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Manufacturing

Autoclaved Aerated Concrete

ACC(​Autoclaved Aerated Concrete) is a lightweight concrete, ACC has been widely using across the world past 6 decades.Autoclaved Aerated Concrete or ACC is made by mixing of Portland cement,lime,flyash,water and aluminum powder the final mixure is poured into moulds .The reaction between aluminum and lime causes microscpic hydrogen bubbles to form lower density concrete by expending it. After evaporation of the hydrogen and intitial setting, aerated concrete is cut into required sizes and cured by steam curing in pressurize chamber-Autoclaved or low pressurized-steam chambers.
The result is non-toxic , high strength, lightweight,airtight material that can be used for a walling application . AAC is green building material that generate no pollutants of hazardous waste during the manufacturing process.

Raw Material

Production Flow Chart

Manufacturing of AAC, the AP Infrahomes has the following activities..

Two Digit Activity

a. Specialized construction activities

b. Manufacture of other non-metallic mineral products.

c. Construction of Building

Four Digit Activity

a. Building completion and finishing

b. Manufacture of clay building materials

c. Construction of buildings

Five Digit Activity

a. Other building completion and finishing

b. Manufacture of bricks

c. Construction of buildings carried out on own-account basis or on a fee or contract basis

Autoclaved Aerated Concrete (AAC), also known as ...

  • • Autoclaved Cellular Concrete (ACC)
  • • Autoclaved Lightweight Concrete (ALC)
  • • Autoclaved Concrete
  • • Cellular Concrete
  • • Porous Concrete
  • • Air crete
  • • Hebel Block

• and tong is a lightweight, precast, foam concrete building material invented in the mid-1920s that simultaneously provides Structure, Insulation, and Fire- and Mold-resistance.

AAC products include blocks, wall panels, floor and roof panels, cladding (façade) panels and lintels.

By using new Formulations, containing only Quartz Sand, Calcimined Gypsum, Lime (Mineral), Cement, Water and Aluminium Powder, tong produced a new type of aerated concrete which no longer contains alum slate and thus has eliminated the problem of radon exposure from this raw material.
The production of this white Autoclaved Aerated Concrete is now state of the art and similar formulations are used by all producers around the world.
This Industry is growing rapidly in Asia due to strong demand in housing and commercial space. China is now the largest Air Crete market in the world with several hundred factories.
Now China, Central Asia, India, and the Middle-East are the biggest in terms of AAC manufacturing and consumption.

Advantages:

AAC has been produced for more than 70 years, and it offers several significant advantages over other cement construction materials, one of the most important being its lower environmental impact

  • • Improved thermal efficiency reduces the heating and cooling load in buildings.
  • • Reduces the cost of the project
  • • Lightweight: Concrete blocks that are made out of AAC weigh about one-fifth of typical concrete. They are also produced in sizes that are easy to handle for quick construction.
  • • Long Lasting: The life of this material is extended because it is not affected by harsh climates or extreme changes in weather conditions. It will not degrade under normal climate changes either.
  • • Porous structure allows for superior fire resistance
  • • Workability allows accurate cutting, which minimizes the generation of solid waste during use.
  • • Resource efficiency gives it lower environmental impact in all phases of its life cycle, from the processing of raw materials to the disposal of waste.
  • • Light weight saves cost & energy in transportation, labor expenses, and increases chances of survival during seismic activity.[6]
  • • Larger size blocks leads to faster masonry work.
  • Environmentally Friendly: When used, it helps to reduce at least 30% of environmental waste as opposed to going with traditional concrete. There is a decrease of 50% of greenhouse gas emissions. When possible, using autoclaved aerated concrete is a better choice for the environment.
  • Energy Saving: It is an excellent property that makes it an excellent insulator and that means the interior environment is easier to maintain. When it is used, there is usually not a need for any supplementary insulation.
  • Fire Resistant: Just like with regular concrete, AAC is fire resistant. This material is completely inorganic and not combustible.
  • Great ventilation: This material is very airy and allows for the diffusion of water. This will reduce the humidity within the building. AAC will absorb moisture and release humidity; this helps to prevent condensation and other problems that are related to mildew.
  • Non-toxic: There are no toxic gases or other toxic substances in autoclaved aerated concrete. It does not attract rodents or other pests nor can it be damaged by such.
  • Accuracy: The panels and blocks made of autoclaved aerated concrete are produced to the exact sizes needed before they even leave the factory. There is less need for on-site trimming. Since the blocks and panels fit so well together, there is a reduced use of finishing materials such as mortar.

Disadvantages:

AAC has been produced for more than 70 years, however some disadvantages were found when it was introduced in the UK (where cavity wall with clay brick two-skin construction has been the norm).

  • Installation during rainy weather: aircrete is known to crack after installation, which can be avoided by reducing the strength of the mortar and ensuring the blocks are dry during and after installation.
  • • Brittle in nature: they need to be handled more carefully than clay bricks to avoid breakages.
  • Fixings: the brittle nature of the blocks requires longer thinner screws when fitting cabinets and wall hangings and wood-suitable drill bits or hammering in.
  • • Insulation requirements in newer building codes of northern European countries would require very thick walls when using AAC alone.
  • • Thus many builders choose to return to traditional building methods installing an extra layer of insulation around the building as a whole.
  • • Hydrogen generated by manufacture outgasses to the atmosphere as a greenhouse gas.