A

Project Report on

AAC (Autoclaved Aerated Concrete)

Submitted

In partial fulfillment of the requirements for the degree of

Bachelor of Technology

In

CIVIL ENGINEERING

By
VISHWAM KUMAR (1900970000107)

DEEPAK RATHORE (1900970000043)

AVIRAL CHANCHAL (1900970000040)

DIWAKAR SINGH (1900970000045)

SAURABH SINGH (1900970000087)

Under the Guidance of

Mr. Faheemul Islam Kirmani

DEPARTMENT OF CIVIL ENGINEERING

Galgotias College of Engineering & Technology

Greater Noida, Uttar Pradesh
India-201306
Affiliated to

Dr. A.P.J. Abdul Kalam Technical University

Lucknow, Uttar Pradesh,
India-226031
May, 2023

i
 GALGOTIAS COLLEGE OF ENGINEERING & TECHNOLOGY
GREATER NOIDA, UTTAR PRADESH, INDIA- 20 13 06 .

CERTIFICATE
This is to certify that the project entitled “AAC (Autoclaved Aerated Concrete)” has been
carried out by the team given below under my guidance in partial fulfillment of the degree of
Bachelor of Technology in CIVIL ENGINEERING during the academic year 2021-2022 (8th
Sem).

VISHWAM KUMAR (1900970000107)

DEEPAK RATHORE (1900970000043)

AVIRAL CHANCHAL (1900970000040)

DIWAKAR SINGH (1900970000045)

SAURABH SINGH (1900970000087)

Date: Mr. Faheemul Islam Kirmani

Assistant Professor

Dept. of Civil Engineering

ii
 GALGOTIAS COLLEGE OF ENGINEERING & TECHNOLOGY
GREATER NOIDA, UTTAR PRADESH, INDIA- 20 13 06 .

DECLARATION
I hereby declare that the project report is an authentic record of my own work as requirements of
project during the period from Sept. 2022 to May 2022 for the award of degree of B.Tech Civil
Engineering, Galgotias College of Engineering and Technology, Greater Noida under the guidance
of Mr. Faheemul Islam Kirmani.

VISHWAM KUMAR (1900970000107)

DEEPAK RATHORE (1900970000043)

AVIRAL CHANCHAL (1900970000040)

DIWAKAR SINGH (1900970000045)

SAURABH SINGH (1900970000087)

Date:

Certified that the above statement made by the student is correct to the best of our knowledge and
belief.

Examined By:

Mr. Faheemul Islam Kirmani

Dr. Rishav Garg

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External Examiner Head of Department

GALGOTIAS COLLEGE OF ENGINEERING & TECHNOLOGY

GREATER NOIDA, UTTAR PRADESH, INDIA- 20 13 06 .

ACKNOWLEDGEMENT
It has taken a lot of effort to complete this project. However, completing this project would not
have been possible without the support and guidance of a lot of individuals. We would like to
extend our sincere thanks to all of them.

We are highly indebted to Mr. Faheemul Islam Kirmani, professor in the department of
electrical engineering at Galgotias College of Engineering & Technology, who deserves special
recognition for her unwavering support and direction during the course of our work. She has
consistently inspired us with her sincerity, thoroughness, and perseverance. Only because of her
conscious efforts have our efforts been made fruitful. We are extremely grateful to Professor Dr.
Rishav Garg, the department head (CE) for his ongoing support, inspiration, and motivation for
our project work on behalf of the government. We would like to thank him for providing the
necessary information and resources for this project.

We would like to extend our sincere gratitude to our project coordinator for sharing their energy
and expertise, as well as for the depth of their direction and priceless suggestions throughout the
project.

We also want to thank the department's faculty and lab instructors for their kind assistance and
cooperation throughout the development of our project.

VISHWAM KUMAR (1900970000107)

DEEPAK RATHORE (1900970000043)

SAURABH SINGH (1900970000087)

AVIRAL CHANCHAL (1900970000040)

iv
 DIWAKAR SINGH (1900970000045)

TABLE OF CONTENT

Sr. No. Particulars PAGE NO.

1. CHAPTER- 1 2-13

1.1 Introduction 2

1.2 Needs Autoclaved Aerated Concrete 3

1.3 Future Scope Autoclaved Aerated Concrete 4

1.4 Applications Of Autoclaved Aerated Concrete 4-6

1.5 Advantages Autoclaved Aerated Concrete 7-10

1.6 Disadvantages Of Autoclaved Aerated Concrete 11-13

2. CHAPTER- 2 13-22

2.1 Literature Review 13-15

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2.2 Experimental Programs Autoclaved Aerated Concrete 16-18

2.3 Market Survey Of Autoclaved Aerated Concrete 19-22

3. CHAPTER- 3 22-39

3.1 Methods And Implementation 22-25

3.2 Instruments Autoclaved Aerated Concrete 25-28

3.3 The Manufacturing Process Of Autoclaved Aerated Concrete 29-31

3.4 Raw Material Suitability Autoclaved Aerated Concrete 31-33

3.5 Test for Autoclaved Aerated Concrete 34-39

4. CHAPTER- 4 40-47

4.1 Result And Discussions 40-43

5. CHAPTER-5 48-51

5.1 Conclusion 48

5.2 Future Scope 48-51

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 TABLE INDEX

SERIAL NO. TABLE PAGE NO.

3.1 Fly Ash 32

3.2 Lime 32

3.3 Cement 33

3.4 Gypsum/Plaster 33

3.5 Aluminum Powder 33

4.1 Mix Details For 1 Metre Cube 40

4.2 Compressive Strength And Density (Mix-1) 40

4.3 Compressive Strength And Density (Mix-2) 41

4.4 Compressive Strength And Density (Mix-3) 42

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 4.5 Comparison 46

4.6 Cost Of AAC 47

FIGURE INDEX

SERIAL NO. FIGURE PAGE NO.

1.1 Autoclaved Aerated Concrete (AAC) 2

1.2 Thermal Insulation 8

1.3 Fire Resistance 9

3.1 Components Of AAC 23

3.6 Consumption Of Raw Material 28

3.7 Manufacturing Process 29

3.8 Manufacturing Flow Chart 31

4.1 Density Test Readings 34

4.2 Compressive Strength Test 36

4.3 Compressive Strength Test Readings 37

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 4.4 Water Absorption Test 38

4.5 Water Absorption Test Readings 39

4.6 Density to Comp. Strength Varriance 42

Abstract:
Autoclaved Aerated Concrete (AAC) is a lightweight, precast, foam concrete building material
that offers significant advantages over traditional construction materials such as brick and
concrete. Natural raw ingredients like sand, lime, cement, water, and a trace amount of aluminium
powder are used to create AAC. This paper explores the properties, production, and sustainability
benefits of AAC, as well as its potential applications in the construction industry. AAC is an
environmentally friendly and sustainable material, with low embodied energy, high insulation
value, and excellent fire resistance. Several building projects can benefit from the usage of AAC,
including those involving load-bearing walls, flooring, roofing, and cladding. The production
process of AAC has been optimized to minimize waste and energy consumption. This paper
presents a comprehensive review of the current research on AAC and its applications, as well as
future directions for research and development.

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 CHAPTER – 1
INTRODUCTION

1.1 Detailed Autoclaved Aerated Concrete (AAC)

The construction industry is one of the largest contributors to global greenhouse gas emissions,
accounting for around 40% of total energy-related CO2 emissions. Therefore, there is an urgent
need to develop sustainable building materials that can reduce the environmental impact of the
construction industry. Autoclaved Aerated Concrete (AAC) is a sustainable building material that
has been gaining popularity in recent years due to its environmental benefits and superior
performance over traditional building materials. AAC is a lightweight, precast, foam concrete
building material that is made from natural raw materials such as sand, lime, cement, water, and
trace amount of aluminum powder.

AAC (Autoclaved Aerated Concrete) is a lightweight, durable, and versatile building material that
is increasingly being used in construction projects around the world. It is made from a mixture of
cement, lime, sand, and aluminum powder, which is then cured using high-pressure steam in an
autoclave. During the curing process, the aluminum powder reacts with other materials in the
mixture to create millions of small air pockets within the material, giving it a unique cellular
structure and exceptional insulation properties.

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 Figure No. 1.1. Autoclaved Aerated Concrete (AAC)

1.2 Needs Autoclaved Aerated Concrete (AAC)

AAC is a sustainable and environmentally friendly building material, as it uses natural and
recyclable materials and has a low carbon footprint compared to other building materials. It is also
highly energy-efficient, as its superior insulation properties can help to reduce heating and cooling
costs in buildings.

Autoclaved Aerated Concrete (AAC) is in high demand due to its numerous advantages in the
construction industry. Its lightweight nature makes it easy to handle and transport, while its
excellent thermal insulation properties help reduce energy consumption. AAC's porous structure
provides effective sound insulation, ensuring a peaceful indoor environment.

It is also highly fire-resistant, offering enhanced safety. With its durability and strength, AAC
provides long-lasting structures with minimal maintenance requirements. Additionally, AAC is
environmentally friendly, utilizing recycled materials and requiring less energy in production. The
versatility of AAC allows for diverse architectural designs. Overall, AAC meets the need for
sustainable, efficient, and high-performance building materials.

Autoclaved aerated concrete (AAC) addresses several crucial needs in the construction industry.
Firstly, AAC fulfills the need for sustainable building materials by using a high proportion of
recycled materials and reducing carbon emissions during production. Secondly, AAC meets the
demand for energy-efficient structures with its exceptional thermal insulation properties, reducing
energy consumption for heating and cooling.

Additionally, AAC fulfills the need for durability and structural integrity, as it is resistant to rot,
pests, and mold, ensuring long-lasting performance. Moreover, AAC addresses the need for faster
construction through its lightweight nature, enabling quicker installation and reducing labor costs.
Lastly, AAC caters to the need for fire-resistant and soundproof structures, enhancing safety and
comfort in buildings. With its wide range of benefits, AAC successfully meets the evolving needs
of the construction industry.

1.3 Future Scope Autoclaved Aerated Concrete (AAC)

AAC is a versatile building material that can be used for foundations, walls, floors, and roofs. It is
easy to install, lightweight, and has excellent thermal and sound insulation properties, making it an
ideal choice for buildings located in noisy or high-traffic areas or regions with extreme
temperature variations.

AAC is a highly adaptable and environmentally friendly building material that has many
advantages over more conventional building materials like bricks and concrete blocks. Its
lightweight, insulation properties and durability make it a popular choice for modern construction
projects.

The future scope of Autoclaved Aerated Concrete (AAC) looks promising as the construction
industry continues to prioritize sustainability and energy efficiency. AAC offers a range of benefits
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that align with these objectives, such as lightweight construction, excellent thermal insulation, and
reduced environmental impact. As technology advances, there are opportunities to further enhance
the properties of AAC, such as improving its strength, fire resistance, and acoustic insulation.

Additionally, research and development efforts can focus on optimizing production processes and
exploring innovative applications for AAC in areas such as high-rise buildings, infrastructure
projects, and off-site construction. The future holds immense potential for AAC to play a
significant role in shaping the construction industry's sustainable and resilient future.

The future scope of autoclaved aerated concrete (AAC) is promising, as it aligns with the global
focus on sustainability and energy efficiency in construction. AAC is likely to witness increased
adoption due to its lightweight nature, thermal insulation properties, and durability. As technology
advances, AAC production processes will become more efficient and cost-effective. The
integration of innovative techniques, such as 3D printing, can revolutionize AAC construction,
allowing for complex and customizable designs.

Additionally, the incorporation of smart building technologies and renewable energy systems can
further enhance AAC's performance and contribute to the development of greener and more
sustainable structures.

1.4. Applications of Autoclaved Aerated Concrete (AAC)

Autoclaved Aerated Concrete (AAC) finds a wide range of applications in the construction
industry. Some key applications of AAC include:

1.4.1 Walls:
AAC blocks or panels are commonly used for constructing exterior and interior walls. Their
lightweight nature makes them easy to handle and install. AAC walls offer excellent thermal
insulation properties, reducing energy consumption for heating and cooling. They also provide
soundproofing capabilities, enhancing the overall comfort of the building.

Walls constructed with autoclaved aerated concrete (AAC) offer numerous advantages. AAC walls
provide excellent thermal insulation, maintaining comfortable indoor temperatures while reducing
energy consumption. Their lightweight nature eases construction and reduces the load on the
foundation. AAC walls have good sound insulation properties, minimizing noise transmission.
They are fire-resistant, enhancing safety. AAC walls also offer durability, with resistance to pests
and mold. Additionally, AAC walls promote sustainability due to the use of environmentally
friendly materials and their ability to be recycled or reused.

1.4.2 Floors and Roofs:

AAC can be utilized for constructing floors and roofs, either as load-bearing or non-load-bearing
elements. Its lightweight nature reduces the overall structural load while maintaining structural
integrity. AAC floors and roofs offer good thermal and acoustic insulation, contributing to energy
efficiency and occupant comfort.

Floors and roofs constructed with autoclaved aerated concrete (AAC) offer numerous benefits.
AAC's lightweight nature makes it ideal for both upper-level floors and roof structures, reducing
the overall structural load. AAC provides excellent thermal insulation, enhancing energy
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efficiency and reducing heating and cooling costs. Its sound insulation properties contribute to a
quieter indoor environment.
AAC floors and roofs are fire-resistant, improving safety. Additionally, AAC's durability ensures
long-lasting performance, while its sustainability attributes make it an eco-friendly choice for
sustainable construction practices.

1.4.3 Partitions:
AAC blocks are commonly employed for creating partitions between rooms or within open floor
plans. These partitions provide soundproofing, privacy, and can easily accommodate electrical and
plumbing installations. Partitions made with autoclaved aerated concrete (AAC) offer several
advantages. AAC partitions provide excellent sound insulation, ensuring privacy and minimizing
noise transmission between rooms. They are lightweight, making them easy to handle and install,
while also reducing the overall structural load.
AAC partitions are fire-resistant, adding a layer of safety to buildings. Additionally, AAC's
thermal insulation properties contribute to energy efficiency, promoting comfortable indoor
environments. AAC partitions are also durable, resistant to pests, and environmentally friendly,
making them a reliable and sustainable choice for interior walls in various construction
applications.

1.4.4 Cladding:
AAC panels can be used as cladding materials for the exterior façade of buildings. AAC cladding
offers aesthetic appeal, Cladding of autoclaved aerated concrete (AAC) offers numerous benefits
to both residential and commercial buildings. AAC cladding panels are lightweight, durable, and
provide excellent thermal insulation. They are easy to install and can enhance the aesthetic appeal
of any structure.
The cladding acts as a protective layer, shielding the underlying AAC blocks from external
elements and improving the overall structural integrity. Additionally, AAC cladding is fire-
resistant, environmentally friendly, and requires minimal maintenance. With its versatility and
superior performance, AAC cladding is an ideal choice for achieving energy efficiency and
architectural excellence in construction projects.

1.4.5 Durability:
AAC is known for its durability and long lifespan. It is resistant to pests, rot, and mold growth,
ensuring minimal maintenance requirements weather resistance, and thermal insulation, enhancing
the overall energy efficiency of the structure. [5]

The durability of autoclaved aerated concrete (AAC) makes it a preferred choice in the
construction industry. AAC is known for its long-lasting performance and resistance to various
environmental factors. It exhibits excellent strength and stability, ensuring the structural integrity
of buildings over time.
AAC is resistant to rot, pests, and mold, making it suitable for both interior and exterior
applications. Additionally, AAC's low water absorption rate minimizes the risk of freeze-thaw
damage. Its inherent durability, combined with proper installation and maintenance, ensures that
AAC structures maintain their integrity and aesthetics for years to come.

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1.4.6 Prefabricated Elements:
AAC can be molded into various precast elements, such as lintels, beams, and columns, offering
ease of construction and precise dimensional accuracy. These prefabricated elements reduce on-
site construction time and labor. Prefabricated elements of autoclaved aerated concrete (AAC)
offer significant advantages in construction projects. These factory-made components, such as wall
panels, floor slabs, and roof elements, are precisely engineered and manufactured to high
standards, ensuring consistent quality.
Prefabricated AAC elements are lightweight, allowing for faster and easier installation, reducing
construction time and costs. They offer excellent thermal insulation properties, contributing to
energy efficiency in buildings. Furthermore, AAC's fire-resistant nature enhances the safety of
structures. By incorporating prefabricated AAC elements, construction projects can benefit from
improved efficiency, durability, and overall performance.

1.4.7 Retaining Walls:

AAC blocks or panels can be used to construct retaining walls due to their lightweight and durable
nature. These walls provide stability, erosion control, and can be engineered to withstand high
loads.

Retaining walls constructed with autoclaved aerated concrete (AAC) bring numerous advantages
to landscaping and engineering projects. AAC retaining walls offer excellent strength and stability,
effectively holding back soil and preventing erosion. They are lightweight, making them easier to
handle and install compared to traditional heavyweight materials. AAC's thermal insulation
properties help regulate temperature and prevent moisture buildup behind the wall. Additionally,
AAC is resistant to rot, pests, and mold, ensuring long-lasting durability. With their aesthetic
appeal, sustainability, and reliable performance, AAC retaining walls provide an efficient and
attractive solution for various retaining and landscaping applications.

1.4.8 Special Applications:

AAC can also be utilized for specialized applications such as fireproofing, acoustic barriers, and
thermal insulation in industrial settings, infrastructure projects, and high-rise buildings. The
versatile nature of Autoclaved Aerated Concrete enables its application in a wide range of
construction projects, contributing to energy efficiency, durability, and sustainable building
practices.

Autoclaved aerated concrete (AAC) finds special applications in various fields due to its unique
properties. In the realm of sound insulation, AAC is an excellent choice for constructing walls and
partitions in theaters, recording studios, and residential buildings where noise reduction is crucial.
Its lightweight nature makes it ideal for constructing floating floors that minimize impact sound
transmission. Moreover, AAC's fire-resistant properties make it suitable for fire-rated walls and
structures. Additionally, its high thermal insulation capabilities make it valuable in creating
energy-efficient buildings. With its versatility and exceptional performance, AAC offers
innovative solutions for special applications in the construction industry.

1.5. Advantages Autoclaved Aerated Concrete (AAC)

Autoclaved Aerated Concrete (AAC) offers several advantages as a building material. Here are
some key advantages of AAC: [3]

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1.5.1 Lightweight:
AAC is significantly lighter than traditional construction materials such as concrete or clay bricks.
Its lightweight nature reduces the structural load on buildings, enabling cost savings in foundation
design and transportation. The lightweight nature of autoclaved aerated concrete (AAC) is one of
its key advantages in construction. AAC consists of millions of tiny air bubbles evenly distributed
throughout the material, resulting in its low density. This characteristic makes AAC significantly
lighter than traditional concrete while maintaining impressive structural strength.
The lightweight nature of AAC simplifies transportation and installation, reducing labor and
equipment costs. It also allows for faster construction, making it an efficient choice for both large-
scale projects and DIY enthusiasts. Additionally, AAC's lightweight properties contribute to
energy efficiency, as it requires less energy to heat or cool structures built with AAC.

1.5.2 Thermal Insulation:

AAC provides excellent thermal insulation, helping to regulate indoor temperatures and reduce
energy consumption for heating and cooling. It minimizes heat transfer through walls, resulting in
energy savings and improved occupant comfort. [4]
Thermal insulation is one of the key advantages of Autoclaved Aerated Concrete (AAC). The
unique cellular structure of AAC, characterized by numerous air pockets, provides exceptional
insulation properties.
These air-filled voids act as barriers to heat transfer, reducing thermal conductivity and improving
energy efficiency in buildings. The insulating properties of AAC help create a more comfortable
indoor environment by minimizing heat loss during colder months and reducing heat gain in hotter
climates.

Figure No. 1.2 Thermal Insulation

xv
This results in reduced reliance on heating and cooling systems, leading to energy savings and
lower utility bills. Additionally, the thermal insulation of AAC contributes to a more consistent
and stable temperature within the building, reducing temperature fluctuations and improving
occupant comfort. AAC walls, with their high insulation value, also contribute to the achievement
of energy efficiency certifications and green building standards. Overall, the thermal insulation
provided by AAC enhances the sustainability, energy efficiency, and thermal comfort of buildings.

1.5.3 Sound Insulation:

AAC's cellular structure and composition contribute to its superior sound insulation properties. It
effectively reduces the transmission of airborne sound, enhancing acoustic comfort within
buildings.
Autoclaved Aerated Concrete (AAC) offers excellent sound insulation properties, making it an
ideal choice for creating quiet and acoustically comfortable spaces. The porous structure of AAC,
filled with air pockets, acts as a barrier to sound transmission, effectively reducing the passage of
airborne noise. AAC walls have the ability to absorb and dampen sound waves, minimizing the
transfer of noise from room to room and from external sources.
This makes AAC particularly beneficial in environments where sound privacy is crucial, such as
residential buildings, hotels, educational institutions, and offices. By reducing noise pollution,
AAC contributes to creating peaceful and conducive living and working environments.
Additionally, the sound insulation provided by AAC can help meet regulatory requirements and
certifications related to noise control. Whether it's blocking external noise or preventing sound
from traveling between rooms, AAC's sound insulation capabilities enhance the overall acoustic
performance and comfort of buildings.

1.5.4 Fire Resistance:

Autoclaved Aerated Concrete (AAC) exhibits excellent fire resistance properties, making it a
reliable choice for enhancing building safety. AAC is an inorganic material that does not combust
or release toxic gases when exposed to high temperatures. Its low thermal conductivity helps
prevent the spread of fire and contributes to containment. AAC walls and structures provide a
significant barrier against flames, protecting occupants and minimizing property damage. This
fire-resistant characteristic of AAC makes it a preferred material for applications where fire safety
is crucial, such as residential buildings, commercial complexes, and industrial facilities.

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 Figure No. 1.3 Fire Resistance

AAC is highly fire-resistant due to its inorganic composition. It does not release toxic fumes or
gases when exposed to high temperatures, making it a safe choice for fire-prone areas. AAC walls
can provide valuable fire compartmentation and increase evacuation time in case of emergencies.
AAC structures have shown good resistance to natural disasters such as earthquakes, thanks to its
lightweight and flexible characteristics.

1.5.5 Sustainable and Environmentally Friendly:

AAC is an eco-friendly building material. Its production process requires less energy and emits
fewer greenhouse gases compared to conventional materials. The use of AAC reduces the demand
for clay and preserves natural resources. It also promotes sustainable construction practices and
can contribute to green building certifications.
Autoclaved Aerated Concrete (AAC) is highly sustainable and environmentally friendly. AAC
production involves the use of recycled materials, such as fly ash, which reduces the consumption
of natural resources. The manufacturing process of AAC requires less energy compared to
traditional concrete production, resulting in lower greenhouse gas emissions.
Additionally, AAC is a durable material with a long lifespan, reducing the need for frequent
replacement. It is also recyclable, and crushed AAC can be reused as aggregate. By incorporating
AAC into construction projects, it promotes sustainability, minimizes environmental impact, and
contributes to the overall goal of creating greener and more sustainable buildings.

1.5.6 Design Flexibility:

AAC can be easily cut, shaped, and molded, allowing for versatile design possibilities. It
accommodates various architectural styles and can be used for both load-bearing and non-load-
bearing applications. AAC blocks can be easily drilled and grooved to accommodate electrical and
plumbing installations. Autoclaved Aerated Concrete (AAC) offers design flexibility, allowing for
a wide range of architectural possibilities. AAC blocks and panels can be easily cut, shaped, and

xvii
customized to fit specific design requirements. The lightweight nature of AAC enables the creation
of intricate designs and complex shapes that may be challenging with other construction materials.
AAC can be used for load-bearing walls, non-load-bearing walls, partitions, and architectural
features. It also allows for easy integration of additional components such as windows, doors, and
utilities. The versatility of AAC enables architects and designers to explore creative and innovative
solutions, making it a favorable choice for achieving unique and aesthetically pleasing building
designs.

1.5.7 Speed of Construction:

AAC blocks and panels are larger in size compared to traditional bricks, resulting in faster
construction. The use of AAC reduces labor and construction time, enabling faster project
completion. These advantages make Autoclaved Aerated Concrete (AAC) an attractive choice for
a wide range of construction projects, offering energy efficiency, durability, fire resistance, and
sustainability.
Autoclaved Aerated Concrete (AAC) offers the advantage of faster construction compared to
traditional building materials. AAC blocks and panels are lightweight, making them easy to handle
and install, resulting in accelerated construction processes.

The larger size of AAC blocks allows for quicker coverage of wall areas, reducing the number of
joints and labor required. Additionally, AAC's precast nature allows for off-site manufacturing,
which can be carried out concurrently with site preparation, further reducing construction time.
The speed of construction with AAC not only helps meet project deadlines but also minimizes
labor costs, making it an attractive choice for time-sensitive construction projects.

1.6 Disadvantages of Autoclaved Aerated Concrete (AAC):

1.6.1 Limited load-bearing capacity:

AAC is not as strong as traditional concrete and may have limitations in supporting heavy
structural loads. Reinforcement or additional structural support may be required in certain
applications, which can increase costs and complexity. One of the disadvantages of Autoclaved
Aerated Concrete (AAC) is its limited load-bearing capacity compared to traditional concrete.
While AAC can adequately support typical loads encountered in construction, it may not be
suitable for heavy structural loads without additional reinforcement or structural support.
This limitation can impact the design and construction of certain types of buildings or structures
that require higher load-bearing capacity. It's important to consider the specific project
requirements and consult with structural engineers to ensure proper design and reinforcement
techniques are employed when using AAC in applications that involve significant structural loads.

1.6.2 Limited availability:

AAC may not be readily available in all regions, especially in areas where AAC production
facilities are not established. This can result in logistical challenges and higher transportation costs
if AAC needs to be sourced from distant locations. The availability of Autoclaved Aerated
Concrete (AAC) may be limited in certain regions or areas where AAC production facilities are

xviii
not well-established. This can pose challenges in sourcing AAC materials for construction
projects, especially if they need to be transported from distant locations.

Limited availability may result in increased costs due to transportation and logistical factors. It's
important for builders and contractors to consider the local availability of AAC and plan
accordingly by exploring alternative construction materials or considering the establishment of
AAC production facilities in areas where demand is high and availability is limited.

1.6.3 Higher initial costs:

The initial cost of AAC can be higher compared to conventional building materials like concrete or
brick. The specialized manufacturing process and raw materials involved in producing AAC
contribute to its higher price point. However, the long-term benefits in terms of energy savings and
durability can offset these initial costs over time. Higher initial strength in autoclaved aerated
concrete (AAC) is attributed to the unique curing process it undergoes. AAC is a lightweight,
precast building material that consists of finely ground sand, cement, lime, water, and a small
amount of aluminum powder. Once mixed, the aluminum reacts with the lime and expands,
creating microscopic air bubbles throughout the mixture. These bubbles contribute to its
lightweight nature.
After pouring into molds, AAC is cured in an autoclave under high-pressure steam, which
accelerates the chemical reactions and enhances the formation of calcium silicate hydrate,
responsible for strength development. This accelerated curing process results in higher initial
strength compared to conventional concrete, making AAC an excellent choice for various
construction applications.

1.6.4 Specialized construction techniques:

Working with AAC requires specific knowledge and expertise. Specialized tools and techniques
are needed to cut, shape, and install AAC blocks or panels correctly. Contractors and builders who
are unfamiliar with AAC may require training and may face a learning curve, potentially leading
to higher labor costs. Autoclaved aerated concrete (AAC) utilizes specialized construction
techniques to ensure optimal performance and efficiency. One key technique is the use of thin-bed
mortar, which involves applying a thin layer of adhesive mortar to bond the AAC blocks together.

This technique minimizes the amount of mortar used, reduces construction time, and enhances the
structural integrity of the finished structure. Additionally, AAC construction often incorporates
pre-engineered components, such as lintels, wall panels, and floor slabs, which are manufactured
off-site and then easily assembled on-site.

1.6.5 Moisture sensitivity during construction:

AAC can be sensitive to moisture during the construction phase. Care must be taken to protect
AAC blocks or panels from excessive moisture exposure, as it can affect their structural integrity
and lead to surface damage or deformation. Moisture sensitivity during construction is a critical
consideration in autoclaved aerated concrete (AAC). As AAC contains cellular structure and air

xix
pockets, it is susceptible to moisture penetration if not properly protected. Moisture can
compromise the material's strength and lead to potential issues like cracking or deterioration.

Therefore, it is essential to implement effective moisture management strategies during

construction, such as applying appropriate waterproofing membranes and ensuring proper drainage
systems, to safeguard the long-term durability and performance of AAC structures.

1.6.6 Limited color and texture options:

Compared to traditional masonry materials, AAC offers fewer choices in terms of color and
texture. The surface of AAC may have a uniform appearance, which may not suit certain
architectural or design preferences. It's important to note that while AAC has its disadvantages,
these can often be mitigated with proper planning, design considerations, and skilled construction
practices.

Autoclaved aerated concrete (AAC) has limited color and texture options compared to other
construction materials. Due to the composition and production process of AAC, the range of colors
available is typically limited to shades of gray or off-white.

Similarly, the texture options are limited to a smooth or slightly textured surface. While this may
limit design possibilities for some projects, AAC's other advantages like lightweight, insulation
properties, and ease of construction continue to make it a popular choice in various applications.

Objectives:
 To introduce AAC blocks as a sustainable and cost-effective building material in the
construction industry.
 Promote the benefits of AAC blocks over traditional building materials, such as better
thermal insulation, sound insulation, and fire resistance.
 To describe the process used in the manufacturing of autoclave aerated concrete.
 To cast standard AAC blocks in laboratory and conduct various tests to check the strength
and capacity of the blocks

CHAPTER – 2
LITERATURE REVIEW

S. Islam

concluded in 2020 that, the construction industry has conducted numerous studies focusing on the
utilization of readily available raw materials in the construction sector. As the construction
industry experiences a rapid boom, particularly in the GCC countries, there is a growing need for
innovation in materials and construction tools. Bricks and concrete blocks have traditionally been
the most commonly used construction materials for building infrastructure. However, the

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manufacturing process for clay bricks and blocks emits a significant amount of CO2, which has a
negative impact on the environment. As a result, there has been a strong emphasis on finding
alternative eco-friendly solutions to create a greener environment. [1]

In response to the environmental concerns associated with traditional construction materials,

alternative materials have been suggested for sustainable construction, encompassing both
conventional and non-conventional options. These alternatives aim to reduce carbon emissions
through various parameters while offering benefits such as being greener, cost-effective, low in
energy consumption, and possessing high thermal conductivity. Autoclaved Aerated Concrete
(AAC) blocks have emerged as a promising eco-friendly construction material, providing a
potential solution to structural construction challenges.

This article specifically explores the transition from clay bricks to eco-friendly AAC blocks as a
corrective action in construction practices. The advantages of AAC blocks are extensive, making
them favorable for the construction of smart infrastructure. AAC blocks are known for their eco-
friendly characteristics, offering significant advantages over traditional clay bricks. They are
produced using a combination of readily available raw materials, including sand, cement, lime,
gypsum, and a small quantity of aluminum powder. The manufacturing process involves aeration,
where the mixture is foamed and cured in autoclaves under high-pressure steam, resulting in the
formation of lightweight blocks with excellent thermal insulation properties.

AAC blocks offer numerous benefits for sustainable construction. Firstly, they contribute to the
reduction of carbon emissions due to the lower energy consumption and lower CO2 emissions
during manufacturing. AAC blocks have a lower density compared to traditional clay bricks,
resulting in reduced transportation costs and improved handling efficiency. Their lightweight
nature also minimizes the structural load on buildings, allowing for more flexible design options
and reducing the need for heavy foundations. AAC blocks possess excellent thermal insulation
properties, leading to energy-efficient buildings that require less energy for heating and cooling.
This, in turn, reduces the reliance on artificial heating and cooling systems and promotes
sustainability.

Furthermore, AAC blocks have proven to be highly durable and possess good resistance to fire,
moisture, and pests. They are also dimensionally stable and provide excellent acoustic insulation,
contributing to a comfortable living environment. AAC blocks can be easily cut, shaped, and
assembled, facilitating faster and more efficient construction processes. The use of AAC blocks
can significantly reduce construction time and costs while ensuring high-quality, durable
structures. These alternatives aim to reduce carbon emissions through various parameters while
offering benefits such as being greener, cost-effective, low in energy consumption, and possessing
high thermal conductivity. Autoclaved Aerated Concrete (AAC) blocks have emerged as a
promising eco-friendly construction material, providing a potential solution to structural
construction challenges.

In conclusion, the transition from clay bricks to eco-friendly AAC blocks represents a significant
step towards sustainable construction practices. The advantages of AAC blocks, such as their eco-
friendly nature, lightweight composition, thermal insulation properties, durability, and ease of

xxi
construction, make them a favorable choice for constructing smart and sustainable infrastructure.
With the construction industry's growing focus on sustainability and environmental responsibility,
the adoption of AAC blocks as an alternative construction material holds great promise for
reducing carbon emissions and creating greener, more efficient buildings.

M. Kalpana, S. Mohith

concluded in 2020 Aerated lightweight concrete offers numerous advantages over conventional
concrete, making it a highly sought-after construction material. One of its key advantages is its
advanced strength-to-weight ratio. The presence of air voids within the aerated concrete
significantly reduces its density, resulting in a lighter material without compromising its structural
integrity. This lightweight characteristic makes it easier to handle, transport, and construct with,
leading to increased efficiency and reduced construction costs. [2]

Another notable advantage of aerated lightweight concrete is its lower coefficient of thermal
expansion. The air voids act as insulating pockets, reducing the transfer of heat through the
material. This property helps to mitigate the effects of temperature changes, minimizing the risk of
thermal cracking and enhancing the overall durability of structures built with aerated lightweight
concrete.

In addition to thermal properties, aerated lightweight concrete also provides excellent sound
insulation. The air voids within the material serve as barriers to sound transmission, reducing noise
pollution and creating a quieter indoor environment. This feature is particularly beneficial for
buildings located in noisy areas or those requiring enhanced acoustic performance, such as
theaters, recording studios, and residential buildings.

To gain a deeper understanding of the properties of aerated lightweight concrete, several research
papers have been studied. These papers explore the changes in properties observed in aerated
autoclaved concrete (AAC) and foamed concrete, which are the two main types of aerated
lightweight concrete. AAC is produced by introducing a foaming agent and finely ground silica
sand to a cementitious mixture, followed by autoclaving to enhance its strength and durability.
Foamed concrete, on the other hand, is created by introducing stable foam into a cementitious
mixture, resulting in a lightweight and highly workable material.

The literature review conducted focuses on four key properties of aerated lightweight concrete:
porosity, permeability, compressive strength, and splitting strength. Porosity refers to the presence
of voids within the material, and it plays a significant role in determining its thermal and acoustic
insulation capabilities. The research studies highlight the influence of different production
methods and material compositions on the porosity of aerated lightweight concrete.

Permeability, which refers to the material's ability to allow the flow of fluids through it, is another
crucial property of aerated lightweight concrete. The literature review explores how different
factors, such as the curing process and the addition of admixtures, can affect the permeability of
the material. Understanding permeability is essential in assessing the material's resistance to water
ingress, which is vital for ensuring the long-term durability of structures.

xxii
Compressive strength and splitting strength are mechanical properties that determine the load-
bearing capacity and resistance to external forces of aerated lightweight concrete. The literature
review examines the effects of various parameters, such as curing conditions, mix proportions, and
the incorporation of reinforcements, on these strength properties. The findings help in optimizing
the production process and enhancing the structural performance of aerated lightweight concrete.

The lightweight nature of autoclaved aerated concrete (AAC) is one of its key advantages in
construction. AAC consists of millions of tiny air bubbles evenly distributed throughout the
material, resulting in its low density. This characteristic makes AAC significantly lighter than
traditional concrete while maintaining impressive structural strength.
The lightweight nature of AAC simplifies transportation and installation, reducing labor and
equipment costs. It also allows for faster construction, making it an efficient choice for both large-
scale projects and DIY enthusiasts. Additionally, AAC's lightweight properties contribute to
energy efficiency, as it requires less energy to heat or cool structures built with AAC.

In conclusion, aerated lightweight concrete offers several advantages over conventional concrete,
including its advanced strength-to-weight ratio, lower coefficient of thermal expansion, and good
sound insulation. Through an in-depth analysis of research papers, this literature review has
provided insights into the properties of aerated lightweight concrete, with a focus on porosity,
permeability, compressive strength, and splitting strength. The findings contribute to the
understanding of how different factors influence these properties and inform the production and
application of aerated lightweight concrete in various construction projects.

2.2. Experimental programs Autoclaved Aerated Concrete (AAC):

Experimental programs related to Autoclaved Aerated Concrete (AAC) can involve research and
development initiatives to explore and optimize various aspects of AAC production, properties,
and applications. Here are some examples of experimental programs related to AAC:

2.1.1 AAC Mix Design Optimization:

Researchers may conduct experimental programs to optimize the mix design of AAC, exploring
different proportions and combinations of raw materials. These programs aim to achieve improved
strength, density, thermal insulation, and other desired properties of AAC.

AAC mix design optimization is crucial in ensuring the desired properties of autoclaved aerated
concrete (AAC). The mix design involves determining the appropriate proportions of raw
materials like sand, cement, lime, water, and aluminum powder to achieve the desired strength,
density, and workability.

Through careful experimentation and testing, engineers can optimize the mix design to meet
specific project requirements, such as improved strength, reduced density, or enhanced thermal
insulation. This process enables the production of high-quality AAC with consistent performance
and helps maximize the benefits of using this innovative building material.

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2.1.2 Performance Testing and Characterization:
Experimental programs can involve comprehensive testing and characterization of AAC samples.
This may include evaluating compressive strength, density, thermal conductivity, fire resistance,
sound absorption, and durability through laboratory experiments and field studies.

Performance testing and characterization play a vital role in assessing the quality and suitability of
autoclaved aerated concrete (AAC). Various tests are conducted to evaluate properties such as
compressive strength, density, thermal conductivity, water absorption, and sound insulation. These
tests help determine if the AAC meets the required standards and specifications for specific
applications.

Additionally, characterizing the material's behavior under different conditions provides valuable
insights into its durability, structural performance, and overall functionality. Performance testing
and characterization enable engineers and builders to make informed decisions, ensuring that AAC
structures perform optimally and meet the desired performance criteria.

2.1.3 Development of Advanced AAC Variants:

Researchers may explore the development of advanced AAC variants with enhanced properties.
This can involve the addition of additives or modifiers to improve specific attributes such as
moisture resistance, impact resistance, or self-cleaning capabilities.

The development of advanced autoclaved aerated concrete (AAC) variants has opened up new
possibilities in construction. Innovations in AAC technology have led to the creation of variations
with improved properties, such as higher strength, enhanced thermal insulation, and increased fire
resistance.

These advanced AAC variants often incorporate additives, fibers, or alternative raw materials to
achieve the desired enhancements. By pushing the boundaries of AAC performance, these variants
provide architects and builders with more versatile options for sustainable, energy-efficient, and
durable construction projects.

2.1.4 Sustainable AAC Production:

Experimental programs can focus on developing sustainable AAC production methods. This may
involve exploring alternative raw materials, optimizing energy consumption during manufacturing,
and implementing recycling or waste reduction techniques.

Sustainable AAC production focuses on minimizing environmental impact throughout the

manufacturing process of autoclaved aerated concrete (AAC). This includes sourcing raw
materials from sustainable and renewable sources, optimizing energy usage during production,
reducing carbon emissions, and implementing efficient waste management practices. Additionally,
AAC's lightweight nature contributes to reduced transportation energy and allows for more
efficient use of resources during construction.

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By adopting sustainable practices, AAC manufacturers strive to create environmentally-friendly
construction materials that contribute to energy efficiency, reduced greenhouse gas emissions, and
overall sustainable building practices.

2.1.5 Innovative AAC Applications:

Researchers may experiment with new and innovative applications of AAC. This can include
investigating its use in specialized areas such as earthquake-resistant structures, green roofs, or 3D
printing of AAC components.

Autoclaved aerated concrete (AAC) has found innovative applications across various construction
sectors. It is increasingly used in residential, commercial, and industrial projects for walls, floors,
roofs, and even prefabricated building components.

AAC's lightweight nature enables faster and more efficient construction, while its excellent
thermal insulation properties contribute to energy efficiency. Additionally, AAC's fire resistance,
acoustic performance, and durability make it suitable for specialized applications like
soundproofing, fire-rated walls, and high-performance buildings. The versatility and unique
qualities of AAC continue to drive its adoption in innovative construction projects worldwide.

2.1.6 Performance in Extreme Conditions:

Experimental programs can assess the performance of AAC in extreme conditions, such as high
temperatures, freeze-thaw cycles, or aggressive chemical environments. This helps evaluate its
suitability for diverse climatic and environmental conditions.

Autoclaved aerated concrete (AAC) demonstrates excellent performance in extreme conditions. It

exhibits high resistance to fire, with its non-combustible nature providing enhanced safety. AAC
also maintains its structural integrity under extreme temperatures, making it suitable for areas
prone to wildfires or high heat.

Moreover, AAC's low thermal conductivity helps regulate indoor temperatures, providing comfort
in hot or cold climates. Its durability and resistance to moisture, mold, and pests further contribute
to its reliable performance in diverse and challenging environmental conditions.

2.1.7 Life Cycle Assessment:

Experimental programs can involve conducting life cycle assessments (LCAs) to evaluate the
environmental impact of AAC throughout its entire life cycle, including raw material extraction,
manufacturing, transportation, use, and disposal. This helps quantify its sustainability and identify
areas for improvement.

These experimental programs contribute to the continuous advancement of AAC technology,

enabling the development of improved products, processes, and applications for the construction
industry.
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2.3. Market Survey of Autoclaved Aerated Concrete (AAC)
The market for Autoclaved Aerated Concrete (AAC) has experienced significant growth and holds
promising prospects in the construction industry. A market survey reveals the following key trends
and insights:

2.2.1 Growing Demand:

The demand for AAC has been steadily increasing due to its numerous advantages. The
construction industry's focus on energy-efficient and sustainable building materials, coupled with
the need for faster construction methods, has driven the demand for AAC.

The demand for autoclaved aerated concrete (AAC) is rapidly growing in the construction
industry. This is due to the increasing focus on sustainable and energy-efficient building materials.
AAC's unique properties, such as its lightweight nature, excellent thermal insulation, fire
resistance, and durability, make it an attractive choice for builders and architects.

Moreover, AAC's ease of use, faster construction time, and reduced transportation costs further
contribute to its rising popularity. With its numerous advantages, AAC is witnessing a surge in
demand as more construction projects prioritize sustainable and high-performance solutions.

2.2.2 Energy Efficiency and Sustainability:

AAC's exceptional thermal insulation properties and energy-saving capabilities have made it
popular in both residential and commercial construction projects. Its eco-friendly attributes,
including reduced carbon footprint and efficient use of raw materials, have aligned with the
industry's sustainability goals. [10]

Autoclaved aerated concrete (AAC) is renowned for its energy efficiency and sustainability.
AAC's low thermal conductivity and excellent insulation properties help regulate indoor
temperatures, reducing the need for heating and cooling energy. Its lightweight composition also
minimizes transportation energy during construction.

Additionally, AAC production utilizes environmentally friendly materials, and its durability
ensures longevity, reducing the need for frequent replacements. With its sustainable attributes and
energy-saving capabilities, AAC is a preferred choice for eco-conscious builders and contributes to
more sustainable and energy-efficient buildings.

2.2.3 Urbanization and Infrastructure Development:

Rapid urbanization, especially in emerging economies, has fueled the demand for affordable and
durable construction materials. AAC's lightweight nature, ease of installation, and reduced
construction time make it an attractive option for infrastructure projects, including residential
buildings, schools, hospitals, and commercial complexes.

Autoclaved aerated concrete (AAC) plays a crucial role in urbanization and infrastructure
development. As cities expand and demand for efficient construction solutions grows, AAC offers
xxvi
advantages such as faster construction, reduced transportation costs, and enhanced energy
efficiency. AAC's lightweight properties make it ideal for high-rise buildings, while its thermal
insulation capabilities contribute to sustainable urban development.

Furthermore, AAC's versatility and durability make it suitable for infrastructure projects like
bridges, tunnels, and sound barriers, contributing to the efficient growth and development of urban
areas.

2.2.4 Regional Variations:

The market for AAC varies across different regions. Developed countries have witnessed
widespread adoption of AAC, driven by stringent energy efficiency regulations and sustainable
construction practices. In emerging economies, the market is expanding as AAC offers a viable
alternative to traditional construction materials like red bricks or concrete blocks.

Regional variations in autoclaved aerated concrete (AAC) are influenced by factors such as local
raw materials, construction practices, and market preferences. Different regions may have specific
requirements and standards, leading to variations in AAC formulations, mix designs, and
production techniques. Additionally, regional architectural styles and climatic conditions can
impact the aesthetic finishes and surface treatments applied to AAC structures.

These regional adaptations ensure that AAC meets the specific needs and design preferences of
different areas, making it a versatile and adaptable construction material worldwide.

2.2.5 Retrofit and Renovation Projects:

AAC's versatility extends to retrofit and renovation projects, where its lightweight characteristics
make it suitable for adding additional floors or constructing extensions on existing buildings. The
demand for AAC in these applications is expected to increase as urban areas seek to optimize
available space.

Autoclaved aerated concrete (AAC) is gaining popularity in retrofit and renovation projects due to
its lightweight nature and ease of installation. AAC's lightweight properties make it suitable for
adding extra floors or extensions to existing structures without compromising the foundation. Its
thermal insulation characteristics contribute to improved energy efficiency in retrofitted buildings.
Additionally, AAC can be used to replace or reinforce walls in renovation projects, providing
enhanced structural stability and durability while maintaining the original aesthetics of the
building.

2.2.6 Market Players and Competition:

The AAC market consists of several established manufacturers and suppliers operating globally.
Competition is driven by factors such as product quality, technological advancements, price, and
customer service. Market players are investing in research and development to enhance AAC
properties and explore new applications.

xxvii
The autoclaved aerated concrete (AAC) market boasts a diverse range of market players and
intense competition. Established manufacturers leverage their extensive experience and global
presence to cater to the growing demand for sustainable construction materials.

Additionally, emerging players are entering the market with innovative product offerings and
advanced technologies, intensifying the competitive landscape. This dynamic environment
encourages continuous research and development, resulting in improved product quality, cost-
effectiveness, and energy efficiency, ultimately benefiting consumers and driving the overall
growth of the AAC industry.

2.2.7 Challenges:
Despite its advantages, the AAC market faces challenges related to high initial costs, limited
awareness among contractors and architects, and the availability of skilled labor for AAC
construction. Overcoming these challenges requires targeted marketing, training programs, and
collaborative efforts from industry stakeholders.

Autoclaved aerated concrete (AAC) faces several challenges within the industry. One major hurdle
is the initial high cost of establishing AAC production facilities, making it difficult for new
entrants to penetrate the market. Additionally, AAC requires specialized knowledge and skilled
labor for installation and construction, which can be limited in certain regions.

Another challenge is the perception and awareness of AAC among architects, engineers, and
contractors, as it may take time to gain widespread acceptance as a viable construction material.
However, ongoing education and awareness efforts are helping to overcome these challenges and
promote the benefits of AAC.

2.2.8 Future Outlook:

The AAC market is expected to witness sustained growth due to the increasing emphasis on
sustainable construction, energy efficiency, and green building practices. Technological
advancements, such as improved AAC formulations and manufacturing techniques, are likely to
drive innovation and expand the market further.

The future outlook for autoclaved aerated concrete (AAC) appears promising as the demand for
sustainable construction materials continues to grow. With advancements in technology and
production processes, AAC is expected to become more cost-effective and energy-efficient. The
focus on green building practices and environmental regulations further contributes to AAC's
potential market expansion.

Moreover, ongoing research and development efforts aim to enhance the strength, durability, and
insulation properties of AAC, making it an attractive choice for a wide range of construction
applications in the years to come.
xxviii
In conclusion, the Autoclaved Aerated Concrete (AAC) market is experiencing positive growth
driven by factors such as energy efficiency, sustainability, urbanization, and infrastructure
development. With ongoing advancements and increasing awareness, AAC is poised to play a
significant role in the construction industry, offering efficient and environmentally friendly
solutions for building projects worldwide

CHAPTER - 3
METHODS AND IMPLEMENTATION

Autoclaved Aerated Concrete (AAC) is a lightweight and versatile building material

that has gained significant popularity in the construction industry. It is made from a
mixture of cement, water, lime, sand, and aluminum powder, which is then cured
under high-pressure steam to create a cellular structure. The resulting AAC blocks or
panels exhibit exceptional thermal insulation, fire resistance, and acoustic properties.
AAC offers several advantages over traditional building materials, including
reduced construction time, improved energy efficiency, and lower environmental
impact. This introduction provides a brief overview of AAC, highlighting its unique
properties and its potential to revolutionize modern construction practices.
Autoclaved Aerated Concrete (AAC) is widely recognized as an eco-friendly
building material due to several key factors. First and foremost, AAC production
requires a significantly lower amount of raw materials compared to traditional
concrete. The cellular structure of AAC, created by incorporating aluminum powder
and the process of autoclaving, results in a lighter material that requires less cement,
sand, and aggregate. This reduces the consumption of natural resources and lowers
the carbon footprint associated with its production.
3.1 The Components of Autoclaved Aerated Concrete (AAC):
3.1.1 Cement:

Figure No. 3.1 Cement

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Portland cement is the main binding agent used in the manufacturing of AAC. It typically makes
up about 10-20% of the total mixture. [6]

Cement is a key component in autoclaved aerated concrete (AAC), providing the binding material
that holds the other ingredients together during the curing process, resulting in the formation of
AAC blocks or panels.

3.1.2 Lime:

Figure No. 3.2 Lime

Quicklime (calcium oxide) or hydrated lime (calcium hydroxide) is added to the mixture to help in
the formation of calcium silicate hydrate, which gives AAC its strength.

Lime is an essential ingredient in autoclaved aerated concrete (AAC), contributing to the chemical
reaction that produces the porous structure and lightweight properties of AAC, ensuring its
strength and durability.

3.1.3 Sand:

Figure No. 3.3 Sand

Sand is an essential ingredient that provides the necessary bulk and texture to the AAC mixture. It
also contributes to the overall strength of the material.

xxx
Sand is a crucial component in autoclaved aerated concrete (AAC), providing bulk and stability to
the mixture. It helps to improve the workability of the AAC mixture and contributes to the overall
strength and density of the final product.

3.1.4 Fine Aggregate:

Figure No. 3.4 Fine Aggregate

Silica sand or fly ash is used as a fine aggregate in the manufacturing of AAC. The fine aggregate
typically makes up around 60-75% of the total mixture.

Fine aggregate, such as crushed stone or sand, plays a vital role in autoclaved aerated concrete
(AAC). It fills the voids between the larger particles, enhancing the workability, density, and
overall structural integrity of the AAC mixture. The fine aggregate contributes to the final strength
and durability of the AAC product.

3.1.5 Aluminum powder:

Figure No. 3.5 Aluminum powder

Aluminum powder is added to the mixture to create millions of small air pockets within the
material during the autoclaving process. The lightweight and insulating qualities of AAC are a
result of these air pockets.

Aluminum powder is a critical additive in autoclaved aerated concrete (AAC) production. When
mixed with other ingredients and subjected to high-pressure steam curing, it reacts with lime and
xxxi
forms hydrogen gas, resulting in the formation of numerous small air bubbles that contribute to
AAC's lightweight and insulating properties.

3.1.5 Water:
Water is used to activate the cement and lime, and to provide the moisture necessary for the
expansion of the material during the autoclaving process.

In addition to these primary raw materials, other additives may also be used to enhance the
properties of AAC, such as gypsum, fly ash, and plasticizers. The exact proportions of these raw
materials may vary depending on the manufacturer and the specific properties desired in the final
product. However, the manufacturing process typically involves mixing the raw materials together
in a precise ratio, pouring the mixture into molds, allowing it to set, and then autoclaving it at high
pressure and temperature to create the final AAC blocks or panels. [6]

3.2 Instruments Autoclaved Aerated Concrete (AAC)

Several instruments are used in the production, testing, and quality control of Autoclaved Aerated
Concrete (AAC). Here are some commonly used instruments in AAC:

3.2.1 Mixer:
A mixer is used to blend the raw materials, including cement, lime, sand, water, aluminum
powder, and the foaming agent, ensuring a homogeneous mixture.
The mixer plays a critical role in the production of autoclaved aerated concrete (AAC). It is
responsible for ensuring the proper blending of raw materials, such as cement, lime, fly ash, water,
and aluminum powder. The mixer should have the capability to achieve a homogeneous mixture
with consistent proportions, ensuring the quality and structural integrity of the final AAC blocks or
panels.
Efficient mixers reduce production time and energy consumption while maintaining the desired
properties of AAC, contributing to a smooth and streamlined manufacturing process.

3.2.2 Autoclave:
An autoclave is a crucial instrument used in the production of AAC. It subjects the AAC blocks or
panels to high-pressure steam, promoting the chemical reaction that forms the cellular structure
within the material.
The autoclave is a vital component in the production of autoclaved aerated concrete (AAC). It is a
pressure vessel that subjects the AAC products to high-pressure steam curing, promoting the
chemical reaction that gives AAC its unique properties. The autoclave ensures the proper curing
and hardening of AAC, resulting in enhanced strength, durability, and thermal insulation. Precise
temperature and pressure control within the autoclave are crucial to achieving optimal AAC
product quality, making it an indispensable element in the AAC manufacturing process.

3.2.3 Cutting Machine:

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AAC blocks or panels are often cut to specific dimensions for different applications. A cutting
machine, such as a wire saw or a stationary blade cutter, is employed to achieve accurate and
precise cuts.
The cutting machine is an essential tool in the production of autoclaved aerated concrete (AAC). It
is used to accurately cut AAC blocks or panels into desired sizes and shapes. The cutting process
ensures precision and uniformity, facilitating easy installation and construction. Advanced cutting
machines equipped with diamond or carbide-tipped blades ensure clean and smooth cuts,
minimizing wastage and optimizing material utilization.
Efficient cutting machines contribute to increased productivity and cost-effectiveness in AAC
manufacturing, enabling the production of high-quality AAC products for various construction
applications.

3.2.4 Compression Testing Machine:

Compression testing machines are used to determine the compressive strength of AAC samples.
This instrument applies a load to the AAC specimen until failure, measuring the maximum force it
can withstand.
The compression testing machine plays a crucial role in assessing the strength and quality of
autoclaved aerated concrete (AAC). It applies a compressive load to AAC specimens, measuring
their resistance to deformation and determining their compressive strength.
This testing process helps ensure that the AAC products meet the required standards and
specifications for construction applications. Accurate and reliable compression testing machines
are essential in quality control and product validation, enabling manufacturers to deliver AAC with
optimal strength and performance to the market.

3.2.5 Density Measurement Device:

Instruments such as a density meter or pycnometer are used to measure the density of AAC
samples. These devices determine the mass of a given volume of AAC, providing insights into its
quality and structural properties.
A density measurement device is a valuable tool in the production and quality control of
autoclaved aerated concrete (AAC). It accurately measures the density of AAC blocks or panels,
which is a critical parameter in determining their structural integrity and insulation properties. By
assessing the density, manufacturers can ensure uniformity and consistency in AAC products,
thereby meeting the required specifications.

This device aids in maintaining quality standards and helps optimize the manufacturing process to
produce AAC with the desired density for various construction applications.

3.2.6 Thermal Conductivity Apparatus:

To assess the thermal insulation properties of AAC, thermal conductivity apparatus is used. It
measures the ability of AAC to resist heat transfer, providing data on its insulation efficiency.
A thermal conductivity apparatus is a significant device used in the evaluation of autoclaved
aerated concrete (AAC). It measures the thermal conductivity of AAC, which is a crucial property
in determining its insulation capabilities. By assessing thermal conductivity, manufacturers can
xxxiii
ensure that AAC products provide efficient heat insulation, contributing to energy savings and
improved comfort in buildings.
This apparatus enables accurate testing and validation of AAC's thermal performance, aiding in the
development and production of AAC with superior insulation properties for sustainable
construction applications.

3.2.7 Sound Insulation Testing Equipment:

Instruments such as sound level meters or sound transmission class (STC) testers are used to
evaluate the sound insulation capabilities of AAC. These devices measure the sound transmission
through AAC panels or walls, helping assess its acoustic performance.
Sound insulation testing equipment is essential in assessing the soundproofing capabilities of
autoclaved aerated concrete (AAC). It measures the sound transmission class (STC) and other
acoustic properties of AAC products. By evaluating sound insulation performance, manufacturers
can ensure that AAC effectively reduces noise transmission, creating quieter and more comfortable
indoor environments.

This testing equipment enables accurate measurement and validation of AAC's sound insulation
capabilities, allowing for the production of AAC with superior acoustic performance for various
construction applications, including residential, commercial, and industrial buildings.

3.2.8 Moisture Meter:

Moisture meters are used to measure the moisture content of AAC samples. This information is
crucial for quality control, as excessive moisture can impact the strength and durability of AAC.
A moisture meter is a valuable tool in assessing and monitoring the moisture content of autoclaved
aerated concrete (AAC). It helps ensure that AAC products have the appropriate moisture levels
for optimal performance and durability. By accurately measuring moisture content, manufacturers
can prevent issues such as excessive shrinkage, cracking, and reduced strength caused by improper
moisture levels. This device aids in quality control and allows for the adjustment of production
parameters to achieve the desired moisture content, ensuring the long-term integrity and
functionality of AAC in various construction applications.

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 Figure No. 3.6 Consumption of Raw Material

Autoclaved aerated concrete (AAC) production relies on the consumption of several key raw
materials. These include cement, lime, fly ash, sand, and water. Cement acts as the primary binder,
ensuring structural integrity. Lime provides stability and enhances the material's durability. Fly
ash, an industrial byproduct, contributes to its thermal insulation and strength. Sand lends texture
and assists in creating a stable mixture. Water is crucial for hydration, facilitating the chemical
reactions that result in the formation of the AAC matrix. This combination of raw materials is
crucial for producing high-quality autoclaved aerated concrete products.

3.3 The manufacturing process of Autoclaved Aerated Concrete (AAC:

Figure No. 3.7 manufacturing process

The production process of AAC involves several stages, including raw material preparation,
mixing, and casting, curing, and cutting. The raw materials used in AAC production are natural
and abundant, and the production process has been optimized to minimize waste and energy
consumption. The basic steps involved in AAC production are: [7]

3.3.1 Raw Material Preparation:

The raw materials required for manufacturing AAC, such as cement, lime, sand, and aluminum
powder, are proportioned and mixed thoroughly to create a slurry or mixture.

Raw material preparation is a crucial step in the production of autoclaved aerated concrete (AAC).
It involves careful selection, proportioning, and mixing of raw materials such as cement, lime, fly
ash, aluminum powder, and water. The raw materials need to be properly crushed, blended, and
homogenized to ensure a consistent and uniform mixture.

This preparation process determines the quality and characteristics of the final AAC product,
including its strength, density, and insulation properties. Accurate raw material preparation is
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essential for achieving consistent and high-quality AAC that meets the desired specifications and
performance requirements.

3.3.2 Pouring and Cutting:

The mixture is poured into a large mold, where it is allowed to set and harden. Once the mixture
has hardened to a sufficient level, it is cut into the desired shape and size using a wire cutting
machine.

Pouring and cutting are crucial stages in the manufacturing process of autoclaved aerated concrete
(AAC). During pouring, the prepared AAC mixture is carefully poured into molds or formwork,
ensuring proper placement and compaction. After the AAC has cured in the autoclave, it is ready
for cutting.

Cutting machines are used to precisely slice the cured AAC into desired sizes and shapes, allowing
for easy installation and construction. Accurate pouring and cutting contribute to the dimensional
accuracy, quality, and versatility of AAC products, making them suitable for a wide range of
construction applications.

3.3.3 Autoclaving:
The cut AAC blocks or panels are then placed in an autoclave, which is a large vessel that uses
high pressure and steam to cure and harden the blocks. The autoclave cures the blocks at a
temperature of around 190°C and a pressure of around 12 bar for several hours, depending on the
thickness of the blocks.

Autoclaving is a critical process in the production of autoclaved aerated concrete (AAC). After
pouring and curing, AAC products are placed in autoclaves, where they undergo high-pressure
steam curing. The autoclaving process triggers a chemical reaction within the AAC, resulting in
the formation of numerous small air cells, enhancing its lightweight and insulating properties.

Autoclaving ensures the proper hardening and curing of AAC, improving its strength, durability,
and thermal performance. This process is crucial for achieving the desired properties and
characteristics of AAC, making it a reliable and sustainable construction material.

3.3.4 Demolding and Packaging:

After the autoclaving process, the AAC blocks or panels are removed from the molds and
trimmed to their final dimensions. They are then packaged and transported to the construction site.

The autoclaving process is a critical step in the manufacturing of AAC, as it causes a chemical
reaction between the aluminum powder and the other ingredients in the mixture, which creates
millions of small air pockets within the material. These air pockets give AAC its lightweight and
insulating properties.

xxxvi
Demolding and packaging are final stages in the production of autoclaved aerated concrete (AAC).
Once the AAC has completed the curing process and achieved the desired strength, it is demolded
from the forms or molds. Careful demolding ensures the integrity of the AAC products.

After demolding, the AAC blocks or panels are packaged, usually in bundles or pallets, for
transportation and storage. Proper packaging protects the AAC from damage during handling and
transit, ensuring its quality and readiness for construction projects.

xxxvii
In addition, the autoclaving process also strengthens the AAC blocks, resulting in a highly durable
and long-lasting mat STEAM CURING FOR 12 erial that can withstand harsh weather conditions
and extreme temperatures.

Overall, the manufacturing process of AAC is highly efficient and environmentally friendly, as it
uses a minimal amount of energy and raw materials compared to other building materials. AAC is
also highly sustainable, as it is made primarily from natural and recyclable materials and has a
long lifespan, reducing the need for frequent replacement and renovation.

Figure No. 3.8 manufacturing Flow chart

3.4 Raw Material Suitability Autoclaved Aerated Concrete (AAC)

Autoclaved aerated concrete (AAC) is a lightweight, precast building material that contains a high
volume of air cells. It is primarily composed of cement, lime, fine sand, water, and a small amount
of aluminum powder. The raw materials used in AAC production should possess specific
characteristics to ensure the suitability of the final product. Here are the key considerations for the
raw material suitability of autoclaved aerated concrete

1. Fly Ash (65-70%)

Index Item Grade (%)

xxxviii
 Gr - I Gr -
II
Degree of (0.045 square hole sieve left amount) ≤ 30 45
fineness (0.080 square hole sieve left amount) ≤ 15 25
Ignition loss ≤ 5.0 10.0

SiO2 ≥ 45-55 40
SO3 ≤ 1 2
Reference: The fineness can be 0.045 or 0.080 square sieve left amount.

Table No. 3.1 Fly Ash

2. Lime (8-25%)
Item Grad
e
Super Gr. 1st Gr. 2nd
Gr
A(CaO+MgO) Quality Fraction % ≥ 90 75 65
MgO Quality Fraction % ≤ 2 5 8
SiO2 Quality Fraction % ≤ 2 5 8
CO2 Quality Fraction % ≤ 2 5 7
Digestion speed ,min ≤ 5-15
Digestion temperature , ℃ ≥ 60-90
Undigested residue quality fraction ,% ≤ 5 10 15
Fineness (0.080 square hole sieve left ≤ 10 15 20
amount) %

Table No. 3.2 Lim

3. Cement

SiO2 Al2O3 Fe2O3 CaO MgO C3S C2S C3A C4AF

21-23 5-7 3-5 64-48 4-5 44-59 18-30 5-12 10-18

Table No. 3.3 Cement

xxxix
 4. Gypsum/Plaster (3-5%)

CaSO4 > 70%

MgO < 2%
Chloride < 0.05%
Preferably ground residue 90μm < 10-15%

Table No. 3.4 Gypsum/Plaster

5. Aluminum Powder (about 0.08%)

Type and recommendation for supply depend on raw materials and mix formula

Metal Content Approx. >=65% Powder

Table No.3.5 Aluminum Powder

AAC also offers excellent thermal insulation properties, which can significantly reduce energy
consumption in buildings. The cellular structure of AAC provides a barrier against heat transfer,
resulting in reduced heating and cooling needs. This leads to lower energy usage for temperature
regulation and decreases the overall carbon emissions associated with building operation.
Moreover, AAC is a durable and long-lasting material, extending the lifespan of buildings and
reducing the need for frequent reconstruction or renovation. This longevity minimizes material
waste and associated environmental impacts over time.
Overall, Autoclaved Aerated Concrete (AAC) stands as an eco-friendly building material due to its
efficient use of resources, reduced energy consumption during production, excellent thermal
insulation properties, and long-term durability. Its adoption can contribute to sustainable
construction practices and a greener built environment.

3.5 Test for Autoclaved Aerated Concrete (AAC):

3.5.1 Density Test:

The density of AAC is a crucial property that affects its strength and durability. The density test
involves measuring the mass and volume of the AAC specimen to determine its density. The
density of AAC typically ranges from 400 kg/m3 to 800 kg/m3. [8]

xl
The density test for AAC (Autoclaved Aerated Concrete) is used to determine the density of AAC
blocks or panels. The density of AAC is an important property as it affects the strength, insulation
properties, and durability of the material. The density of AAC typically ranges from 500 to 900
kg/m³.

Figure No. 4.1 Density Test Readings

To perform the density test, the following equipment is needed:

 A balance with an accuracy of ±0.1% of the weight of the specimen.
 A water tank or container large enough to immerse the specimen.
 A wire basket with a mesh size of 6.3 mm.
 A soft-bristled brush.

The steps to perform the density test for AAC are as follows:
 Clean and dry the specimen to remove any dust or debris.
 Weigh the specimen and record the weight as "W1".
 Fill the water tank or container with enough water to completely submerge the specimen.
 Place the wire basket into the water and zero the balance.
 Gently place the specimen into the wire basket and immerse it in the water.
 Allow the specimen to remain submerged for at least 24 hours to ensure it is completely
saturated.
 Remove the specimen from the water, allowing any excess water to drain off.
 Wipe the surface of the specimen with a soft-bristled brush to remove any water droplets.
 Weigh the saturated specimen and record the weight as "W2".

The density of the AAC specimen can then be calculated using the following formula:
xli
Density (kg/m³) = (W1-W2) / (W1-W2) x 1000

Where:

W1 = weight of dry specimen

W2 = weight of saturated specimen

The result of the density test can be used to verify the quality of the AAC material and ensure that
it meets the required specifications.

3.5.2 Compressive Strength Test:

The compressive strength of AAC is a critical property that determines its load-bearing capacity.
The compressive strength test involves applying a compressive load to an AAC specimen until it
fails. The maximum load that the specimen can withstand before failure is recorded as its
compressive strength. The compressive strength of AAC typically ranges from 2.5 MPa to 10
MPa. [8]

The compressive strength test for AAC (Autoclaved Aerated Concrete) is used to determine the
compressive strength of AAC blocks or panels. The compressive strength of AAC is an important
property as it affects the load-bearing capacity and structural integrity of the material. The
compressive strength of AAC typically ranges from 2.5 to 4.5 N/mm².

Figure No. 4.2 Compressive Strength Test

To perform the compressive strength test, the following equipment is needed:

 A compression testing machine with a capacity of at least 500 kN.

xlii
  AAC specimens of size 150 mm x 150 mm x 150 mm.
 A ruler or caliper to measure the dimensions of the specimens.
 A water tank or container large enough to immerse the specimens.
 A curing room or chamber maintained at a temperature of 20 ± 2°C and a relative humidity
of 90%.

The steps to perform the compressive strength test for AAC are as follows:

 Prepare the AAC specimens by cutting them to the required size of 150 mm x 150 mm x
150 mm. Measure the dimensions of the specimens and record them.
 Immerse the specimens in water at a temperature of 20 ± 2°C for 24 hours to ensure that
they are fully saturated.
 After removing the samples from the water, wipe off any extra moisture.
 Place the specimen on the compression testing machine, ensuring that it is aligned
centrally.
 Apply a load to the specimen at a rate of 0.2 N/mm² per second until failure occurs. Record
the maximum load that the specimen can withstand and calculate the compressive strength
of the specimen.
 Repeat steps 4 and 5 for each specimen.
 The compressive strength of each specimen can be calculated using the following formula:
 Compressive strength (N/mm²) = Maximum load (N) / Cross-sectional area of the
specimen (mm²)

Figure No. 4.3 Compressive Strength Test readings

xliii
where:

Cross-sectional area of the specimen = 150 mm x 150 mm = 22,500 mm²

The average compressive strength of the specimens can then be calculated to determine the
compressive strength of the AAC material.

The compressive strength test is an important quality control test for AAC manufacturers, as it
ensures that the material meets the required specifications and standards for load-bearing capacity
and structural integrity

3.5.3 Water Absorption Test:

The water absorption test evaluates the ability of AAC to resist water penetration. In order to
conduct the test, an AAC specimen is submerged in water for a predetermined amount of time.
The lower the water absorption, the better the durability and resistance of AAC to moisture. [8]

The water absorption test for AAC (Autoclaved Aerated Concrete) is used to determine the
amount of water that is absorbed by AAC blocks or panels. The water absorption of AAC is an
important property as it affects the durability, insulation properties, and resistance to freeze-thaw
cycles of the material.

Figure No. 4.4 Water Absorption Test

To perform the water absorption test, the following equipment is needed:

 A balance with an accuracy of ±0.1% of the weight of the specimen.
 A water tank or container large enough to fully immerse the specimen.
xliv
  A wire basket with a mesh size of 6.3 mm.
 A soft-bristled brush.

The steps to perform the water absorption test for AAC are as follows:
 Clean and dry the specimen to remove any dust or debris.
 Weigh the dry specimen and record the weight as "W1".
 Fill the water tank or container with enough water to fully immerse the specimen.
 Place the wire basket into the water and zero the balance.
 Gently place the specimen into the wire basket and immerse it in the water.
 Allow the specimen to remain submerged for 24 hours.
 Remove the specimen from the water, allowing any excess water to drain off.
 Wipe the surface of the specimen with a soft-bristled brush to remove any water droplets.
 Weigh the saturated specimen and record the weight as "W2".

Figure No. 4.5 Water Absorption test Readings

The water absorption of the AAC specimen can then be calculated using the following formula:

Water absorption (%) = [(W2 - W1) / W1] x100

where:

W1 = weight of dry specimen

xlv
W2 = weight of saturated specimen

The result of the water absorption test can be used to verify the quality of the AAC material and
ensure that it meets the required specifications. The water absorption of AAC should typically be
less than 10%. If the water absorption is higher than this, it may indicate that the material is of
lower quality and may not have the required durability and insulation properties.

In conclusion,

Autoclaved Aerated Concrete (AAC) has emerged as a highly versatile and sustainable building
material. Through the process of autoclaving, AAC achieves exceptional strength while
maintaining its lightweight nature, resulting in improved energy efficiency and reduced
construction costs. AAC offers excellent thermal insulation properties, soundproofing capabilities,
and fire resistance, making it an ideal choice for various construction applications. Moreover,
AAC's low environmental impact, recyclability, and durability contribute to sustainable
development. As the demand for environmentally friendly and efficient construction solutions
grows, AAC stands as a promising option for the future of the building industry.

CHAPTER – 4

RESULT AND DISCUSSION

4.4 Mix Details for 1 Metre Cube

Mix Cement(kg) Sand(kg) Lime Aluminium Water(kg)

powder(kg) Powder (%)

Mix 1 384 298.67 50.371 0.10 296.30

Mix 2 384 298.67 50.371 0.13 296.30

Mix 3 384 298.67 50.371 0.18 296.30

Table No. 4.1

Compressive Strength and Density (Mix-1)

xlvi
Samples Compressive Avg. Comp. Density Avg. Density Aluminium
Strength Strength (N/ (kg/m³) (kg/m³) Powder
mm²) Content (%)

Sample 1 5.10 625 0.10

Sample 2 5.30 689 0.10

5.20 662
Sample 3 5.15 660 0.10

Sample 4 5.25 675 0.10

Table No. 4.2

Compressive Strength and Density (Mix-2)

Samples Compressive Avg. Comp. Density Avg. Density Aluminium

Strength Strength (N/ (kg/m³) (kg/m³) Powder
mm²) Content (%)

Sample 1 5.64 614 0.13

Sample 2 5.84 744 0.13

5.74 679
Sample 3 5.50 643 0.13

Sample 4 5.98 715 0.13

Table No. 4.3

Compressive Strength and Density (Mix-3)

Samples Compressive Avg. Comp. Density Avg. Density Aluminium
Strength Strength (N/ (kg/m³) (kg/m³) Powder
mm²) Content (%)

xlvii
Sample 1 5.00 600 0.18

Sample 2 4.94 654 0.18

4.07 677
Sample 3 5.10 619 0.18

Sample 4 4.84 635 0.18

Table No. 4.4

Figure No.4.6 Density to Comp. Strength Varriance

The low density was achieved by the formation of air voids to produce a cellular
structure called aerated concrete and give the materials its characteristics
appearance. With Portland cement, the initial development of strength in the product
depends primarily on the normal setting are reported in literatures.

Conclusion:

From the above test it was concluded that:

Aerated concrete blocks of strength between 4.84-5.98 (N/mm²) can be prepared
using aluminium powder. The change in alumina powder content gave a magical
change to the strength and density. Replacement of clay bricks was made possible
with the development of aerated concrete blocks.

4.5 Properties of Autoclaved aerated concrete (AAC):

xlviii
Autoclaved aerated concrete (AAC) possesses several advantageous properties. It is lightweight,
providing ease of handling and reduced structural load. AAC exhibits excellent thermal insulation
capabilities, leading to energy efficiency and reduced heating and cooling costs. Its low density
contributes to sound insulation, creating quieter indoor environments. AAC is fire-resistant,
offering enhanced safety. It is also durable, with good resistance to pests, rot, and decay.
Moreover, AAC is an environmentally friendly material, made from readily available raw
materials and promoting sustainable construction practices.

4.5.1 Lightweight and Thermal Insulation Properties:

Autoclaved Aerated Concrete (AAC) exhibits a low density due to the presence of air-filled pores,
making it a lightweight construction material. The density of AAC typically ranges from 400 to
800 kg/m³, which is significantly lower than conventional concrete. This lightweight nature of
AAC contributes to easy handling, reduced structural loads, and improved construction efficiency.

The air-filled pores in AAC provide excellent thermal insulation properties. AAC walls and other
building components offer superior thermal performance, reducing heat transfer and improving
energy efficiency in buildings. Studies have shown that AAC can significantly contribute to
reducing energy consumption for heating and cooling purposes.

4.5.2 Structural Behavior and Load-Bearing Capacity:

AAC possesses satisfactory structural strength and load-bearing capacity. Compressive strength
tests have revealed that AAC can achieve compressive strengths ranging from 1.5 to 8 MPa,
depending on the manufacturing process and material composition. The flexural and shear
strengths of AAC are also found to be adequate for various structural applications.

4.5.3 Durability and Long-Term Performance:

AAC exhibits favorable durability characteristics, contributing to its long-term performance. It
demonstrates resistance to moisture penetration, reducing the risk of moisture-related damage such
as cracking and deterioration. Studies have indicated that AAC structures show good resistance to
freeze-thaw cycles and chemical attack. [5]

Moreover, AAC has high fire resistance due to its inorganic composition and low flammability. It
does not emit toxic gases when exposed to fire, making it a safe construction material.

4.5.4 Thermal Performance and Energy Efficiency:

Numerical simulations and experimental studies have shown that AAC provides excellent thermal
insulation properties. It helps in maintaining comfortable indoor temperatures and reducing energy
consumption for heating and cooling, leading to energy-efficient buildings.

Energy simulation and modeling techniques have demonstrated that buildings constructed with
AAC can significantly reduce energy demands, resulting in lower greenhouse gas emissions and
improved overall energy performance.

xlix
4.5.5 Environmental Impact:
Life cycle assessments (LCAs) and carbon footprint analyses have indicated that AAC has a lower
environmental impact compared to traditional construction materials. The production of AAC
involves minimal use of cement and lime, leading to reduced carbon dioxide emissions during
manufacturing. Additionally, AAC utilizes industrial waste materials such as fly ash, contributing
to resource conservation and waste reduction.

4.6 AAC (Autoclaved Aerated Concrete) blocks and conventional bricks:

4.6.1 Weight:
AAC blocks are significantly lighter than conventional bricks, weighing only about one-third of
the weight of traditional bricks. This makes them easier to handle and transport and reduces the
overall weight of the building structure, which can result in cost savings on the foundation and
structural components.

4.6.2 Thermal Insulation:

AAC blocks have a much higher thermal insulation value than traditional bricks. This means that
they can help to keep buildings cooler in hot climates and warmer in colder climates, leading to
energy savings on heating and cooling costs.

4.6.3 Sound Insulation:

AAC blocks are perfect for use in structures located in busy or noisy regions because they have
great sound-insulating qualities.

4.6.4 Durability:
AAC blocks have a high compressive strength, which means that they can withstand greater
pressure and loads than conventional bricks. They are also highly resistant to fire, pests, and mold,
making them a durable and long-lasting building material.

4.7 Autoclaved Aerated Concrete (AAC) Manufacturing in India

Autoclaved Aerated Concrete (AAC) manufacturing in India is spread across several regions. Here
are some prominent manufacturing places of AAC in India:

4.7.1 Surat, Gujarat:

Surat is a significant hub for AAC manufacturing in western India. It hosts numerous AAC
production facilities, catering to the growing demand for sustainable construction materials in the
region.

4.7.2 Hyderabad, Telangana:

l
 Hyderabad has emerged as a key manufacturing center for AAC in southern India. The city
houses several AAC manufacturing units, contributing to the construction industry's needs in the
region.

4.7.3 Kolkata, West Bengal:

Kolkata serves as a prominent manufacturing hub for AAC in eastern India. It accommodates
several AAC production facilities, supplying materials for construction projects in the eastern
states.

4.7.4 Bengaluru, Karnataka:

Bengaluru, known for its technological advancements, also has AAC manufacturing units. The
city's manufacturing capabilities contribute to meeting the demand for AAC in southern India.

4.7.5 Mumbai, Maharashtra:

As a major commercial and industrial center, Mumbai has a presence of AAC manufacturing
facilities. The city's strategic location and connectivity make it an important hub for supplying
AAC materials to various construction projects.

4.7.6 NCR (National Capital Region), Delhi:

The National Capital Region, including Delhi and neighboring cities like Gurugram, Noida, and
Faridabad, has several AAC manufacturing units. The region's construction activities drive the
demand for AAC in this area.

4.7.7 Chennai, Tamil Nadu:

Chennai is another significant manufacturing place for AAC in southern India. It accommodates
several AAC production facilities, catering to the construction needs in Tamil Nadu and
neighboring states.These are just a few examples of manufacturing places for Autoclaved Aerated
Concrete (AAC) in India. The demand for AAC as a sustainable building material has led to the
establishment of AAC manufacturing facilities in various regions across the country.

4.8 Comparing the Cost of Autoclaved Aerated Concrete (AAC) and red bricks
AAC generally has a higher initial cost per unit compared to red bricks. The cost of AAC blocks or
panels is influenced by factors such as raw material prices, production techniques, and market
demand. On the other hand, red bricks have been a traditional and widely available construction
material for a long time, which can make them more affordable in some regions.

However, it's important to consider the overall cost-effectiveness of AAC in the long run. AAC
offers several advantages that can lead to cost savings over time. For instance, AAC's lightweight
nature reduces transportation costs and makes installation faster and easier, potentially reducing
labor expenses. AAC's thermal insulation properties can contribute to energy savings and lower

li
heating and cooling costs. Additionally, AAC's durability and low maintenance requirements can
result in reduced long-term repair and replacement costs compared to red bricks.

Ultimately, the cost comparison between AAC and red bricks will vary depending on factors such
as location, project requirements, and local market conditions. It is advisable to consider the
specific needs of the project and assess the long-term benefits and cost-effectiveness of both
options before making a decision.

PARTICULARS CONVENTIONAL RED AAC BLOCKS

BRICKS
Strength 30-40 Kg/cm2 35-40 Kg/cm2
Shape & Size Non Uniform & Irregular Uniform & Regular
Water Absorption 40 – 45 % 15 – 20 %
Breakage / Wastage 8 – 10 % Nil – 0.5 %
Mortar Consumption High Less
Density 1500 – 1700 Kg/M3 550 – 650 Kg/M3
Nos. of Bricks for per Cubic Meter 592 Nos [9x4x3inch] 67 Nos.
[25x9.6x4inch]
Mortar Joint Thickness 15 – 18 mm 8 – 10 mm
Plaster Thickness 15 – 20 mm 10 – 12 mm

Table No. 4.5 Comparison

4.6.5 Cost:
AAC blocks are generally more expensive than traditional bricks, but they offer cost savings in
other areas, such as reduced labor costs for installation, lower transportation costs due to their
lighter weight, and energy savings on heating and cooling costs due to their superior insulation
properties.

Overall, AAC blocks offer several advantages over conventional bricks, including better
insulation, durability, and ease of use. While they may be more expensive upfront, they can
provide cost savings in the long run through reduced energy costs and maintenance requirements.

Size (in Inches) Size (in mm) No of bricks / Weight Market Price
m3 (Kg’s)
24 * 8 * 4 600 x 200 x 83 8 – 9.5 41 – 44
100
24 * 8 * 6 600 x 200 x 56 9.5 – 11.5 61 – 64
lii
 150

24 * 8 * 8 600 x 200 x 42 13.5 – 15 82 – 85

200

Table No. 4.6 Cost of AAC

Comparing the costs of Autoclaved Aerated Concrete (AAC) in India, it is important to consider
various factors. Generally, the initial cost of AAC blocks or panels may be higher compared to
traditional construction materials like clay bricks or concrete blocks.

However, AAC offers advantages in terms of reduced construction time, lower labor costs, and
enhanced thermal insulation, which can contribute to long-term cost savings. Additionally, AAC's
lightweight nature leads to lower transportation costs and easier handling during construction.
Overall, while the upfront cost of AAC may be higher, its long-term benefits and efficiency make
it a cost-effective choice in the Indian construction market

CHAPTER – 5

CONCLUSION AND FUTURE SCOPE

5.1 Conclusion
Offers several advantages over traditional construction materials. AAC is lightweight, has high
insulation value, excellent fire resistance, and sound insulation properties. The production process
of AAC has been optimized to minimize waste and energy consumption. There are several tests
that can be conducted to evaluate the properties of AAC and ensure its quality, including density,
compressive strength, sound insulation, thermal conductivity, water absorption, and fire resistance
tests. AAC has potential applications in various construction applications and can help reduce the
environmental impact of the construction industry.

Autoclaved aerated concrete (AAC) has established itself as a versatile and sustainable building
material in the construction industry. Its unique combination of lightweight properties, excellent
thermal insulation, durability, and fire resistance makes it an attractive choice for various
applications. AAC's integration with advanced manufacturing techniques, digitalization, and
sustainable technologies further enhances its structural design, performance, and market

liii
penetration. As the demand for energy-efficient and environmentally friendly construction
solutions continues to rise, AAC's future looks promising. With ongoing research and
development, AAC is poised to play a pivotal role in creating sustainable, efficient, and
aesthetically pleasing structures for a greener and more sustainable built environment.

5.2 Future Scope

Overall, the future of Autoclaved Aerated Concrete (AAC) lies in the continuous development of
advanced manufacturing techniques, improved structural design, integration with sustainable
technologies, and the creation of innovative AAC products. By embracing these opportunities,
AAC has the potential to further establish itself as a sustainable and efficient building material in
the construction industry.

The future scope of autoclaved aerated concrete (AAC) holds immense potential in the
construction industry. With a growing emphasis on sustainable and eco-friendly building
materials, AAC is poised to play a significant role. The continuous research and development in
AAC technology aim to enhance its properties, such as strength, durability, and thermal insulation.
Moreover, the integration of advanced manufacturing techniques and automation can streamline
the production process, further reducing costs and increasing efficiency. As urbanization continues
to rise, AAC's lightweight and versatile nature make it an ideal solution for constructing energy-
efficient buildings. The future holds great promise for AAC, as it becomes an integral part of
sustainable construction practices worldwide. [9]

a. Advanced Manufacturing Techniques:

There is scope for further advancements in the manufacturing process of AAC. Researchers can
explore innovative techniques to enhance the efficiency and quality of AAC production. This
includes optimizing the autoclaving parameters, refining the material composition, and improving
the curing process. By incorporating advanced manufacturing technologies, such as automation
and robotics, the production capacity of AAC can be increased, leading to cost-effective and
sustainable construction practices.

Advanced manufacturing techniques are revolutionizing the production of autoclaved aerated

concrete (AAC). One notable advancement is the implementation of automated processes that
optimize efficiency and precision. Robotic systems and computer-controlled machinery enable the
precise measurement, mixing, and molding of AAC components. Additionally, the use of
innovative formwork and casting methods enhances the manufacturing process, resulting in
consistent quality and reduced waste.

Moreover, advanced curing techniques, such as steam curing, accelerate the curing process,
reducing production time. These advanced manufacturing techniques not only improve
productivity but also contribute to the overall sustainability and cost-effectiveness of AAC
production, paving the way for its widespread adoption in the construction industry.

b. Enhanced Structural Design and Performance:

liv
Future research can focus on developing advanced structural design methodologies and codes
specifically tailored for AAC. This would enable engineers and architects to maximize the
structural potential of AAC, leading to optimized designs and efficient use of the material.
Moreover, investigations into the behavior of AAC under various loading conditions, such as
seismic and wind loads, can further enhance its applicability in regions prone to natural disasters.

Autoclaved aerated concrete (AAC) offers enhanced structural design and performance, making it
a valuable choice in construction. AAC's cellular structure, formed by air bubbles throughout the
material, provides excellent thermal insulation and soundproofing properties. Its lightweight nature
reduces the load on the foundation and structural elements while maintaining remarkable strength.
AAC also exhibits impressive fire resistance, durability, and resistance to pests and mold.
Moreover, AAC's precise manufacturing process allows for customization, enabling architects to
design intricate shapes and structures. With its unique combination of properties, AAC ensures
enhanced structural integrity, energy efficiency, and overall performance in various construction
projects.

c. Integration of Sustainable Technologies:

There is potential for integrating AAC with other sustainable technologies to create high-
performance buildings. For instance, incorporating renewable energy systems, such as solar panels
and geothermal heating, in conjunction with AAC construction can enhance energy efficiency and
reduce environmental impact. Research can explore the integration of AAC with other sustainable
materials and technologies, such as rainwater harvesting systems and green roofs, to create more
sustainable and resilient buildings.

The integration of sustainable technologies with autoclaved aerated concrete (AAC) opens up new
possibilities for environmentally friendly construction. AAC already boasts excellent thermal
insulation, reducing the need for additional energy consumption in heating and cooling. By
incorporating renewable energy sources like solar panels, AAC structures can achieve greater
energy efficiency and reduce carbon emissions.

Furthermore, rainwater harvesting systems and greywater recycling can be seamlessly integrated
with AAC buildings, promoting water conservation. The use of sustainable materials, such as
recycled aggregates or incorporating AAC waste back into the production process, further
enhances the eco-friendliness of AAC structures. The integration of these sustainable technologies
with AAC showcases its potential to create greener, more sustainable buildings for a better future.

d. Development of Innovative AAC Products:

Future research and development efforts can focus on creating new and innovative AAC products
that cater to specific construction needs. This could include the development of AAC blocks with
improved thermal insulation properties or enhanced fire resistance. Additionally, exploring the
feasibility of incorporating functional additives or reinforcement materials in AAC can expand its
applications and improve its performance in specialized areas such as sound insulation, impact
resistance, and enhanced durability.

lv
The development of innovative autoclaved aerated concrete (AAC) products is driving
advancements in the construction industry. Manufacturers are continuously exploring new
formulations and production techniques to create AAC products with enhanced properties and
functionalities.

These innovations include AAC blocks with improved strength and durability, specialized AAC
panels for faster and easier installation, and AAC insulation boards for superior thermal
performance. Additionally, new AAC products are being developed to cater to specific
applications such as flooring systems, roofing elements, and prefabricated modules. The
development of these innovative AAC products offers architects and builders a wider range of
options to create sustainable, efficient, and aesthetically pleasing structures.

e. Digitalization and Building Information Modeling (BIM):

The integration of digital technologies, such as Building Information Modeling (BIM), can
facilitate the efficient design, construction, and management of AAC structures. BIM can enable
the optimization of AAC designs, clash detection, and accurate quantity estimation, leading to
reduced material waste and improved project coordination. The utilization of digital tools can also
aid in the monitoring and maintenance of AAC structures, ensuring their long-term performance
and durability.

Digitalization and Building Information Modeling (BIM) are transforming the use of autoclaved
aerated concrete (AAC) in construction. BIM software allows architects, engineers, and builders to
create detailed virtual models of AAC structures, enabling efficient design coordination and clash
detection. Digitalization streamlines the planning and construction processes, optimizing material
quantities, and reducing waste. Additionally, BIM facilitates the integration of AAC elements with
other building systems, ensuring seamless collaboration and efficient project management. The use
of digital tools and BIM in conjunction with AAC enhances accuracy, productivity, and cost-
effectiveness, ushering in a new era of intelligent construction practices.

The global market penetration of autoclaved aerated concrete (AAC) is steadily expanding. The
demand for sustainable and energy-efficient construction materials has propelled the growth of
AAC in various regions. Developed countries, such as Europe and North America, have witnessed
significant adoption of AAC due to its superior thermal insulation and environmental benefits.
Emerging economies, including Asia and the Middle East, are also embracing AAC as a cost-
effective solution for affordable housing and infrastructure projects. With ongoing advancements
in AAC technology, coupled with increasing awareness of its advantages, the global market
penetration of AAC is expected to continue growing in the coming years.

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