Aerated Autoclaved

Concrete
Noaina Hassan Khan---Tanzeel Ahmed--- Reema Khan
Nadia Ali --- Atia Khursheed

Introduction

Autoclaved aerated concrete (AAC), is one of the many

building products being

environmentally friendly.

touted

as

green

or

Developed

in Sweden in the 1920s in response to

increasing demands on timber supplies, AAC is a
lightweight manufactured building stone.

. Comprised of all natural raw materials, AAC is used in a

wide range of commercial, industrial, and residential

applications.
AAC now accounts for over 40% of all construction in the

United Kingdom and more than 60% of construction in

Manufacturing Process
AAC is a precast product manufactured by combining silica (either in

the form of sand, or recycled fly ash), cement, lime, water, and an
expansion agent - aluminium powder, and pouring it into a mould.
In structurally reinforced AAC products like lintels or roof panels,

steel rebar or mesh is also placed in the mould.

Once added to the concrete, the aluminium powder reacts with the

silica, resulting in the formation of millions of microscopic hydrogen

bubbles. The hydrogen bubbles cause the concrete to expand to
roughly five times its original volume.
The hydrogen subsequently evaporates, leaving a highly closed-cell

aerated concrete, then cut into which are further steam and
pressure cured in an autoclave.

Product Types
AAC products consist of load bearing, non-load

bearing and cladding applications.

Complete load bearing applications, however, are
limited to low-rise construction.
Cladding and large panels are available to take
advantage of AACs insulative, fire proofing, and
other benefits on mid- and high-rise projects.
The large wall, floor, and roof panels, measuring up
to 20 feet long, 2 feet wide, and in various
thicknesses, are also used in load-bearing capacities
and are common in commercial and industrial
applications.
The remainder of the AAC system consists of blocks,
also called units which are stacked using thin-set
mortar, as opposed to the traditional cement-based
mortar.

Types of Blocks
The blocks are available in a variety of sizes and types.
STANDARD BLOCKS - typically measuring 24 inches long, 8 inches

high, and in thicknesses between 6 (non-load-bearing) and 12

inches
CORED BLOCKS also known as O-blocks, which are used

adjacent to corners and openings and have a centred, 4 inch

vertical core at one end of the block to form a continuous
vertical core through the wall that is then filled with rebar
and concrete.

 JUMBO BLOCKS - which reduce construction time.

U-BLOCKS- which have a channel running the length of

the block that once filled with concrete, provides

structural support as headers and on the top course of
each floor (the bond beam). AAC lintels with
integrated structural support are also manufactured
and are an alternative to using the U-block system for
headers.

Product Advantages
AAC reduces additional material use and minimizes waste and pollution.
AAC is approximately 80% air, the finished product is up to 5 times the volume of the

raw material consumed in its production.

AAC production raw materials are generally locally sourced and may consist of recycled

materials.
AAC consumes approximately 50%-20% less energy than that needed to produce CMUs.
The manufacturing process, produces no waste or pollution and the final product is

completely recyclable.
Due to its light weight and dimensional accuracy, AAC can be assembled
with minimal waste and a reduced need for additional equipment.
The product is virtually maintenance free, eliminating the need for repair

materials, pesticides, and chemical treatments, while also lowering

operating costs

AAC Has High Thermal Efficiency

AAC structures result in solid wall construction with integrated

insulation, preventing thermal bridging, creating an airtight

building envelope, minimizing uncontrolled air changes.
AAC benefits from low thermal conductivity value.

AAC Reduces Noise Pollution and Improves Indoor Air

Quality
Its millions of independent air cells dampen sound

transmission.

Because AAC construction has very low air infiltration and is

mold resistant, indoor air quality of AAC structures is

improved.

AAC Structures Are Well-Suited to Withstand Fires, Earthquakes, and

Other Natural Disasters
It receives a 4 hr. UL fire rating and has a melting point of over 2900 F.
AAC is also termite and mold resistant, and nearly fireproof.

AAC Structures Are Price Competitive

AAC buildings constructed near a suppliers manufacturing

facilities cost approx. the same as traditional materials.

AACs light weight helps lower shipping costs.

The higher initial cost must be balanced against savings due to

lower operating and maintenance costs, the structures longer

lifespan.

Easily workable
Less time consuming due to large size of blocks.
Light weight also makes it easy to handle.

Product Disadvantages
Scarcity of Manufacturing Plants.
Projects far from manufacturing facilities will suffer

from higher initial costs.

Familiarity with Product

Few contractors are a currently familiar with the product, and trained

masons must adjust to using thin-set mortar as opposed to traditional

cement-based mortar, which requires less precision in its application.

Design Considerations
General considerations
AAC masonry components(block units) can be used to build
load bearing or non load bearing walls.
O-block units used to build pilasters.
U-block units used to build bond beams and lintels.
Control joints on AAC reinforced walls must be placed at

maximum 16 ft. o.c.

Installation Guide
Check foundation.
Receiving and distribution of AAC

wall units.

 Installation requirements.
Tools
Equipment
Other materials
Installing O-block for pilasters in first

course.

Laying the first course (levelling course).

Lay the first course over a semi-dry cement

mortar levelling bed- to 2 thick.

Corner blocks are laid first and the first
course should be completed before second
course installation.
Once corner blocks are placed apply thin bed
mortar, to the vertical joints for other blocks.
Thin bed mortar 1/16 inch to 1/8

Anchoring vertical
reinforcement to foundation

 Cutting blocks (adjustments and chases )

A hand saw or band saw to cut the blocks to specific lengths.

Placing control joints in first course

These are vertical joints taken through the full wall thickness, and from

bottom to top.
3/8 to thick.
Maximum spacing between control joints should be 15 ft.
Laying the subsequent courses
For subsequent courses use only thin bed mortaring on all joints between

AAC blocks.
Minimum overlapping of vertical joints between layers should be 4.
Metal strip ties should be placed every two courses at 1) connection of
secondary walls to main walls 2) connection of walls to concrete columns.
Control joints in subsequent layers.
V-shaped metal strips should be set at every two courses unless

there are two pilasters on both sides of control joints and less
than 2 from the joint.
Once the wall is built fill the gap using backer rod and seal with
caulking.

 Fill up pilasters by pouring concrete.

Building on site lintels using U-blocks.
Install temporary supports before putting U-blocks in place apply thin bed

mortar to the vertical joints.

Once U-block are set, place rebars according to construction drawings and
with concrete.
Installing U-blocks to build bond beams.
Lay U-block course applying thin bed mortar on all joints.
At each pilaster location, drill a hole in the bottom side so the vertical

bars can be attached in the bond beam.

Before pouring concrete place rebar and anchor bolts according to
construction drawings.
Utilities installation after the walls are built:
For electrical conduits and piping installation, a chase is cut using an
electrical router or a chasing tool.
When required depth of chase is bigger than maximum depth
recommended, additional O-blocks are used to lodge the pipes or
interrupt wall continuity.
After installation, the chase are filled with repair mortar or cement sand
mortar.

Bond beam and pilaster

connection

 Renders and finishes

Surface patching: rasp block joints and other areas where AAC
surface is out of plane.
Surface must be cleaned using a scrub brush and any loose or
damaged material be removed.
A rubber float is commonly used to smooth the wall surface.
Fiber glass mesh: This should be installed directly over one layer of
render in all control joints, around windows, doors and utility
locations.
Finishes:
AAC masonry walls can be finished with stucco , acrylic texture

coats, or a combination of both, also laminated stones, ceramic or

clay tiles, concrete pieces and ornamental products.

 Anchoring to AAC:
Fasteners: Anchors used with AAC shall be made of plastic or nylon. Wood, fiber,
lead, metal or expansion anchors are not recommended.
Use power drills to make holes for fasteners. Percussion drilling or inverting the
rotation direction when drilling shall be avoided.
The anchor shall penetrate tightly to avoid rotation when placing the screw.
Hebel AAC nail: Galvanized nails are designed specifically to provide definitive
anchorage in the AAC, and are directly hammered into it.
Screws: minimum length of screw is defined by anchor length plus thickness of
the finish layer and the element to be fixed.