Aerated Concrete is a composite material made up of 60-70% air. It's widely used in construction and building industry as light weight product, compared to normal concrete. In autoclave process, hydrated lime stones are mixed with silica sand and heated at elevated temperature around 100 °C to 120 °C to form blocks. The material is extremely tough due to small pores present between aggregates and very high strength due to large content of lime stone powder.
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Further it has good insulation property which makes it suitable for thermal and acoustic applications. Further, it has superior fire resistance quality owing to its massive structure. Also if required rubber can be added in cement mix during autoclaving process giving extra abrasion resistance property making it suitable for flooring application in heavy traffic area like commercial premises or hospital operation theatres where wet floorings pose major health risk.
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Advantages of AAC block over other types
AAC is an autoclaved aerated concrete that can be manufactured with very high early strength. A variety of mixes and applications are possible and AAC systems can provide solutions to challenges in areas such as foundations, bridge decks, precast and tilt-up walls, light towers, elevated water tanks and precast building components. It offers a competitive alternative to heavy materials like steel and reinforced concrete.
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The material is ideal for applications where weight reduction is desirable or necessary, since it offers nearly 40% more structural efficiency than conventional aggregate concrete. The finished product possesses superior performance in tensile strengths, modulus of rupture and flexural strength compared to ordinary portland cement concrete. In addition, its excellent formability allows for numerous design options not available when using traditional methods.
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Manufacturing Process of AAC Blocks from Silica Sand & Lime Stone Powder
The process begins with mixing raw materials in appropriate proportions. The cement, lime stone powder, natural silica sand etc. are mixed in a batching unit. Then it is conveyed to an Air preheater, where air is added to raise its temperature to required point. It goes through mechanical shaker for 10-15 minutes to eliminate any chances of lumps formation during setting period. And then it’s passed through Kiln Dryer (8-10 hours) and cooled at room temperature or ambient temp. This AAC block manufacturing process can be applied to make lightweight blocks or heavy blocks depending on type material used.
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Market Demand
AAC blocks are a type of building material that can be used for a variety of purposes. Apartments, terrace houses, hospitals, schools, and commercial structures are all built with it. They can be used to build highways, bridges, and runways, to name a few. These blocks are in high demand, especially in emerging countries like India, where the population is rapidly growing and resources to meet the country's construction needs are in low supply.
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As a result, to avoid harming the environment while meeting these objectives, businesses must utilise cost-effective and ecologically acceptable building materials. Local resources have a lower environmental impact because they are numerous and require less transportation to gather. This reduces the overall cost of constructing with these components. As a result, natural lightweight aggregates such as silica sand and limestone powder are important in a variety of industries, including civil engineering, because they address issues such as global warming and raw material scarcity.
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Autoclaved aerated concrete (AAC) blocks are made using the above-mentioned basic ingredients, as well as some extra inert elements, to meet demand. From 2020 to 2027, the market for autoclaved aerated concrete (AAC) is predicted to increase at a CAGR of 7.2 percent, reaching $26,964.5 million. Increased urbanisation and industrialization, infrastructure expansion, the growing demand for lightweight construction materials, rising preferences for low-cost housing, and a growing emphasis on green and soundproof structures are all propelling the AAC sector forward.
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Key Players:
· Ashoka Pre-Con Pvt. Ltd.
· Baliapatam Tiles & Business Ventures Ltd.
· Biltech Building Elements Ltd.
· Gannon Dunkerley & Co. Ltd.
· H I L Ltd.
· J K Lakshmi Cement Ltd.
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