PAAC - A NEW PRECAST PRODUCT IN THE U.S.

By Dr. Fouad H. Fouad

Dr. Fouad is professor of the Department of Civil and Environmental Engineering, The
University of Alabama at Birmingham.
Precast autoclaved aerated concrete (PAAC) is a lightweight artificial stone of uniform
cellular structure. The cellular structure is similar to that of a sponge and contains
millions of air cells ranging in size between 0.1 and 1.0 mm. t is due to that structure
that the material achieves its lightweight and all the concomitant high!performance
"ualities. The manufacturing process ultimatel# results in the production of the following
basic building component$
%loc&s (unreinforced)
Panels (steel!reinforced)
'intels (steel!reinforced)
The bloc& units are used in the construction of load!bearing and non load!bearing walls(
whereas the panels are primaril# used for roof and floor dec&s as well as e)terior walls
and interior partitions. The dr# bul& densit# of the material ranges from *+ to +0 pcf( and
the compressive strength ranges from ,00 to 1000 psi. PAAC is generall# produced in
different grades depending on the nominal compressive strength of the material. The
bloc& units are unreinforced while the panels and lintels contain steel reinforcement( in
the form of prefabricated steel wire cages( for providing additional strength. %ecause of
the low!al&alinit# cellular structure of PAAC( the reinforcement must be coated to provide
additional protection against steel corrosion.
Brief History
PAAC has been in use for over -0 #ears. t was first produced in .weden in 1/*/ based
on a patented process b# 0ohan 1ri&sson( and since that time the material has gained
wide acceptance in 1urope as well as across the world. 2ore than ,00 production
facilities are now in operation in 1urope and man# parts of the world including 0apan(
Australia( China( the 2iddle 1ast( Central and .outh America( and the 3...
Although PAAC was used on a small scale in the 3... during the si)ties( the first ma4or
production plant was not constructed until 1//-. The plant was built b# a 5erman
compan# (6ebel) and is located in Adel( 5eorgia. n 1//7( a second production plant
was in full operation in 6aines Cit#( 8lorida9 this plant was built and operated b# another
5erman compan# (:tong). %oth plants are state!of!the!art capable of producing a wide
range of PAAC units for commercial and residential construction. t appears that the
constant rising cost of lumber( increase in environmental awareness( and the need for a
more durable construction material have finall# paved the wa# for the entr# of PAAC into
the 3... mar&et. The material has been gaining rapid acceptance( and numerous
construction pro4ects are currentl# underwa# in the southeastern and south central
regions of the 3... Additional production plants are now in the planning or construction
stage b# investor companies( and it is e)pected that the material will soon be available
to all parts of the countr#.
The raw materials for the manufacture of PAAC consist of portland cement( finel# ground
sand (or fl# ash)( and lime. The batched raw materials are thoroughl# mi)ed together
with water and a gas!forming agent (usuall# a small amount of aluminum powder) and
then cast as slurr# into steel molds. Chemical reactions ta&e place between the
aluminum powder and the al&alis in the slurr# mi) thus generating h#drogen gas( which
forms the air cells. As the mi)ture sets( a stable cellular structure is formed. After setting
(appro)imatel# ,!; hours)( and before hardening( the mass is machine cut with high
accurac# into the desired product sizes. The components are then steam cured under
pressure in autoclaves where the material is transformed into hard calcium silicate. After
completion of the curing c#cle( which ma# ta&e appro)imatel# 1* hours( the product is
removed from the autoclave and pac&ed read# for shipment to the site.
Proper "ualit# control is fundamental to the production process due to the sensitivit# of
the aerated concrete mi) to the "ualit# of the materials and the proportions of the
ingredients. The sand must be ground to a specific fineness in a ball mill( and certain
additives such as g#psum ma# be added in predetermined amounts in order to control
the setting properties of the mi). The consistenc# of the slurr# mi) must be ad4usted to
allow for the liberated gas to e)pand the slurr# without escaping. 5enerall#( the mi)
proportions and temperature must be such that the speed of gas evolution( consistenc#
of the slurr#( and the slurr#<s setting time are compatible.
Autoclaving is vital to the production process and is the basis for the improved ph#sical
properties of PAAC. 3nder the conditions of high temperature and pressure in the
autoclave (appro)imatel# ,7+ degrees 8 and 17+ psi respectivel#)( the chemistr# of
h#dration is substantiall# altered. The fine siliceous materials react chemicall# with the
cement h#dration products (and lime) resulting ultimatel# in the formation of a low!lime
micro!cr#stalline calcium silicate h#drate called tobermorite. The formation of that
structure renders PAAC more dimensionall# stable and enhances the shrin&age and
compressive strength properties of the material.
Typia! Produt Si"es
PAAC bloc&s( panels( and lintels can be produced in a broad range of sizes. A t#pical
bloc& size is =)=)*; in. (which is solid having no cavities)( weighs about the same
(appro)imatel# ,0 lb.) as a lightweight concrete hollow bloc& (110 pcf densit#) but with
the added advantage of providing +0 percent additional surface area. 'arger size bloc&s
(for e)ample 10)*;);0 in.)( which are handled using simple lifting devices( are also
produced for the sa&e of e)pediting construction. The reinforced panels are produced in
widths up to * ft.( thic&ness of - to 1* in.( and with spans up to *0 ft. in length.
>einforced PAAC lintels that complement the bloc&s used in wall construction are also
produced with spans up to 10 ft.
P#ysia! Properties
PAAC has a number of uni"ue ph#sical properties that are primaril# derived from the
lightweight cellular structure of the material. A brief summar# of the important properties
and their impact on the product performance is given herein based on s#nthesis of
literature information.
The bul& densit# of the dr# material is in the range of 1+!-0 pcf. The low densit# is
attributed mainl# to the large volume of air bubbles in the mass( which in effect replace
the coarse aggregate in normal weight concrete. 8or a t#pical grade of PAAC with dr#
bul& densit# of ,* pcf( appro)imatel# =0 percent of a unit volume is air. t is primaril# due
to the low densit# that the material ac"uires its improved and fascinating properties.
2anufacturers t#picall# specif# the e)act dr# densit# of their product( which ma# differ
depending on the raw materials and the manufacturing process. The actual densit# of
the product is usuall# higher due to moisture or reinforcement.
Moisture content. .hortl# after manufacture( the moisture content is usuall# in the
range of *+ ! ;0 percent b# mass of the dr# material( the lower the densit# the greater
the initial moisture content. ?ith time( however( the material graduall# dries out and an
e"uilibrium moisture content of ; to - percent b# mass is reached in about 1 to * #ears
(C1%). 2easurements of moisture in t#pical PAAC structures in service indicated that
the moisture content in /0 percent of the cases was less than + percent b# mass
(6ums).
Pore structure. The pore structure of PAAC has a direct effect on the ph#sical
properties of the material such as the strength( thermal conductivit#( and freeze!thaw
resistance. Pores present in PAAC can be divided according to size into micropores (@ 1
mm) and macropores (0.1 to 1.0 mm)( or what are referred to as structural pores and
artificial pores respectivel#. Af the total porosit# or pore volume( appro)imatel# ,+
percent is micropores and the remainder -+ percent is macropores.
Compressive strength. PAAC is t#picall# classified according to its compressive
strength( which ranges from about *+0 psi to 1000 psi. These have corresponding oven!
dr# unit weights ranging from *+ to +0 pcf. The compressive strength is highl#
dependent on the densit# of the material( and it increases with increasing densit#. The
relationship is somewhat linear and ma# be estimated using empirical e"uations similar
to the following$
f<c B *, ? ! *=0
where f<c is e)pressed in lbCin* and ? is the oven!dr# unit weight in lbCft,. .uch an
e"uation( however( has to be ad4usted to account for actual raw materials and
production process.
Modulus of rupture. The modulus of rupture is appro)imatel# 1C; the compressive
strength and ma# reach ;0D of the compressive strength in some cases. The relativel#
high value for the modulus of rupture in PAAC ma# be advantageous in bloc&
construction where fle)ural tension stresses ma# be allowed under transient loads.
Direct Tensile Strength. The direct tensile strength is somewhat less than the fle)ural
tensile strength of the material. t is estimated at about 1C+ of the compressive strength.
Eer# limited test data is available on the direct tensile strength of PAAC( and direct
tension is t#picall# not allowed in the design of unreinforced construction.
Shear strength. Pure shear strength values ma# be estimated at 1C; the compressive
strength. These values are particularl# needed in the design of shear walls and
diaphragms.
Modulus of elasticity. The modulus of elasticit# (:oung<s modulus) is a function of the
densit# and compressive strength. t is affected b# the moisture content almost in the
same manner as the compressive strength. The modulus of elasticit# is dependent on
the direction of load application in relation to the direction of the e)pansion of the
material. %oth properties are about / percent lower on the average when measured in
the direction of e)pansion.
.imple relationships for the modulus of elasticit# 1 as a function of densit# ma# be
obtained from statistical anal#ses of test data. Ane such relationship ma# be given as
1 B (10./ r ! 7+) 10,
?here 1 is in lbCin* and r is the dr# bul& densit# in lbCft, at a moisture content of about ,
percent b# mass.
Freezing and thawing. Fue to the pore structure of the material( PAAC has good
resistance to freezing and thawing as demonstrated b# field performance of untreated
(uncoated) PAAC in severe environments. The macropores( which are spherical and
large in size( are almost closed and not connected. These pores possess negligible
capillar# suction. Capillar# suction ta&es place onl# through the micropores. 6ence the
rate of water penetration through PAAC is ver# low.
Thermal insulation. The air bubbles and low densit# give PAAC e)cellent thermal
insulation properties( and in most cases the use of supplementar# insulation can be
avoided. The thermal conductivit#( &( is the (time) rate of heat transfer b# conduction(
through a unit thic&ness( across a unit area( for a unit difference in temperature. 3nits of
& are %tu!inChr!ft*!G8( or ?attsCmeter!GHelvin. The lower the densit# the lower the
thermal conductivit# I&I and the better the thermal performance. Thermal conductivit# is
also dependent on the moisture content of the material$ it increases with increase in
moisture content. As shown in 8ig. ,( PAAC is about 10 times better than ordinar# dense
concrete with respect to heat conductivit#. Additionall#( PAAC has good thermal inertia
which in combination with the good thermal insulation properties results in reducing the
temperature e)tremes e)perienced in a building. 8urthermore( the airtightness of the
construction( achievable due to the high tolerances of the product( contributes to the
energ# efficienc# of PAAC building s#stem.
Sound isolation. The structure of PAAC provides better sound absorption as compared
to that of smooth( dense concrete. Tests according to A.T2 1 /0 ! Acoustical
2easurement of .ound Transmission 'oss of %uilding Partitions were performed on =
and 10!in. thic& PAAC walls with dr# bul& densities of ,*( ,=( and ;; pcf. The wall sides
were either unrendered or had specified finishes. The .ound Transmission Class (.TC)
for all cases was in the range of ;+ to +0( whereas the Autdoor ndoor Transmission
Class (ATC) was in the range of ,/ to ;;.
Fire Resistance. PAAC has remar&able fire resistance properties. The material is non!
combustible and has low thermal conductivit#. Fue to the low thermal conductivit#( heat
migration ta&es place at a ver# slow rate as compared to dense concrete. ?ater within
the material (in a cr#stalline form) also acts as a heat sin&( and the porous structure of
PAAC allows the steam to escape without causing surface spalling. Tests on =!in. thic&
load!bearing walls in accordance to A.T2 111/ I8ire Tests of %uilding Construction and
2aterialsI indicated that an =!hour fire rating could be achieved.
Shrinage. 'oss of moisture in PAAC results in dr#ing shrin&age. t is determined
according to 1uropean standards as the relative length change for specimens at
specified moisture contents of ,0 and - percent b# mass respectivel#. The average
shrin&age for PAAC is *00)10!- as compared to +00)10!- for ordinar# concrete. The
lower shrin&age for PAAC is attributed mainl# to the high pressure steam curing
(autoclaving) that the fresh material is sub4ected to during production.
!irtightness. 1ven with normal construction procedures( PAAC buildings have e)cellent
airtightness "ualities. Tests on PAAC buildings measured 1 to *.+ air changes per hour
at a reference pressure of +0 Pa. This compares favorabl# with other t#pes of
construction( such as wood frame or concrete bloc&( where normall# the average air
change rate at +0 Pa is about 7.
Thermal e"pansion. The coefficient of thermal e)pansion of PAAC is about =)10!-CGC(
which is about *0 percent less than that of normal weight concrete. Fue to the thermal
insulation properties of PAAC( it is necessar# in calculations of thermal effects to
account for the time lag between air temperatures and concrete temperatures. The
PAAC unit will not simpl# elongate or contract under temperature changes but will e)hibit
a camber towards the side with increasing temperature.
#nergy a$sorption.Test results from unpublished sources on e)terior PAAC walls
indicated that the material has high bullet resistance. An 2, classification (>epetier
.#stC;; 2agnum( speed ;;1 mCs( energ# 1++1 4oule) was achieved for PAAC with
nominal dr# bul& densit# of ,* pcf. The tested wall had an interior plaster finish on one
side and a lime cement plaster on the other side.
Strutura! Desi$%
PAAC ma# be used in unreinforced or reinforced construction. 3nreinforced construction
is basicall# construction using PAAC bloc&s. The design in this case is usuall# based on
elastic theor# using service loads and permissible unit stresses. Although some of the
design rules in AC +,0 for masonr# structures( and AC ,1= (Chapter **!.tructural
Plain Concrete)( ma# be used( the information in these codes must be modified to
account for the PAAC material properties. Additional details specific to PAAC( which can
be found mainl# in 1uropean specifications( must also be &ept in mind.
n the case of reinforced elements( the reinforcement adds significantl# to the comple)it#
of the design. AC ,1= does not address PAAC( but 1uropean standards and codes
such as FJ( >'12( etc. are available and do provide detailed coverage of the material.
These standards and codes( however( differ in their treatment of PAAC design. .ome
use an ultimate strength approach( with load factors assigned to service loads and
capacit# reduction factors to account for understrength( and others utilize a simpler
allowable stress approach.
Currentl# considerable interest and activities have been initiated in technical committees
of professional societies( such as AC and A.T2( in an effort to produce documents that
cover the design and use of PAAC. A.T2 Committee C*7 Precast Concrete has a
newl# developed standard that is approved for publication entitled I.tandard
.pecification for Precast Autoclaved Aerated Concrete ?all Construction 3nits(I and
AC Committee +*, Cellular Concrete is wor&ing on developing a document on the
design of PAAC. These technical efforts are regarded as a step in the right direction
since their success is crucial to the establishment of PAAC as a reliable building material
in the 3... The availabilit# of the technical information will encourage the engineer to
specif# and design PAAC and hence promote the overall use of the material.
Co%strutio%
%ecause of the low weight of PAAC and the larger size of units( the components can be
economicall# transported and erected. Construction time is further minimized due to the
ease of cutting and shaping the material in the field (8ig. ;). Although special e"uipment
is needed for handling the reinforced panels( these are simple ine)pensive lifting devices
that do not represent a ma4or capital e)pense. 8urthermore( the material is highl#
wor&able as it can be sawn( nailed( and drilled similar to wood using hand tools. A
variet# of anchorage devices is also available for attachments to PAAC.
Applications of PAAC are numerous and have proven to be limited onl# b# one<s
imagination. Common applications for which PAAC is most suitable include single!famil#
and multi!famil# residential construction as well as low!rise commercial and industrial
buildings (8ig. +). .pecialized applications such as firewalls( sound walls( earth"ua&e!
resistant s#stems( and cladding for high!rise buildings have also been used successfull#.
Co%!usio%
PAAC is a s#stem of ultra lightweight precast concrete products with uni"ue material
characteristics. t is a new precast product in the 3... mar&et that was first commerciall#
produced on a large scale in 1//-. t is e)pected that the usage of PAAC will proliferate
as more production plants are constructed and as the &nowledge and familiarit# with the
material increase. Although the material has a proven trac& record and wealth of
information is available in the foreign literature( considerable technical developments are
still needed in the 3... in order to provide the specifier and user with a reasonable level
of confidence in PAAC. .everal efforts have alread# begun through the domestic PAAC
producers as well as through the wor& of professional societies such as AC and A.T2.
Considering these efforts and the success of the ongoing construction pro4ects( it is
inevitable and beneficial that PAAC will soon be established as one of the ma4or precast
products in the 3...
Se!eted Refere%es