AAC Blocks
Largest Manufacturer Of AAC Blocks In India.
Why CONECC AAC Blocks?
Conecc is a prime manufacturer of AAC Blocks in Karnataka. Autoclaved Aerated Concrete (AAC) blocks are perfect for foundations, inner leaves of cavity walls, dwelling partitioning walls, plus internal, external, and firewalls in both load-bearing and non-load-bearing designs. Fly-Ash building blocks are proven as being highly efficient for both house construction and commercial and industrial buildings as well.
In addition to their versatility and energy efficiency properties, Lightweight blocks are characterized by their ease of working and construction. we can easily be sawn even with a hand saw to meet the required AAC block size. This results in higher construction speed which may deliver cost savings. Notable savings can also be made in faster weatherproofing, lower scaffolding costs, and less on-site waste. In addition, when using the thin-bed joint application, you use up to 5 times less mortar. AAC block’s weight is 33% lighter compared to traditional bricks and depending on the project design, savings of up to 20% in structural costs can be achieved, due to the reduction of dead load.
High Quality
With our precision manufacturing, stringent quality control, and the use of top-notch raw materials, ensuring consistent durability and performance in diverse construction applications.
4 Different Sizes
600mm x 200mm x 100mm
600mm x 200mm x 150mm
600mm x 200mm x 200mm
600mm x 200mm x 225mm
Ribbed Face
CONECC Block comes with a unique ribbed finish on the face. It helps in better bonding of plaster with the blocks. Due to the ribbed face only, you can directly apply wall putty or Plaster of Paris without plastering.
Size Comparison :- AAC Blocks vs Concrete Blocks vs Hollow Bricks vs Red Bricks
“From traditional Red bricks to innovative Conecc AAC Blocks, construction has evolved to meet the demands of modern architecture.”
Benefits Of Our AAC Blocks
Strong and Durable
CONECC AAC blocks surpass normal bricks in strength with a compressive strength of 3.5-4 MPa, a lower density for enhanced structural integrity, and advanced manufacturing processes ensuring durability under extreme conditions
4 times Lighter
CONECC AAC blocks are lighter than normal bricks due to their lower density and unique cellular structure, making them a more efficient and lightweight building material.
Fire Resistant
CONECC AAC blocks are fire-resistant because they are made from inorganic materials and undergo a high-temperature curing process during manufacturing, resulting in a composition that does not combust or contribute to a fire.
Ribbed Face
CONECC Block comes with a unique ribbed finish on the face. It helps in better bonding of plaster with the blocks. Due to the ribbed face only, you can directly apply wall putty or Plaster of Paris without plastering.
Eco-Friendly
Composed of 60% of Fly Ash, aerated concrete blocks have been certified to be one of the most ecological building materials.
Pest Resistant
Since CONECC AAC Block does not contain organic material, they will be protected from pests and long-lasting in normal atmospheric conditions.
Moisture & Damp Resistant
CONECC AAC blocks have a closed-cell structure, which means they contain tiny, closely packed air bubbles. These cells act as a barrier against the penetration of moisture.
Higher Earthquake Resistance
CONECC AAC blocks have higher earthquake resistance owing to their lightweight composition, uniform structure, excellent strength, ductility, interlocking design, and reduced dead load, collectively enhancing their ability to withstand seismic forces.
Sound Proof
CONECC AAC Block has perfect soundproofing properties due to its aerated structure preventing sound waves from crossing.
CONECC AAC BLOCKS VS RED BRICKS
| No | Parameter | CONECC AAC Blocks | Clay Bricks |
|---|---|---|---|
| 1 | Size | 600 x 200 x 100 - 225mm | 230 x 75 x 150 mm |
| 2 | Precision in Size | Variation 1.5 mm (+/-) | Variation 5 mm (+/-) |
| 3 | Compressive Strength | 3-5 MPa | 1 .5-2 MPa |
| 4 | Mortar Consumption per cum with 1 :6 | 0.5 bag of cement | 1 .35 bags of cement |
| 5 | Chemical Composition | Fly-ash is used approx. 60% which reacts with binders (lime & cement) to form AAC which is an inert material. | Soil is used which contains many inorganic impurities like sulfates etc which results in fungus and pest growth. |
| 6 | Contribution to Carpet Area | 3-5% | None |
| 7 | Finishing | Can be directly incised, rasped to round edge, cut for arches, tapered to create profiles, sculptured, etc | Not Possible |
| 8 | C02 Emission | One sq ft of carpet area will emit 2.2 kg of C02 | One sq ft of carpet area will emit 1 7.6 kg of C02 |
| 9 | Dry Density | 550-650 kg/m3 (Oven Dry) | 1900 kg/m3 |
| 10 | Fire Resistance | Upto 7 hours | Around 2 hours |
| 11 | Cost Benefit Factor | Depending upon project design, savings up to 20% in structural cost due to reduction of dead load. | None |
| 12 | Energy Saving | Upto 30% of air-conditioning load, both heating and cooling load will come down. | None |
| Cost Component | Saving In Component | Estimated Impact On Project Cost | Explanation |
|---|---|---|---|
| Mortar Material | 60% | 1% | Conecc AAC Blocks are 9 times the size of conventional bricks, resulting in 1/3rd the number of joints. Thus an overall mortar savings of up to 65%. |
| Plastering Material | 35% | 2% | Exceptional dimensional accuracy & and smooth surfaces eliminate the need of three-coat plaster walls and allows for a final 6mm skin coat (putty/gypsum plaster). |
| Breakages | 65% | 1% | Breakage in Conecc AAC Blocks are less than 3% as compared to 15% in bricks. |
| Structural Material (Steel & Concrete) | 15% | 6% | Being light weight, Conecc AAC Blocks reduce dead weight of the building. This translates to design of lighter structures leading to reduction in steel and concrete by up to 20%. |
| Increase in Floor Space Area | 2% | 4% | Due to exceptional thermal insulation and weather barrier properties, it is possible to use thinner blocks, which results in increase of carpet area. |
| Savings in Capex (for HVAC Systems) | 30% | 0.30% | Conecc Blocks have excellent insulation properties, which results in saving of capex of HVAC systems. |
| Savings in Power Consumption | 12% | 0.20% | Conecc AAC Block has strong thermal insulation properties that keep the heat during winter and prevent hot air from getting in during summer resulting in high savings on heating and cooling. |
Frequently Asked Questions
What Are AAC Blocks?
AAC (Autoclaved Aerated Concrete) blocks are special bricks made by mixing materials like cement, lime, fly ash, and water in the right amounts. This mix is then poured into molds and treated with high-pressure steam. The result is lightweight, strong bricks that are good at keeping your home insulated and are friendly to the environment. They’re great for construction because they’re easy to work with and contribute to making buildings energy-efficient and sustainable.
Why CONECC AAC Blocks?
CONECC AAC Blocks stand out for several reasons:
1. Quality Assurance: CONECC prioritizes quality, ensuring that its AAC blocks undergo rigorous testing and adhere to industry standards.
2. Innovation: CONECC employs advanced manufacturing processes and technology, staying at the forefront of innovation in the construction materials sector.
3. Lightweight Construction: CONECC AAC Blocks are lightweight, making them easy to handle and reducing the overall load on structures.
4. Energy Efficiency: These blocks offer excellent thermal insulation, contributing to energy-efficient buildings and reducing heating and cooling costs.
5. Strength and Durability: CONECC AAC Blocks undergo a special curing process, enhancing their strength and durability, ensuring long-lasting and resilient structures.
6. Environmental Friendliness: CONECC is committed to eco-friendly practices, and AAC blocks contribute to sustainability by using recycled materials and being energy-efficient.
7. Versatility: CONECC AAC Blocks find applications in various construction projects, offering versatility and adaptability to different building needs.
8. In-House Expertise: With over 15 years of experience, CONECC relies on the expertise of professionals in the field of AAC technology to deliver high-quality products.
Choosing CONECC AAC Blocks means opting for a reliable, innovative, and environmentally conscious solution for your construction needs.
Uses Of AAC Blocks?
AAC (Autoclaved Aerated Concrete) blocks find applications across various construction projects due to their versatile and beneficial properties. Here are some common uses of AAC blocks:
Residential Construction: AAC blocks are widely used in residential buildings for walls, floors, and roofs. Their lightweight nature facilitates easier construction, and their thermal insulation properties contribute to energy-efficient homes.
Commercial Buildings: AAC blocks are suitable for constructing commercial structures such as offices, malls, and hotels. Their versatility allows for the creation of durable and well-insulated spaces.
Industrial Buildings: The strength and durability of AAC blocks make them suitable for industrial structures where robust construction is essential.
Partition Walls: AAC blocks are often used for internal partition walls in both residential and commercial buildings. Their lightweight nature simplifies the construction process.
Exterior Walls: AAC blocks serve as excellent materials for exterior walls, providing insulation and contributing to the overall energy – efficiency of a building.
Load-Bearing Walls: Due to their strength, AAC blocks are often used in load-bearing wall systems, providing structural support to buildings.
Firewalls: The fire-resistant properties of AAC blocks make them suitable for constructing firewalls, enhancing the safety of buildings.
Soundproofing: AAC blocks have good acoustic insulation properties, making them ideal for soundproofing walls in buildings like recording studios or residential units.
Foundation Walls: AAC blocks can be used in foundation walls, contributing to the stability and durability of the building’s foundation.
Greenhouses: The thermal insulation properties of AAC blocks make them suitable for constructing greenhouses, providing a controlled environment for plant growth.
Retaining Walls: AAC blocks are used in the construction of retaining walls due to their strength and ability to withstand lateral pressure.
These diverse applications showcase the versatility, durability, and energy efficiency of AAC blocks, making them a popular choice in modern construction.
History Of AAC Blocks?
Aerated Concrete (AAC), also known as Autoclaved Cellular Concrete (ACC), and Autoclaved Lightweight Concrete (ALC), is a lightweight, precast, foam concrete building material invented in the mid-1920s that provides structure, insulation, fire and mould resistance, and a variety of other benefits. It is also an environmentally friendly product, as it is made with 65-70% sand/fly ash (by weight). AAC Blocks have gained massive popularity in Northern, Western, and Southern India due to their many desirable attributes, with nearly 80% of constructions using AAC Blocks as a replacement for traditional fried clay bricks. It has been gaining popularity in the North Eastern region since 2012, with the goal of completely replacing the use of traditional fried clay bricks.
Dr. Johan Axel Eriksson, a Swedish architect, and inventor perfected AAC in the mid-1920s while working with Professor Henrik Kreuger at the Royal Institute of Technology. The method was patented in 1924. Production began in the Swedish town of Yxhult in 1929. “Yxhultbolaget” later became the world’s first registered building materials brand: Ytong. The second major international cellular concrete Hebel brand can be traced back to Memmingen-based company founder and technician Josef Hebel. The first Hebel plant in Germany opened in 1943.
Ytong autoclaved aerated concrete was originally produced in Sweden with alum shale, whose combustible carbon content made it advantageous to use in the manufacturing process. Unfortunately, the slate deposits used for Ytong in Sweden contain very little natural uranium, causing the material to emit radioactive radon gas into the building. After 1975, Ytong produced a new type of aerated concrete blocks that did not contain alum slate by using new recipes containing only quartz sand/fly ash, calcined gypsum, lime (mineral), cement, water, and aluminium powder, and thus the problem of radon exposure from this raw material was eliminated. Since those days, the production of this white autoclaved aerated concrete has been cutting-edge, and similar recipes are used by all producers around the world.
Why AAC Blocks Are Ecofriendly?
- Autoclaved aerated concrete has a low environmental impact throughout every phase of its life cycle, from the processing of raw materials to the disposal of aerated concrete waste, thanks to its great resource efficiency.
- Aerated concrete block production uses five times less raw resources per meter cube of finished product than other building material production because of ongoing efficiency advancements. No raw materials are lost during production, and all production waste is recycled back into the production process.
- Aerated concrete production uses less energy than all other masonry products, resulting in a decrease in the consumption of fossil fuels and related carbon dioxide (CO2) emissions. Because steam curing occurs at relatively low temperatures and the hot steam produced in autoclaves is reused for successive batches, the curing process also uses less energy.
CONECC
CONECC AAC BLOCKS
Raw Material Preparation:
The first step in the manufacturing process of AAC blocks is the preparation of the raw materials. The materials used in the process are cement, lime, fly ash, gypsum, water, and a small amount of aluminium powder. The raw materials are mixed in the right proportions using a mixing machine.
Mixing:
Our fullly automated batching plant enables accurate dosing, weighing and mixing of all the raw materials. The next step is mixing the prepared raw materials. The mixture is placed in a large vessel and mixed thoroughly until it forms a homogeneous mixture.
Aeration:
Once the mixture is prepared, it is poured into moulds and allowed to be set for a few hours. During this time, the aluminium powder reacts with the other materials in the mixture, producing hydrogen gas. This process is called aeration and results in tiny air pockets throughout the material, making it lightweight and porous.
Curing:
After the blocks are poured into moulds, they are left to cure for a few hours. Once the blocks have hardened, they are removed from the moulds and cut with wires into blocks with precision accuracy. Then the blocks are placed into an Autoclave.
Autoclaving:
The blocks are then subjected to steam and heat in an autoclave. The autoclave is a high-pressure chamber that exposes the blocks to high temperatures (approx 180-190 °C) and steam, which helps to further harden and strengthen them. The autoclaving process takes several hours and is critical in ensuring that the blocks are durable and resistant to damage.
Sorting And Packaging
Once the blocks are removed from the autoclave, they are ready for use in construction. Each block is sorted for any damages and breaks and then packed perfectly for delivery. They can be easily cut, drilled, and shaped using standard tools, making them versatile and easy to work with.