Aerobild Autoclaved Aerated Concrete (AAC) blocks are made to be top-of-the-line in all aspects, from one of the biggest and most advanced manufacturing facilities in India. The uncompromising approach, in even the smallest of details, has ensured complete understanding and authority over the manufacturing process. It has put in place the technological edge.
Aerobild symbolises the synergy of all the advancements of the last 90 odd years, since AAC blocks were first made by the Swedish architect and inventor, Dr. Johan Axel Eriksson in the mid-1920s. It was and continues to be one of the greatest developments in the construction industry. AAC, a light-weight green building material, is fire resistant and has good thermal insulation, solid structure and is easy to work with. AAC is a fully integrated building system of panels and blocks that are used extensively for residential, commercial and industrial buildings.
Aerobild AAC is basically obtained from a chemical reaction between finely powdered sand, calcined gypsum, lime, cement, flyash (which has 50-65% silica content) and aluminium powder, in the presence of water. The slurry formed with the addition of water and elaborate mixing is poured into a mould for curing.
The addition of aluminium causes expansion of the mixture through the aeration process. The reaction between aluminium and the rest of the mixture releases hydrogen gas resulting in the formation of microscopic bubbles. When the hydrogen gas evaporates it leaves the bubbles filled with air, which expands the concrete to about five times its original volume, in the mould.
In a few hours the slurry firms up and is ready to be removed from the mould and transported to a cutting machine where it is cut precisely into blocks, panels or lintels of specific size as required. Waste material is recycled back for crushing and remixing.
The cut aerated concrete is further cured in a pressure chamber where they are subjected to high pressure saturated steam for up to 12 hours. The chamber is called an autoclave and the curing process is autoclaving.
Autoclaving hardens the aerated concrete blocks, panels and lintels, rendering them airtight, lightweight, non-toxic and non-organic and loading them with superlative advantages/benefits that make them the smartest building material. After autoclaving the blocks are ready to be packed and delivered.
About 80% of Aerobild AAC is pores. Which straightaway means Aerobild AAC can be manufactured with very less amount of raw material. It can be easily said that about one fourth of raw material is all that is required for manufacture when compared with other construction material. Low consumption of raw material directly contributes to their conservation.
Aerobild AAC uses flyash as one of its chief raw materials, an industrial waste, which is the hallmark of recycling. Further, AAC – both hardened and unhardened, wasted during the manufacturing process can be 100% recycled back into the production of AAC. The consequential lowering of the carbon footprint puts Aerobild right up on the eco-friendly pedestal and thus Opus Industries becomes eligible for carbon credits.
Maximum energy is consumed during the autoclaving in the manufacture of Aerobild AAC blocks followed by integrating various raw materials into making the slurry. Yet the total amount energy consumed for production of Aerobild AAC blocks is nearly 2 or 3 times lower than producing other building material such as burnt bricks.
Aerobild AAC manufacture produces very low quantity of gases such as CO2, CO and NO – which emanate during the generation of steam, as compared to the burning process in brick production. The advanced manufacturing process ensures there is zero harmful effluence, pollutants or toxic waste.
Aerobild AAC provides thermal insulation to the buildings negating the need for supplementary insulation. Also less power is consumed to heat or cool a building built with Aerobild.
Aerobild’s porous nature and breathable quality ensures lower moisture levels and consequently achieves correct relative humidity. Mould-free living is a reality with Aerobild.
The light weight of Aerobild enables loading of higher quantity while transportation and effects maximum capacity utilization – almost 5 times more as compared to normal materials.