GUBBI

ENTERPRISES

ADVANCE AREATED CONCRETE (AAC) /

AREATED LIGHT WEIGHT CONCRETE (ALC)

MANUFACTURING PLANT

What is AAC/ ALC Blocks ?

AAC is called as Advance Aerated Concrete block or ALC is

called Aerated lightweight concrete.

The blocks are made to aerate by creating a reaction between

silica in base material such as fly ash, active lime, and
aluminium powder. The block hardness is being achieved by
cement strength, and instant curing. Gypsum acts as a long
term strength gainer.

The finished product is a 2.5 times lighter Block compared to

conventional Bricks, while providing the similar strengths. The
specific gravity stays around 0.6 to 0.65. This is one single
most USP of the AAC / ALC.

This unit is proposed to manufacturer AAC/ ALC Block by

consuming the Fly ash as one of the prime raw material..

AAC Blocks are largely used in various constructions, such as

load bearing and pillar structure Buildings, Boundary walls,
Roads, Culverts, Pavements, and wherever conventional
bricks can be used.

Using these blocks in structural buildings, the builder saves

around 25 to 35% of structural steel and concrete.

These green bricks can attain very regular & uniform shapes.
As no burning is involved, so the shapes also remains
unchanged.

As per IS: 2185 (Part 3)

Physical Properties of
AAC/ ALC Blocks
Sr.

Density In Ovendry

Compressive

Thermal Conductivity

No.

Condition

Strength

In Air Dry Condition

Grade I

Grade 2

Kg/m2

N/mm2

N/mm3

W/m.k

451 to 550

2-0

1-5

0-21

ii

551 to 650

4-0

3-0

0-24

iii

651 to 750

5-0

4-0

0-30

iv

751 to 850

6-0

5-0

0-37

851 to 1000

7-0

6-0

0-42

Workability

Energy Saving

Thermal Insulation

Less Weight

Fire Resistance

Cost Saving

Easy to Install

High Strength

Water Barrier

Earthquake Resistant

Faster Construction

Versatile

Long Lasting

Future Product

Eco- Friendly

Light in
Weight

Ventilation
Very airy thus
allowing more
diffusion of
water, reducing
humidity of the
building

One fifth weight

of concrete and
are
produced in easily
handled sizes.

Thermal
Insulation

Fire Resistance
Extremely high fire
rating of at least 4
hours and more

Material
Saving
AAC blocks are
bigger in size
then conventional
bricks, resulting in
lesser number of
joints. So, result
in Saving of
mortar

Long life
products are not
affected by harsh
climatic conditions
and will not
degrade under
normal
atmospheric
conditions

Very Low Thermal

Conductivity &
therefore very high
thermal energy
efficiency is
achieved

Uniform
Block can be
produced in large
variety of size, from
standard blocks to
large reinforced
panels.

Eco friendly

Energy saving

Reduce at least 30%

of environmental
waste, decrease over
50% of greenhouse
radiation and over
60% integrated
energy on the
surface of the bricks.

Pleasant interior
environment is
achieved. In most
cases the need for
supplementary
insulation can be
avoided.

Accuracy

Workability

panels and blocks are

always produced to
size as they leave the
factory. This results in
less on-site trimming
and reduced quantities
of mortar and finishing
materials use

Excellent size/ weight

ratio, constructing with
AAC is very rapid. It
can be cut, sawn,
drilled, nailed & mailed
like wood, making it an
extremely workable
product

Fly-Ash:
This Raw material is freely available in Thermal Power plants. There are no taxes on this
item whatsoever. Transportation charges are only to be attended by the entrepreneur.

Lime:
Active powered lime is a requirement for giving the real aeration to the product. In phase
1 we can aim to buy the active lime directly. In phase -2 we can think of having backward
integration and making a lime powering unit at site to have a more competitive
advantage,
Different qualities of lime are available, and depending on the raw materials, the
mix design can be chosen to get the optimal quality of production.

Cement:
This Project aims to utilize OPC cement as main binder material. It will give faster
strength to the bricks, besides giving improved consistent quality. It also ensures a better
cost effectiveness for the same. Using OPC will be a standardized practice. The other
prime advantages of using OPC (compared to other binders) is its easy availability
locally through nationwide Retail Network of Cement Companies.

Gypsum:
This too is an industrial waste. This is available as an industrial by product of Fertilizer
Plant. Gypsum is responsible to give long term strength to the Blocks.

Aluminium Power.
Finely ground Aluminium power is used in very limited quantity ( less than 0.5%), so that
it reacts with active lime, and silica in base material to make the aeration, and swell the
product, making it very light weight product.

Chemical:
This is solely supplied by M/s Gubbi enterprises.

TECHNICAL COMPARISON
Particulars

AAC Blocks

Conventional Red Bricks

2

30 -40 kg/ cm2

Strength

35-40 kg/ cm

Shape & Size

Uniform & Regular

Non Uniform & Irregular

Plaster Thickness

10 12 mm

15 20 mm

Density

550- 650 kg/ cm3

1500 1700 Kg/ cm3

Water Absorption

15 20%

40 45%

Mortar Consumption

Less

High

Mortar Joint Thickness

8 10 mm

15 18 mm

Breakage/ Wastage

Nil 0.5%

8 - 10%

Comparison Between AAC Block & Bricks

Parameter

AAC Block

Clay Brick

Size

600 x 200 x 100-300mm

230 x 115 x 75mm

Variation in dimensions

+/-1mm

+/-5mm

Compressive Strength

30 -40 kg/cm2

25 -30 kg/cm2

Dry Density

550-700 kg/m3

1950 kg/m3

Wet Density

800 850kg /m3 (Approx)

2400 kg / m3

Fire Resistance

4-6 hour depending on

thickness

2 hours

Sound Reduction Index

(dB)
Energy Saving

45 for 200mm thick wall

50 for 230mm thick wall

32 % (App.) Air-Condition

No Saving

Load Both Both Heating And

Cooling Will Come Down

Thermal Conductivity

0.16 0.17 (approx)

0.81 approx

Mortar Consumption

0.018 Per M3 With 1:6 / 0.5

0.1 Per M3 With 1:6 / 1.35 Bag

Bag Of Cement

Of Cement

Procedure for
Making AAC / ALC
Block
Fly Ash is mixed with water, and made slurry in a slurry mixture. If sand is used
as base material, we need a ball mill to grind the sand to fine power.

After that, weigh batcher weighs the slurry in preset quantities and lime, OPC,
Gypsum and aluminum powder mixes thoroughly. The mixture also pours the
mix into the mould carried in the mould cart. The full pouring of the mixture is
just enough to fill around 60% to 70% of the mould.
.
After that, chemical reaction takes place for aeration and the light initial setting
takes place.

Next process is de-moulding process of the big block, in which a sophisticated

overhead hoist takes the mould, de-moulds the block.

Next process is the level wire cutting of the Block, while the block passes on the
cutting trolley through the series of wires. This process follows a vertical wire
cutting where as the block remains stationary, and the cutter cuts the block
vertically.

The final cut blocks are Steam cured for 10 hours at 12 KG/Sq cm pressure,
and 100D C. Hence, the product is ready to go into the market for commercial
purpose.

Process Chart/ Flow Chart

Raw Material
Fly Ash

Gypsum

Lime

Slurry,
Water,
Fly ash

Pouring Mixture to mix

ingredients

Bricks casting on mould

De- moulding and wire cutting

Steam curing for 10 Hours

Blocks Ready for sale

Cement

EQUIPMENT

Blender

Cutting Machine
Silo

De- Moulder

Slurry Tank

Steam Curing Machine

AAC Mould

Application

AAC / ALC Block

AAC / ALC BLOCKWALL

Housing make by AAC /

ALC BLOCK

GUBBI ENTERPRISES
18/26, Dev Prayag CHS Ltd,
Bhakti Mandir Road, Nr. Hari Niwas Circle,
Thane (W)-400 605
__________________________________
Tel No: 022- 25387711/ 25383839
Mob No. 9322451475/ 9819901129
Email: clcplant@gmail.com
___________________________________
Web: www.clcplant.com