Aircrete also has good acoustic properties and it is durable, with good resistance to sulfate attack and to damage by fire and frost.Īutoclaved aerated concrete is cured in an autoclave - a large pressure vessel. Autoclaved aerated concrete is easily cut to any required shape. It is possible to construct virtually an entire house from autoclaved aerated concrete, including walls, floors - using reinforced aircrete beams, ceilings and the roof. They are also used in the outer leaf, when they are usually rendered, and in foundations. They resist deterioration caused by environmental factors, ensuring a longer lifespan for walls and partitions built with this material.Figure 2 Detailed view of cellular pore structure in an aircrete block.Īutoclaved aerated concrete blocks are excellent thermal insulators and are typically used to form the inner leaf of a cavity wall. Durability: AAC blocks exhibit high compressive strength and durability. Additionally, their lightweight nature reduces the carbon footprint associated with transportation. Environmentally friendly: The manufacturing process of AAC blocks involves minimal waste. This is particularly advantageous in urban areas, reducing the impact of external noise and enhancing the overall livability of spaces. Sound insulation: The porous structure of AAC blocks contributes to effective sound insulation. This contributes to energy efficiency and reduces the reliance on artificial heating and cooling systems. Thermal insulation: AAC blocks possess excellent thermal insulation properties which are 30% better than bricks, helping to maintain comfortable indoor temperatures. This characteristic simplifies transportation, reduces construction time, and eases the overall load on the structure. Advantages of AAC blocks Lightweight: one of the standout features of AAC blocks is their lightweight nature. The cutting process is crucial as it determines the final size and shape of the AAC blocks. 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. This involves exposing the mixture to high-pressure steam, triggering a chemical reaction known as hydration. Once the moulds are filled, the curing process begins. It is fed with steam at high pressure for 12 hours, typically reaching 800-1200 KPa and a temperature of 180☌. After the rising process, the cake is left to settle and pre-cure for 60-240 minutes.Curing: An autoclave is a 30 to 40-metre-long steel tube with a 3-metre diameter. The lightweight and insulating properties of the AAC block are due to its expansion and the size of the bubbles, which are typically 2-5mm. The key stages in manufacturing include:Mixing of raw materials: Fly ash, cement, lime, and aluminium powder are mixed in precise proportions to form a homogenous mixture. Manufacturing processThe production of AAC blocks involves a meticulous process that combines science and technology to achieve the desired properties. When mixed with lime and cement, it reacts with the alkaline elements to produce hydrogen gas, leading to the formation of numerous tiny air bubbles within the mixture. It reacts with aluminium powder during the curing process, forming hydrogen gas and creating air pockets that give AAC its lightweight nature.Īluminium powder: The inclusion of finely powdered aluminium is a key factor in the aeration process. It plays a crucial role in holding the other components together, ensuring the structural stability of the blocks.Lime: Lime is added to improve the workability of the mixture and contributes to the overall durability of the blocks. This unique blend undergoes a specialised manufacturing process, resulting in a lightweight yet high compressive strength building material.Cement: Ordinary Portland Cement serves as the binding agent in AAC blocks. The pores produced affect the performance of AAC. The gas forms bubbles under the action of pressure to expand the slurry. The pores of AAC are mainly produced by the chemical reaction of aluminium powder in an alkaline environment. Aluminium powder is a commonly used gassing agent in AAC production. What distinguishes them is the inclusion of aeration agents, typically finely powdered aluminium. Composition of AAC blocksAAC blocks are primarily composed of fly ash, cement, lime, gypsum and aluminium powder. Let's delve into autoclaved aerated concrete, exploring its composition, manufacturing process, and the advantages that make it a preferred choice in contemporary construction. These lightweight and versatile blocks offer a range of benefits, influencing the way walls and partitions are built. Autoclaved Aerated Concrete (AAC) blocks have emerged as a revolutionary building material in the construction industry.
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