Around the worlds with the increased population and demand, the construction industry has evolved over the years. First, we used to build our houses with mud bricks; later, red clay bricks were introduced. But as we know, burnt clay bricks require a large amount of energy, release smoke, and are manufactured using top-quality fertile soil. There is a need to find an alternative use for more eco-friendly construction materials. Due to increased demand for building materials, a new building material has been introduced: Autoclaved Aerated Concrete (AAC) blocks.
Autoclaved Aerated Concrete (AAC) blocks are low-maintenance building materials with excellent thermal insulation and durability. The heat-insulating properties of Brixo AAC blocks keep the building cooler and prevent external heat from entering, resulting in significant savings on air-conditioning costs. Brixo make AAC blocks, which also reduce foundation load, structural steel consumption, and mortar consumption. A brief introduction to the AAC Blocks manufacturing process.
The production of AAC blocks is a meticulous process that combines science and technology to achieve the desired properties. The key stages in manufacturing include
Mixing of raw materials: Fly ash or sand, cement, lime, and aluminium powder are mixed in precise proportions to form a homogeneous mixture. This mixture is then poured into moulds. The lightweight, insulating properties of the AAC block arise from its expansion and the size of the bubbles, which are typically 2-5 mm. After the rising process, the cake is left to settle and pre-cure for 60-240 minutes.
Autoclaving Steam Curing: An autoclave is a 30- to 40-metre-long steel tube with a 3-metre diameter. It is fed with high-pressure steam for 12 hours, typically at 800-1200 kPa and 180°C. Once the moulds are filled, the curing process begins. This involves exposing the mixture to high-pressure steam, triggering a chemical reaction known as hydration. The reaction causes the lime to react with aluminium powder, releasing hydrogen gas and forming the characteristic air bubbles.
Cutting and shaping: After curing, the soft blocks are cut into specific dimensions. The cutting process is crucial, as it determines the final size and shape of the AAC blocks.
The Advantages of Blocks Are Below
- Easy & Faster Workability
Brixo AAC blocks weigh about half as much as traditional bricks and are ten times their size. This combination allows for simple installation and easy cutting and shaping. Brixo AAC blocks have fewer joints and consistent dimensions, making them easier to lay and speeding up construction. Finally, lightweight blocks are easy to transport, reducing overall logistics and shipping costs compared with those for traditional bricks
- Disaster Resistant
Self-weight and gravity are the two primary vertical forces a building is designed to withstand. Earthquakes, for example, generate horizontal forces. As a result of the manufacturing process, Brixo AAC blocks become extremely strong, producing a durable finished structure. Compared with conventional bricks, Brixo AAC bricks can withstand higher seismic loads.
- Thermal Insulation and Energy Conservation
By foaming the concrete with hydrogen, the material provides excellent thermal insulation, keeping temperatures warm in winter and cool in summer. Thus, it can reduce your air-conditioning costs by about 25%. Due to their energy-efficient production, Brixo AAC blocks remain energy-efficient throughout their lifetimes.
- Soundproof
Because Brixo AAC blocks are lightweight and porous, they significantly reduce sound. For these reasons, AAC blocks are widely used in the construction of studios, hospitals, hotels, etc.
- Sustainable And Pocket-Friendly
Brixo AAC blocks are produced with minimal waste from natural, non-toxic raw materials. Some waste or offcuts can be recycled or used to make aggregates. Their use of non-biodegradable materials makes the building more durable and stable, preventing rot and mould. Furthermore, because Brixo AAC blocks are lightweight, energy-efficient, and simple to install, they reduce labour costs.
- Fire Resistance
Compared with other building materials, Brixo AAC blocks are non-combustible, provide fire resistance of up to 6 hours (depending on thickness), and can withstand temperatures up to 1,200 degrees Celsius. Therefore, they also have significant fire safety implications.
- Moisture Proof
Moisture can cause significant structural damage. The macro-pores within Brixo AAC blocks ensure low water absorption. As a result, they offer better moisture protection.
AAC Blocks have become a game-changer in the construction industry. Their lightweight, energy-efficient, and eco-friendly properties make them an excellent choice for modern construction projects. Whether you’re building a small house or a large commercial structure, Brixo AAC blocks provide the perfect blend of durability, affordability, and sustainability. Embrace AAC blocks for a better, greener future!
