time the popularity of green building materials started growing. Even with all the positive benefits that AAC blocks delivers, it is faced with a number of challenges that cause its limited use as a building material.

The preferred raw material for AAC blocks is fly ash or pond ash—a by-product of burning coal that is composed of silicon dioxide, aluminium oxide and calcium oxide. This inorganic mix is ideal for processing into blocks. While the material itself is cheap, transportation ramps up the costs, as fly ash in India has to be transported from 300km away. Sand—another component for making AAC blocks—is not easily accessible due to legal and environmental concerns, and this likewise drives the prices upwards. The relatively high cost compared to conventional fired blocks ultimately limits the accessibility of AAC blocks, which is why they are often utilized only in high rise construction and higher-end projects.

Overcoming the Issues

To remedy this, a campaign for greater awareness of the benefits of AAC materials is essential. The campaign needs to focus on boosting the popularity of AAC as a building material that is more efficient, durable, and practical in the long term.

Legislation to support the sourcing of materials will also contribute to driving costs down, making AAC more accessible for everyone as the supply is guaranteed and the prices become more affordable. Mandatory recommendation for the use of AAC materials for schools and institutional construction work can also boost usage.

Standard Size Available in Light Weight Bricks

Today’s construction technology offers a myriad of options when it comes to building materials. Traditional components have been improved upon to meet the growing and changing demands and requirements of modern structures. As building projects go higher and the need for robust but cost effective building materials arise, light weight bricks have been developed as a solution.

Light weight concrete bricks or Autoclaved Aerated Concrete (AAC) blocks are similar to conventional hollow building blocks but with a few added features and improvements. AAC is designed to be 80% lighter than conventional blocks while keeping the same strength, making them ideal for high rise buildings and structures. These blocks come in 625 mm lengths by 240 mm height, and are available in 90 mm, 100 mm, 150 mm, and 200 mm thicknesses. They are noticeably larger in length and height compared to conventional blocks, so laying them is easier because fewer blocks are needed for the same area coverage as regular blocks. Fewer blocks does not only mean easier and faster laying—it also translates to lower material and labor costs.

Despite its lightness, AAC blocks retain a good amount of strength, with a rated shear strength of .06 and a compressive strength of 3 N/mm2.  AAC blocks also have better acoustic properties for better soundproofing, as well as better thermal qualities that make them really good for insulation. They are likewise rated for fire resistance and are able to withstand temperatures up to 1200 degrees Celsius before failing. They are also impervious to water and have a low absorption rate, so they are moisture barrier materials for basements and below-ground applications (with little to no waterproofing necessary). AAC blocks are also certified for LEED compliance and are worked the same way as regular blocks, requiring no special tools or equipment.

Know How to Lay Light Weight AAC Concrete Blocks

The benefits of light weight bricks can be better experienced by employing the right techniques for laying the bricks. While the general rules of construction apply to all types of construction material, it is important to take care in certain specific areas. For instance, the thickness of the joints, the method of laying etc. are different from conventional techniques and it is best to understand and incorporate the techniques for harnessing better results. Take a look at better masonry with light weight concrete blocks.

Laying directions

The laying direction for the light weight concrete blocks could begin from either end or corner of the structure and meeting up midway. Alternatively, the laying can commence from one end and proceed to the other corner. However, it is important that the first row is laid with great care after ensure that the surface is properly leveled and aligned. The use of a plumber’s line or other equipment to ensure leveling and alignment is mandatory.

Dispensing with the need to soak the light weight bricks

Unlike traditional bricks, it is not necessary to soak the light weight bricks in water before laying. All that is required is a dampening the surfaces slightly. This is different from soaking the bricks entirely in water. This ensures that the speed of laying the bricks is faster than the conventional bricks. The right ratio of bonding or plastering material needs to be ensured. The ideal ratio is 1:6 for bonding which will ensure that the construction is of the right quality with better durability.

Laying of mortar and joint thickness

This is perhaps one of the most important aspects of construction. The mortar needs to be laid at the right time. Prior to the laying of the bricks, the mortar needs to be spread with the right consistency. The thickness of joints should ideally be 10 mm which will lend great strength and bonding to the bricks. Uniformity of the mortar is crucial to ensure that the alignment is perfect. The actual laying of bricks needs to be done with the right amount of pressure for a firm grip and better bonding.

Using AAC Blocks for Manufacturing Building Structures

AAC blocks have made their way into most construction by virtue of being one of the most durable and economical product to hit the construction industry. The precast solutions available to builders are numerous as AAC blocks manufacturing offer various options for the construction sector. Precast solutions in the form of non load bearing panels and walls, make construction a lot easier and quicker. With options offering solutions for virtually most requirements, AAC blocks manufacturing units offer quick erection of buildings and structures that are not just economical, but offer a pleasing façade. Profiled herein are some of the different ways in which precast solutions help in quick completion of structures.

Fast erection of stairwells

Buildings without stairwells are a rarity. However, the construction of staircases take up considerable time and effort as it is a specialised job calling for making allowances in the configuration as the building construction progresses. This time consuming activity will most likely have a bearing on the completion of the building itself as no structure can be considered complete when the stairway remains incomplete. Additionally, stairways are also used for carting construction materials to the upper floors of the building. The use of precast staircases will help to greatly cut down on the time required for construction, while also offering an economical option.

Beams, and columns for structures

The skeletal structure of buildings incorporate beams and columns around which other construction activity proceeds. With precast solutions in beams and columns, it is possible to create the perfect complete structure for commercial buildings in great speed. Offering better stability, and improved resistance to fires, the precast solutions help in constructing a framework around which other precast solutions can be incorporated for quick completion of project with greater durability. Mega projects around the work have been completed in record time through the use of precast solutions and it makes a lot of sense to rely on the same technology and concepts to build superior structures. A combination of various precast solutions can be deployed to get the right design and build a superior structure.

Make Durable Home to Withstand In Any Climate with AAC Bricks

AAC blocks are considered as marvels that have ushered in innovation in construction material. With manifold benefits that stretch across all activities in the construction, the blocks have rung in changes hard to ignore. The lightweight wonders have replaced the traditional bricks with greater savings in cost, not to mention the eco-friendly nature of the product. Some of the reputed aac blocks manufacturers in India possess world class facilities with huge capacity to meet the needs of a growing construction industry. Here are compelling reasons that prove AAC blocks to be the best suited for homes across all climatic conditions.

Will not rot easily with constant exposure to damp or wet conditions

The structure of the AAC blocks make them resilient and strong, with a capacity to withstand the vagaries of nature. Wet and damp conditions throughout the year are the biggest enemies of traditional bricks. The sodden bricks tend to lose their strength and give way to rot. However, with AAC blocks, the formation of the honeycomb structure with air, cured by high pressure steam renders them strong to ward off the effects of wet climatic conditions.

Cooler interiors during summers

The volume of air in the AAC blocks makes interiors cooler. The fire rating of the blocks, the shear strength, the water absorption and all other attributes make the blocks most suitable as construction material for homes. Offering the highest degree of safety when compared with other construction materials, AAC blocks are considered as the innovation that has truly given a fillip to construction.  Homes are cooler in summers and are more fire resistant, making the living spaces more safe to occupy.

High compressive strength gives the blocks greater capacity for loads

The compressive strength of the blocks lend the blocks greater capacity for loads. This makes buildings sturdier blowing away apprehensions of a building that may be compromised by heavier structures. Additionally, the buildings are also insulated from noise on the exterior. This makes homes more enjoyable to live in. Depending on the area of the residence, some homes may have to put up with heavy noise levels, and it surely helps to have a noise free atmosphere.

Things to Keep In Mind While Choosing Light Weight Brick

The winds of change sweeping through architecture and construction have replaced heavy construction material with light weight and stronger materials. And the light weight brick has come to replace the traditional heavier bricks in a manner that has revolutionized construction. The light weight bricks have brought down construction timelines, saved the amount of mortar used, while offering superior strength and thermal qualities that protect the occupants of the building. Listed below are a few points that need to be borne in mind while choosing the right light weight brick for your needs.

ISO Certification of manufacturer

ISO certification is an indication of high standards in processes and this will reflect in the quality of the manufactured products.  AAC blocks manufactured by an ISO certified company would offer all the advantages without any dilution whatsoever of the qualities, such as high strength, acoustic properties, thermal insulation, energy efficiency etc.  Most of the parameters required to check the quality of light weight bricks are all factored in the processes that are covered by ISO certification.

Steady supply of raw materials

AAC blocks require raw materials that are by products of thermal plants.  Reputed manufacturers of AAC blocks locate their manufacturing facilities within short distances of thermal plants. This will ensure that they receive a steady supply of raw materials to enable smooth manufacturing processes.  Manufacturers who are unable to source raw materials may have to compromise with available materials and this may reflect on the quality of the output. The choice of light weight blocks over traditional bricks is mainly due to the qualitative difference. Poor raw materials may affect the quality.

Technical knowledge and manufacturing capacity

Manufacturing facilities that have high capacities would follow automated processes. This would be a better choice than small makeshift facilities that manufacture the blocks. AAC blocks require the use of the right processes to ensure that the blocks are state of the art products. The personnel manning the machinery and equipment need to be adequately trained to maintain consistent high standards. Choose AAC blocks from manufacturers who rely on highly trained manpower to man the facility.

How to Find the Top Green Building Material Supplier

More and more construction companies are going green. They have become more aware of their significant effect on the environment and now prefer using green building materials and eco-friendly technology when they are building commercial, industrial, or residential infrastructures. Why? Because green building materials can be recycled and have low toxicity. Sometimes, they are completely non-toxic, even. Green construction materials are also known for producing fewer chemicals that potentially pollute the air, water, and soil.

If you are determined to leave a smaller footprint and promote sustainability, then use only green building materials. Partner with a leading supplier that will help achieve your purpose. When choosing a supplier, consider the following factors:

1. History

The best green building material supplier is often a pioneering company that has been in the business for many years. It is important to know how they started so that you'll have an idea what their values, vision, and mission are. Find out more about their founders, business expansions, and other relevant company milestones through the years.

2. Where they source and manufacture

Green building materials that are manufactured in the country are usually cheaper. They are also easier to transport. 

3. Clients

Has the company worked with other companies similar to yours? By looking at their previous projects and list of clients, you will see if they truly cater to environment-friendly constructions.

4. Rewards and recognition

Top suppliers are recognized by award-giving bodies because of their excellence and dedication to green building. These recognitions indicate that they are one step ahead of their competitors, taking the lead, and setting new standards in the construction industry.

5. Green building materials and other services

You should not only base your decision on the history and recognition of the supplier. The best way to determine if they can be trusted is by checking out their products and services. See to it that what they offer are exactly what you need in your construction project before choosing them as a partner.

Dry Mix Concrete: Providing Excellent Structural Strength to the Building

The main difference between dry and wet mix concrete is the timing at which water is added to the material. To create dry mix concrete, manufacturers mix all dry materials (such as the cement and aggregate) while the water is added evenly, as the mix is being projected. When creating wet mix concrete, on the other hand, water is added to the mixture right away. Dry mix concrete is arguably better at strengthening constructions. This is especially true if you buy pre-mix cement from a trusted manufacturer. While mixing dry cement is less time-consuming and tiring, the consistency is still hard to achieve. Below are some other benefits of ready-made dry mix concrete:

Concrete Strength

The best manufacturers produce dry mix concrete through the use of advanced and computerized technology. This way, they ensure that their product has high-quality adhesive properties, with superior bond strength as well as load-bearing capacity.

Consistent Quality

Consistency is the key to any type of construction. In a factory environment, no human intervention affects the stages of dry mix cement production. Because of that, manufacturers can ensure that the output quality of the all their pre-mix cement is the same.

Convenient and Faster Construction

Setting a dry mix concrete is faster than setting a wet mix mortar. But what makes it even better is the fact that it is already pre-mixed. Some manufacturers are able to create pre-mix mortar that is ready to be applied to AAC blocks. They only need to add water to start the construction. Therefore, this process is ideal for small applications or for people who like home DIYs. Of course, they are favorable for large projects that requires several cubic meters of dry mix concrete because they can help reduce overall labor costs. When choosing the right supplier, it pays to consider the quality and the shelf life of the dry mix cement. The best ones should have at least 6 months of shelf life.