Advantages of aerated concrete (AAC) wall panels in construction

(1) Reduce wet work on the construction site, improve construction efficiency and shorten the construction period by about 1/2:

The use of blocks must increase the structural columns and anti-seismic waist beam, the single wall construction needs more than three days to complete. And the block wall needs to be plastered on both sides to meet the flatness requirements. The wall plastering is completed, and it needs more than 30 days to dry. Only after drying can the construction of the coating and painting process be carried out. Aerated concrete lightweight wallboard for field measurement, size processing and production, the construction of a single wall can be completed in one day at most, the wallboard for dry construction, there is no wet field operation. After the completion of the installation of the wall roughness error is not more than 3mm, the wall without plastering, the completion of the construction can enter the wall coating paint construction process.

AAC panel

(2) Save the project cost, the maximum savings of about $10 /㎡ :

① Compared with 200mm thick aerated concrete block wall, the lightweight wall plate eliminates the constructional column and waist beam in the block wall and reduces the consumption of steel and concrete; Metope need not hang net plastering, blow putty directly. Compared with the block partition wall, the project cost can be reduced by 15.00-25.00 yuan /㎡.

②Compared with the aerated concrete block wall, the slab does not need to set constructional column and concrete waist beam, and the vertical dry bulk density of light wall slab is no more than 650kg (conservative design value is 850 kg/m3); There are masonry mortar, concrete waist beam, constructional column and plastering mortar on both sides of the aerated concrete block wall (concrete bulk density is 2400 kg/m3, cement mortar bulk density is 2000 kg/m3). Under normal conditions, the comprehensive cubic bulk density is about 1300-1400kg. The lightweight wallboard is used to effectively reduce the bearing load of the structure; Design phase according to the plate bulk density calculation and structural load, can save the steel content of about 4-6kg/㎡;

AAC panel

(3) To meet the requirements of various technical indicators and increase the indoor area:

① 150mm thick aerated concrete lightweight wallboard meets the heat preservation, heat insulation and sound insulation indexes of 200mm thick aerated concrete block; Compared with the use of aerated concrete block wall, the thickness can be reduced by more than 50mm, reducing the space occupied by the wall and increasing the indoor usable area;

②The crack resistance performance of the wall board is more obvious than that of the block wall, because there are two layers of two-way steel mesh inside to strengthen and restrict its expansion and contraction, and the contact parts of the whole wall and beam column are filled with special binder, and few cracks appear; With the passage of time, the settlement of the wall will produce more cracks in the wall and wall side, and it is difficult to deal with the cracks once they occur.

AAC panel

③high seismic performance, after the relevant seismic load failure test, the plate in the engineering structure can resist 8.0 earthquake to the wall does not fall, even if the fracture, due to the connection of the steel mesh in the plate, but also to break and do not collapse;

④Compared with sandwich color steel composite plate, the fire performance advantage is more obvious in steel structure engineering. The plate is made of inorganic materials, which is non-combustible in case of fire. The fire resistance limit of 100mm thick can reach more than 3.5 hours.

What’s the difference in the quality of construction between red bricks and AAC blocks?

AAC block is made up of fly ash, gypsum, cement, lime, and water. This is 8 times bigger than normal brick and lighter than red clay brick. Low energy required in production, low raw material consumption and recyclables of AAC block work make it environment-friendly.

METHOD OF MASONRY:

Conventional brick work has many steps – collect materials required for mortar, sand, cement, and water. Transportation of cement and sand to the place of mixing.Screening of sand before mixing in mortar. Pre-wetting of bricks before use at the site. Mixing of all the material as per the desired specification. Supervision at the time of brickwork. Curing after brickwork is complete.

AAC block has few steps – transportation is easy as the only bag of ready mix mortar is used. No pre-wetting before brickwork and curing after brickwork is required. Add water as per the required consistency. Ready-mix mortar is ready for use.

AAC block

DIFFERENCE:

1. AAC block is eco-friendly whereas conventional red brick is not.

2. On AAC block dead load on the structure is low which reduces the consumption of cement, steel, and water. Whereas using red clay brick there’s a heavy dead load on the structure.

3. AAC blocks emit less heat in the atmosphere due to less use of cement, steel, and concrete whereas on the other hand red clay bricks emits high heat to the atmosphere.

4. AAC blocks have less material wastage whereas conventional red clay bricks have high material wastage.

5. AAC block has high thermal and sound insulating properties whereas red clay bricks have low thermal and low sound insulation.

AAC blocks is a lightweight, load-bearing, high-Insulating, and durable Building Product. APEX manufacturers best quality high strength, excellent finish, cost-effective, etc. APEX, a well-known manufacturer, exporter and supplier of AAC blocks in China aims to deliver the clients with the best possible products to achieve maximum client satisfaction. Ultra-light, eco-friendly and easily transportable on-site areas these AAC blocks come very handy for construction purposes. APEX AAC blocks are the smartest choice for your construction needs.

Autoclaved aerated concrete

Autoclaved aerated concrete, or AAC, is concrete that has been manufactured to contain lots of closed air pockets. Lightweight and fairly energy efficient, it is produced by adding a foaming agent to concrete in a mould, then wire-cutting blocks or panels from the resulting ‘cake’ and ‘cooking’ them with steam (autoclaving).

In Europe AAC has a long history of development, having been in use for more than 70 years. It has a moderate embodied energy content and performs well as thermal and sound insulation, due to the aerated structure of the material and its unique combination of thermal insulation and thermal mass. It is light, does not burn, is an excellent fire barrier, and is able to support quite large loads. It is relatively easy to work with and can be cut and shaped with hand tools including woodworking tools.

AAC block

AAC relatively easy to work with, and can be cut and shaped with hand tools including woodworking tools.

Blocks are made to very exacting dimensions and are usually laid in thin-bed mortar that is applied with a toothed trowel, although more conventional thick-bed mortar can be used. Wall panels are storey height, reinforced and mechanically fixed. AAC can also be used in panel form for floor and roof construction. It has a long life and does not produce toxic gases after it has been put in place.

Performance characteristics of AAC panel

Autoclaved lightweight aerated concrete panel: AAC panel is a high-performance autoclaved lightweight aerated concrete panel produced by introducing and absorbing the advanced technology and application experience of Japan and European countries after 40 years of development. It is based on silica sand, cement, lime and other raw materials, after high-pressure steam curing into the multi-porosity concrete sheet forming; Can not only do wall material, but also do roof board, is a kind of superior performance of new building materials. Its main features are as follows:

1.Bulk density: AAC board bulk density is light, (absolutely dry) Y0= 600-700kg /m3, dry density is 1/3 of red brick, 1/4 of concrete, dry density is lighter than water, known as floating on the surface of the concrete.

2.Strength: Cube compressive strength ≥ 4Mpa, single point hanging force ≥1200N. As a non-load-bearing maintenance structural material, it can fully meet the bending resistance, cracking resistance and joint strength requirements of the plate under various use conditions. It is a kind of lightweight and high strength maintenance structural material.

AAC panel

3.Thermal insulation: the material not only has good thermal insulation performance, thermal conductivity is only 0.11-0.16W/M.K, but also has good thermal insulation performance [thermal storage coefficient S=2.75W(M2.K)]. When a reasonable thickness is used, it can not only be used in cold areas with high insulation requirements, but also in hot summer and warm winter areas or hot summer and cold winter areas with high insulation requirements to meet the requirements of energy saving standards.

4. Sound insulation: the material is a kind of porous material composed of a large number of uniform and disconnected small pores, with good sound insulation performance, the average volume of 100 thick AAC board 40dB, the average volume of 150 thick AAC board 45dB;

5. Fire resistance: AAC plate is a non-combustible inorganic material, with good fire resistance, fire resistance limit as wallboard 100 thick plate >3 hours; 150 thick plate >4 hours; 50 thick plate protection steel beam fire resistance >4 hours; All exceed the first-grade fire resistance standard;

AAC panel

6. Durability: AAC is a kind of inorganic silicate material, not aging, good durability, its service life can match the service life of all kinds of buildings;

7. Freezing resistance: good frost resistance, mass loss <1.5%(national standard <5%) after freeze-thaw test, strength loss <5%(national standard <20%);

8. Impermeability: good impermeability, 5 times better than the standard brick impermeability;

9. Softening coefficient: high softening coefficient, RW/RO =0.88;

10. Green environmental protection material: the material is no radioactivity, no harmful gas escape, is a green environmental protection material;

11. Construction: AAC plate production, standardization, industrialization of installation, sawing, cutting, planing, drilling, construction dry work, fast;

12. Matching: AAC board has a perfect application supporting system, equipped with special connector, pointing agent, repair powder, interface agent, etc.

13. Construction is simple and low cost: the use of this material without plastering, reduce the cost of 20-25 yuan/square meter; Can directly blow putty spray paint;

14. Surface quality is good, no cracking: the use of this material because of the use of dry construction, so there is no empty drum crack phenomenon on the surface;

15.The use of AAC board for internal partition can increase the usable area.

A very different building system- AAC Block

In building with AAC, most blocks are solid and uniform, but some are typically ordered with round cores approximately 3.5 inches in diameter. By aligning these cores at the corners of a building and at window and door openings, continuous vertical channels are created into which steel re-bar is placed and concrete grout is poured. At the top of a wall, specialized U-shaped blocks are used that create a continuous channel or trough into which re-bar is placed and concrete is poured—creating a structural bond beam.

AAC BLOCK

Building with AAC blocks is quite different from building with standard hollow-core concrete blocks. Starting with a level footing, a thin-set mortar is laid down using a specialized toothed trowel that holds a scoop of mortar. The end of the adjoining block is also buttered with the mortar. The block is then set down and tapped into place with a rubber mallet.  It is so different from concrete block installation. It’s much easier to work with AAC 。In addition to standard-dimension blocks, AAC is available in a wide range of precast panels that are produced with steel reinforcement to meet specific needs.

AAC BLOCK

Comparison of prefabricated building construction technology and traditional technology

Prefabricated building construction features

1. Components can be industrialized production in the factory, the construction site can be directly installed, convenient and fast, can shorten the construction period.

2. Components in the factory using mechanization production, product quality is more effective control.

3. The turnover of material input decreased, material rental costs decreased.

4. Reducing the amount of wet work on the construction site is conducive to environmental protection.

5. Material waste can be reduced to a certain extent due to the reduction in the amount of work on the construction site.

6. The component mechanization degree is high, can greatly reduce the site construction personnel.

prefabricated buildings

Process introduction of the whole building assembly stage

1. Installation of external wall panel (sandwich insulation cake);

2. Installation of wall panel connectors and treatment of board joints.

3. Installation of composite beams.

4. Installation of inner wall panel.

5. Column, shear wall steel binding.

6. Elevator shaft template installation.

7. Installation of shear wall and column formwork.

8. Pouring concrete for walls and columns.

prefabricated buildings (2)

Comparison with traditional crafts

Compared with the traditional method: the external frame is cancelled in the construction site, the indoor and external wall plastering process is cancelled, the steel reinforcement is distributed uniformly by the factory, the floor bottom mold is cancelled, the wall plastic template replaces the traditional wood template, and the construction waste on the site can be greatly reduced. In addition, the components are prefabricated in the factory, transported to the construction site and then lifted and placed by large lifting machines. The operator only needs to place the buttress plate and fix it temporarily, which greatly reduces the labor intensity of the operator.

 

Construction Methods of AAC Block

AAC block is generally used in infill walls, and the strength grade of the used blocks is generally A3.5 for partition walls and A5 for external walls. The strength of the mortar is not less than M5.

Before building aerated concrete blocks, a block arrangement diagram should be drawn according to the plan and elevation of the building. Set the skin count bar at the corner of the wall, draw the block skin number and block height on the skin count bar, and draw the alignment line between the upper edge lines of the opposite block, and build according to the alignment line.

The masonry surface of aerated concrete blocks should be watered appropriately. Masonry aerated concrete should use special tools (laying shovel, saw, drill, engraving, straight frame, etc.).

AAC block

The vertical mortar joints of the upper and lower skin blocks of the aerated concrete block wall should be staggered, and the staggered length should be 300mm and not less than 150mm. If it is not possible to meet the requirements, 2Φ6 tie bars or Φ4 steel mesh pieces should be installed in the horizontal mortar joints, and the length of tie bars or steel mesh pieces should not be less than 700mm.

The mortar joints of aerated concrete block walls should be horizontal and vertical, with full mortar. The mortar fullness of horizontal mortar joints should not be less than 90%; the mortar fullness of vertical mortar joints should not be less than 80%. The thickness of the horizontal mortar joint and the width of the vertical mortar joint shall not exceed 15mm.

At the corners of the aerated concrete block wall, the blocks of the vertical and horizontal walls should be laid on each other, and the end faces of the partition blocks should be exposed. At the T-shaped junction of aerated concrete block walls, the cross-wall blocks should be exposed on the sidewalls and sit in the middle of the vertical wall blocks.

Ultra-thin plate decoration (composite granite, marble

If there are no effective measures, the aerated concrete block wall shall not be used in the following parts:

The part below the moisture barrier of the building;

Long-term flooding or chemical erosion of the environment;

Walls that have been in a vibration source environment for a long time;

The surface of the block is often in a high temperature environment above 80℃. No scaffold eyes shall be left on the walls of aerated concrete blocks. The block walls in each floor should be built continuously without any connection and rubbing. If it is necessary to leave the chase, it should be kept as an oblique chase or intermittently on the side of the door and window opening.

Characteristics of autoclaved aerated concrete

Autoclaved aerated concrete combines insulation and structural capability in one material for walls, floors, and roofs. Its light weight/cellular properties make it easy to cut, shave, and shape, accept nails and screws readily, and allow it to be routed to create chases for electrical conduits and smaller-diameter plumbing runs. This gives it design and construction flexibility, and the ability to make easy adjustments in the field.

Durability and dimensional stability. A cement-based material, AAC resists water, rot, mold, mildew, and insects. Units are precisely shaped and conform to tight tolerances.

Characteristics of autoclaved aerated concrete

Fire resistance is excellent, with eight inch thick AAC achieving a four-hour rating (actual performance exceeds that and meets test requirements for up to eight hours). And because it is noncombustible, it will not burn or give off toxic fumes.

The light weight means that R-values for AAC are comparable to conventional frame walls, but they have higher thermal mass, provide air tightness, and as just noted, are not combustible. That light weight also gives a high sound reduction for privacy, both from outside noises and from other rooms when used as interior partition walls.

But the material does have some limitations. It is not as widely available as most concrete products, though it can be shipped anywhere. If it has to be shipped, its light weight is advantageous. Because it is lower strength than most concrete products or systems, in load-bearing applications, it must typically be reinforced. It also requires a protective finish since the material is porous and would deteriorate if left exposed.

Advantages of Autoclaved Aerated Concrete Panel in construction

At present, traditional aerated concrete blocks are generally used in the walls of the frame structure in our country, and a few use gypsum and ash concrete partition panels. Due to the difficult construction of aerated concrete blocks, the long construction period, the difficult construction of concrete components, the quality is not easy to guarantee; The anti-cracking performance of gypsum or ash concrete partition panels is poor, while the construction of autoclaved aerated concrete panel is less difficult and short, which can greatly guarantee the quality. In addition, the sound insulation, thermal insulation and sound absorption effects of autoclaved aerated concrete panels are very good.The lightness is 25% of that of concrete, and the use of autoclaved aerated concrete panels can greatly reduce the weight of the wall itself.The raw materials of autoclaved aerated concrete panels are measured on site, and the manufacturer makes them according to relevant data. The construction is simple and the quality standard after formation is high. In addition, due to the particularity of the materials, the construction saves the process of plastering. As a result, construction costs are greatly saved, and the use of autoclaved aerated concrete panels is the main trend in the development of infill walls in the future.

Autoclaved Aerated Concrete Panel

The AAC project of the bus company’s office building went smoothly

December 6, our company signed an office building and plant construction project with the city bus company. Recently, the panels have been installed in the factory. This project is used for the daily office work of the Municipal Public Transport Group and the coordinated operation of vehicles. The building area is about 6,000 square meters. The interior wall panels and partition walls of the building use autoclaved aerated concrete panels produced by our company. The project is expected to be completed by the end of this month.

AAC project

AAC project

AAC project