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AAC Manufacturing Process

Unlike most of the other concrete applications, AAC is produced using no aggregate larger than sand. Quartz sand, calcined gypsum, lime (mineral), cement and water are used as a binding agent. Aluminum powder is used at a rate of 0.05%–0.08% by volume (depending on the pre-specified density). In some countries, like India and China, fly ash is generated from thermal power plants with the use of 50-65% silica content on an aggregate.

When AAC is mixed and cast in forms, several chemical reactions take place that give AAC its light weight (20% of the weight of concrete) and thermal properties. Aluminum powder reacts with calcium hydroxide and water to form hydrogen. The hydrogen gas foams and doubles the volume of the raw mix creating gas bubbles up to 3mm in diameter. At the end of the foaming process, the hydrogen escapes into the atmosphere and is replaced by air.

When the foams are removed from the material- it is solid but still soft. It is then cut into either blocks or panels and placed in an autoclave chamber for 12 hours. During this steam pressure hardening process, when the temperature reaches 190° Celsius (374° Fahrenheit) and the pressure reaches 8 to 12 bars, quartz sand reacts with calcium hydroxide to form calcium silica hydrate, which gives AAC its strength along with other unique properties. Because of the relatively low temperature used, ACC blocks are not considered fired brick, but a lightweight concrete masonry unit. After the autoclaving process, the material is ready for immediate use on the construction site. Depending on its density, up to 80% of the volume of an AAC block is air. AAC's low density also accounts for its low structural compression strength. It can carry loads of up to 8 MPa (1,160 PSI), approximately 50% of the compressive strength of regular concrete.

AAC blocks are :

1. Light Weight/Cellular Properties
2. Termite/Pest /Water Resistant
3. Acoustic Performance
4. Earthquake Resistance
5. Eco Friendly
6. Fire Resistance
7. Precision
8. Faster Construction
9. Easy Workability and Design Flexibility
10. Thermal Insulation and Energy Efficient

Natural Hazard : Earth quake resistance

Tiny cells in Richa AAC blocks form major force and prevent progressive collapse.

Lightweight blocks reduce mass of a structure, thus decreasing the impact of an earthquake on a building.

Non-combustible nature provides an advantage against fires, which commonly accompanies earthquakes.

Resist damage by Termites and other Pests

AAC blocks are made up of non-allergic materials which prevent damage by termites and other pests.

Wall painting and plastering lasts longer as almost nil efflorescence affects.

Retain properties for long time

Provide superior resistance to air and moisture penetration.

Blocks have much lower water retention or capillary action.

Its silicon based activates enhance water barrier properties

Acoustically Absorbent

AAC blocks consist of millions of micro non-interconnected air cells, giving low air porosity. This gives a high resistance to the passage of air- borne sound relative to density.

Thus AAC blocks provide excellent sound absorption with an STC (Sound Transmission Class) rating of 44. Because of its tiny air cell structure, it provides superior sound insulation, hence these blocks are preferred in construction of flat systems, hotels, IT offices, recording studios, multiplexes, etc.

Superior sound absorption qualities due to porous structure of blocks increase work efficiency.

Sound Transmission Class (STC) rating of 44- Results in virtually sound proof interiors.

Thermal Insulation and Energy Efficient

Richa AAC Blocks have the highest thermal ratings in the industry and approximately 1/3rd density that of Conventional Building Blocks.

Tiny air pores and thermal mass of blocks provide excellent thermal insulation.

Thermal conductivity of AAC is 0.16W/(K-M)

Low specific conductivity makes heating and cooling very efficient.

Reduction in electrical load helps to reduce cost in terms of DG set, electrical transformer, panels.load connection, running bill of electricity etc.

Generates regular saving of energy and global warming.

Fewer joints make better thermal and sound insulation

Fire Resistant

Richa blocks are totally inorganic and incombustible . The product is especially suited for fire-rated applications. The fire resistance of Richa blocks has proven its outstanding fire ratings.Richa AAC Blocks are fire resistant up to 1600°C (more than twice the typical temperature in a building fire of 650°C)allows it to maintain its structural integrity even after fire.

–Can withstand up to 6 hours of direct exposure.

–Non-combustible

–Well suited for fire walls and fire protection of structural steel.

Savings due to Light Weight

Richa -AAC Blocks has an average compressive strength of (28-35)kg/cm2 which is superior to most types of light weight blocks, 25% more stronger than other products of same density.

Richa AAC blocks are ideal for the entire building structure and possess high structural integrity. The Product’s light weight and easy work ability means that it is very quick to install on site.

– Very light weight (550- 600 kg/m3) makes them 3-4 times lighter than traditional bricks.
– Usage reduces overall dead load of a building, thereby direct reduction of cost in terms of steel up to 15% and concrete upto 7%.
– Less breakage-less wastage in comparison to other similar products.
– Save construction time and total materials required for the construction of the entire building.

Product specifications - AAC Blocks : In different shapes and sizes

L, M-F and U shape

AAC blocks are highly versatile and come in different shapes and sizes.

The basic M-F block is also known as Male and Female block are designed in such away that they lock easily.

The L block creates the ability to reinforce the walls with rods tying them to the horizontal structure of the ceiling.

U shaped AAC blocks allow a horizontal reinforcement of the wall.

Eco Friendly Richa AAC – Blocks

Formed out of the reaction of Aluminium on a proportionate blend of Lime, Cement and Fly ash. The hydrogen gas that escapes creates millions of tiny air cells, giving it a strong honeycomb like structure.

Richa uses the process of automation and steam-curing applications to give strength to Richa AAC blocks

Advantage : Richa AAC blocks

100% Green Building certified by Leadership in Energy and Environment Design (LEED)

Make productive use of fly ash. (Pollutant waste of power plant)

Non-polluting manufacturing process – the only by-product is steam.

Made of non-toxic ingredients.

Does not exude gases.

Carbon credits can be earned on AAC