International Journal of Research in Engineering, Science and Management 539

Volume-1, Issue-9, September-2018

www.ijresm.com | ISSN (Online): 2581-5782

Comparative Study of AAC Blocks and Clay

Brick and Costing
Utkarsh Jain1, Muskan Jain2, Smriti Mandaokar3
Student, Department of Architecture, SDPS Women’s College, Indore, India
1,3

2
Assistant Professor, Department of Architecture, SDPS Women’s College, Indore, India

Abstract—Brick is the most commonly used building material curing processes. It has lightweight, high strength, good
in construction. AAC blocks are new construction material which durability, heat preservation, sound insulation, fire proofing,
is very light in weight. Compare to same size of (200mm x 100mm impervious, good anchoring properties.
x 100mm,its 3 times lighter than traditional brick (clay brick);it
means it covers more area in same weight as clay brick gives in one Significant research studies have been conducted on the
bricks. In this paper; attempt has been made to replace the clay development of new construction materials using different
brick with light weight AAC blocks. The usage of AAC block kinds of material. However, the application of these
reduces the cost of construction up-to 25%. The use of AAC block construction materials in real construction is limited. Therefore
also reduces the requirement of materials such as cement and sand more research is needed to study the actual behavior or
up-to 55% performance of new construction materials under field
conditions to encourage their practical applications. Many
Index Terms— autoclaved aerated concrete (AAC), light weight,
clay bricks, cost reduction, difference. research studies had been conducted utilizing various new
construction materials. Most of these research works focused
I. INTRODUCTION on the physical and mechanical properties of construction
products. Some of those studies attempted to investigate the
Bricks are one of the most important building materials in the
durability performance of several construction materials
India. In recent years, with expanding urbanization and
including AAC block like material. However, more research
increasing demand for construction materials, brick kilns have
studies are needed to confirm the beneficial effects of new
grown to meet the demand. It has directly or indirectly caused
construction material. In this context, research work has been
a series of environmental and health problems. At a global
started to investigate Cost effectiveness by using AAC Blocks
level, environmental pollution from brick-making operations
for building construction. This paper highlights different
contributes to the phenomena of global warming and climate
aspects of using AAC block masonry construction. Findings of
change. Also, extreme weather may cause degradation of the
comparative statistical analysis of cost effectiveness of using
brick surface due to frost damage. Global warming and
AAC block instead of traditional bricks are presented in this
Environmental pollution is now a global concern. Various types
paper.
of blocks can be used as an alternative to the red bricks, to
reduce Environmental pollution and Global warming. AAC
II. OBJECTIVES
blocks may be one of the solutions for brick replacement.
Similar to foam concrete, Autoclaved Aerated Concrete (AAC)  The objective of study is practical comparison between
is one of the certified green building materials, which can be traditional clay bricks, and AAC blocks under seismic
used for commercial, industrial and residential construction. It loading.
is porous, non-toxic, Perusable, renewable and recyclable.  To study the economical, constructional and structural
AAC was developed in 1924 by a Swedish architect, who difference between the structures using above two
was looking for an alternate building material with properties constructional materials.
similar to that of wood having good thermal insulation, solid  Through this study, we will accomplish the relationship
structure and reaction. It is one kind of new type green warm between the two materials. Also due to two different
preservation wall material formed easy to work with, but materials there would be changes in loading, structure,
without the disadvantage of combustibility, decay and termite construction cost, construction techniques; which would be
damage. As AAC Block uses fly ash, sand as main raw material, observed through this project.
cement, lime as accessory materials, aluminum powder as
forming agent, it refers to foaming through III. MATERIALS AND METHODS
Chemical through raw materials grinding, batching and The materials used for the study are burnt clay bricks and
mixing, pouring and foaming, quiet stop and cutting, autoclave
 International Journal of Research in Engineering, Science and Management 540
Volume-1, Issue-9, September-2018
www.ijresm.com | ISSN (Online): 2581-5782

autoclaved aerated concrete blocks. The burnt clay bricks of V. COST ANALYSIS
size 200 x 100 x 100 mm are collected from locally available The cost analysis is shown in Table-2
processing units of burnt clay bricks. AAC blocks are collected
from the distributors of Aerocon blocks in Cochin. Aerocon is VI. CONCLUSION
India’s leading manufacturer of AAC blocks. These Aerocon
However it is difficult to replace 7millenium old materials
has a long time association with Indian Green Building Council
with new one. Also availability is still a challenge in India.
(IGBC) and consistently work together for the cause of
AAC blocks are easily available in southern and western
sustainable construction. These blocks offer effective and
regions of country. AAC blocks are gaining popularity in
practical solutions for the current building regulations and are
northern region and demand in tier –II cities. Comparative
manufactured using the latest technologies at India’s most
Analysis indicates that in almost all the parameters, the AAC
advanced AAC facilities located in Chennai and Surat . These
blocks have a superior edge over burnt clay bricks. The use of
blocks are manufactured by using fly ash, cement, lime and an
AAC blocks leads to savings in overall project cost; enables to
aeration agent like aluminum powder. An AAC block of face
speed up the construction process reduced environmental and
size 600 x 200 mm is collected from GEETEE Traders,
social impact. Therefore we can conclude that use of ACC
Aerocon supplier, Cochin. The thickness of the collected
blocks over burnt clay bricks is recommended. It is advisable to
specimen is 100 mm. The density of blocks ranges from 600 to
developers, contractors, and individuals to encourage this
800 kg/m3. The collected blocks are cut and conditioned before
product as its use is in national interest.
testing. The methodology adopted for the study is as follows:
Literature survey of previous studies is conducted to derive the
objectives and scope of work. Collection of AAC blocks are
done on the basis of objectives. Cutting and conditioning of
blocks into required sizes are done.
Comparative study of AAC blocks and burnt clay bricks are
done.
Experimental studies:
Size of different brick taken in analysis:
Clay brick = 200mm x 100mm x 100mm
AAC block = 300mm x 200mm x 100mm

IV. COMPARATIVE ANALYSIS

The comparative analysis is shown in Table-1.

TABLE II
COST CALCULATION FOR AAC BLOCKS AND CLAY BRICK FOR 1 M³ [1:4]
S. No. Parameter Clay Bricks AAC Blocks
1. Quantity Analysis 200mmx 100mm x 100mm 600mm x 200mm x 200mm
2. No. of bricks / blocks 500 No. 37 No.
3. Mortar Quantity 0.2766 M³ 0.1344 M³
4. No. of begs of cement 1.65 NO. 1 No.
5. Quantity of Sand 0.221 M³ 0.1075 M³
6. Quantity of Water 31 Liters 16 Liters
7. Rate Analysis 5252.00 Rs. per square meter 5052.00 Rs. per square meter
(As per MP PWD SOR building (As per MP PWD SOR building
work2014 clause no.6.3 page no.85) work 2014 clause no.6.27 page
no.89)
Plaster Work
1. Volume of mortar for plaster 1.8M³ 1M³
2. The volume of mortar by 25% for wastage and frog filling 2.25 M³ 1.25 M³
3. Quantity of cement 0.45 M³ 0.25 M³
4. No. of begs of cement 13.5 NO 7.5NO.
5. Quantity of Sand 1.8 M³ 1 M³
6. Quantity of Water 236.25 Liters 131.25 Liters
7. Rate Analysis 171.00 Rs .per square meter,(As per 91.10.00 Rs. per square meter
MP PWD SOR building work 2014 (As per MESSOR building work
clause no.13.6 page no.244) 2010 item no.14001 page no.287)
 International Journal of Research in Engineering, Science and Management 541
Volume-1, Issue-9, September-2018
www.ijresm.com | ISSN (Online): 2581-5782

TABLE I
COMPARATIVE ANALYSIS
S. No. Parameter Clay Bricks AAC Blocks Remarks
1. Material Silica (sand) + Alumina Quartz sand + calcined The raw materials used for AAC Blocks production,
composition (clay) + gypsum + have been found to be eco – friendly, as very little
Lime + Iron oxide lime (mineral) and/or cement cement is used. The use of fly ash in this venture
+ Magnesia Aluminum powder + fly ash makes us to utilize a waste material from thermal
In other words-Top Soil In Other Words-Cement +Fly plants. AAC blocks can use fly ash(70% of its
Ash weight), thus provides the most constructive
solution to the nation’s fly-ash utilization problem
2. Size 225 mm x 100 mm x 65 mm 600 / 625 mm x 200 / 240 Bricks need more mortar since size is smaller. But
/ 230 mm x 75 mm x 115 mm x100-300 mm Mortar requirement is lesser in AAC blocks due to
mm Bigger size.
3. Precision in Size 5 mm (+/-) 1.5 mm (+/-) The AAC block is dimensionally more accurate as it
is produced with wire cut technology in a certified
factory.
4. Compressive 2.5-3 N/mm2 3-4 N/mm2 (IS 2185, Part- AAC blocks has higher compressive strength i.e.it
Strength 3) can withstand greater loads than bricks
5. Dry Density 1800-2000 kg/ m3 600-800 kg/m3 Using AAC Blocks reduces the load on the
foundation and other structural components in a
structure due to its lower self-weight. 55%reduction
in weight of walls. Up to 15% savings in cost of
structure has been observed. Because of reduction in
self-weight, AAC block
Construction attracts, Less earthquake load.
6. Fire Around 2 hours Up to 7 hours. AAC blocks have air voids and hence have better
Resistance (8″ fire resisting property compared to red clay bricks.
wall) The melting point of AAC blocks are over 1600
Degree Celsius, more than twice the typical
temperature in building fire 650 degree Celsius.
7. Energy Saving Low Approx. 25% reduction in air AAC blocks are resistant to thermal variations. It
conditioner load /25 – 30% reduces the total load of refrigeration and air
less electricity consumption conditioning. Though initial installation cost may
on HVAC remain same but AAC blocks reduces operation and
maintenance cost drastically.
8. Reuse of waste None Fly ash AAC blocks use Bio product of power plants
product
9. Efflorescence Generally Present Absent AAC blocks don’t have efflorescence, superior than
Bricks
10. Pigmentation Mineral oxides in clay plus Natural and synthesized -
natural and synthesized mineral oxide pigments
miner a oxide pigments
11. Thermal K value = 0.81 W/mk K value = 0.16 W/mk AAC Blocks with very low thermal conductivity
Conductivity keeps interior remain cool in summer and warm in
winter and best for both internal and external
construction
12. Embodied AAC Blocks consume approx. 70% less energy
Energy /Energy High (900-1000 kWh/m3) Low. (50-100 kWh/m3) than Clay bricks. AAC block covers greater area for
needed to the same mass of brick used thus saves on
produce the transportation costs and conserves precious fuel.
building
material
Soil Consumption AAC block is 100% Green building material & is a
One clay brick consumes No top soil consumed walling material of a choice in LEED certified
3.2 kgs of top soil buildings. This helps in reducing carbon Footprint.
One sq. ft. of carpet area Uses fly ash which is a In India itself AAC blocks has potential to avert
with clay brick thermal power plant waste 200mn tones of CO2 emissions into environment – a
13. Environmental walling will consume 25.5 product & thus no saving of $20 billion every year.
Impact kgs of top soil consumption of top soil
Fuel Consumption
One sq. ft. of carpet area One sq. ft. of carpet area with
with clay bricks will AAC blocks will consume
consume 8 kgs of coal 0.9677 kgs of
coal
CO2 Emission
One sq. ft. of carpet area One sq. ft. of carpet area will
will emit 17.6 kg of CO2. emit 2.2 kg of CO2
 International Journal of Research in Engineering, Science and Management 542
Volume-1, Issue-9, September-2018
www.ijresm.com | ISSN (Online): 2581-5782

TABLE I
COMPARATIVE ANALYSIS
S. No. Parameter Clay Bricks AAC Blocks Remarks
14. Social Impact Labor AAC blocks are manufactured under organized
Unorganized sector (child Organized sector. Nation sector, which contributes towards government taxes
labor rampant in building through Corporate and has standardized factory facility.
unorganized sector) Governance, Statutory Labor
and HR practices
Tax Contribution
Does not contribute to Contributes to government
government taxes in form of Central
exchequer (taxes) Excise, VAT& Ontario.
Production Facility
Unhealthy working Standardized factory facility
conditions due to toxic with automated processes.
gases. Mostly involves
manual processes
Very high due to bigger size,
light weight. Can have a The Productivity of the mason (with AAC blocks)
15. Speed of Comparatively lower Tongue -Groove Profile, which increases up to 3 times, because of less number of
construction results in faster joints
construction, saving on Labor
and jointing mortar due to
elimination of vertical joints
AAC Blocks do not have any ‟micro-pores‟ or
continuous ‟capillaries‟ through which exterior
surface water can be absorbed to interiors. It means
16. Moisture Average Very Good longer life to the paints and interiors free from growth
Resistance of any kind of fungus, providing healthier and long
lasting interiors to the occupants.
AAC Block’s water barrier properties are further
enhanced by adding silicon based additives.
17. Water 22 – 30 (suction through 4 – 6 (no continuous Use of AAC Blocks leads to Long life of paint and
Absorption capillary action) pores and capillaries) healthy interiors.
Coefficient
in Kg/ m2 x h0.5
The volume of AAC is 20% solid material and80%
air. Due to the closed cell structure of AAC, the water
absorption only takes place through the soli material.
18. Water absorption High. 20% by volume Very High. 45% by This solid is only 20% of the volume, which the water
% by weight volume absorption of AAC strongly reduces.
The AAC Block has better sound insulation
properties, due to its air voids presence. AAC blocks
have an excellent Sound transmission Class (STC)
19. Noise rating of up to 45 db. Therefore it is an ideal material
Transmission / More than 50db for 40-45db for 200mm thick wall for wall construction in hotels,
Sound Insulation 230mm thick wall auditoriums, studios, hospitals etc.
High Can be cut into require AAC Blocks can be easily cut, drilled, nailed, milled
sizes. and grooved to fit individual requirements. Available
20. Ease of Use / It can be sawn, drilled, nailed, in custom sizes. Simplifies hydro-sanitary and
Workability Low grooved etc. Can be used to electrical installations, such as pipes or ducts, which
create arches, curves etc. Can can be installed after the main construction is
have Hand Grips, which gives complete.
ease in lifting & placement.
21. Cost Benefit None Dead weight reduction leads AAC blocks reduce overall cost of construction
reduction in consumption of
steel and cement and lesser
excavation for foundations.
AAC Reduces construction time by 20%.
22. Speed of Low High Different sizes of blocks help reduce the number of
manufacturing joints in wall masonry.
Lighter blocks make construction easier and faster.
Easy to install. Sets and hardens quickly.
23. Quality / Normally varies Uniform and finished AAC Blocks being produced in a factory with
Durability automated processes, so, they have uniform quality
and hence are more durable.
24. Water Usage High, needs curing before Low, needs only surface AAC saves water consumption.
during use wetting before use
Manufacturing
 International Journal of Research in Engineering, Science and Management 543
Volume-1, Issue-9, September-2018
www.ijresm.com | ISSN (Online): 2581-5782

TABLE I
COMPARATIVE ANALYSIS
S. No. Parameter Clay Bricks AAC Blocks Remarks
-Load Bearing masonry up to 2 Band width of applicability is higher in AAC
to 3 story. Blocks, they are especially used in
-Partition walls in Load
Bearing and Framed Structures.
25. Applicability Load bearing & Non-load -Infill walls in Multistory
bearing Building Frames both internal
and external
Walls.
-All Filling are as including in
flat slabs and instead of brick
bats in
Weathering course, over roof.
26. Earth quake Average. Conditional Good. Generally, they have Earthquake forces on structure are proportional to the
resistant Conformance to Conformance to requirement of weight of the building, hence AAC blocks shows
seismic zones IV & V seismic zone IV & V. excellent resistant to earthquake forces. They absorb
and transmit less seismic forces in event of any
earthquake. The structure has millions of tiny cells
which cushions buildings from major force,
preventing progressive collapse. Regions of the
seismic activities like exclusively use AAC blocks. It
has been proven to withstand wind loads of category
5 tropical storms
27. Mortar 1.40 bag of cement 0.5 bag of cement AAC blocks are 7 times bigger than the size of the
consumption conventional bricks. Bigger size means less number
per M3 with 1:6 of joints. Less joints results in lesser quantity of
mortar for building. There is overall60% reduction in
use of Mortar.
28. Savings in - Overall 35% reduction in the AAC blocks have uniform shape and texture which
Plaster cost of plastering. gives even surface to the walls. The AAC Block,
when built has both faces as fair faces unlike brick
work, which has only one face as a fair face. Hence,
the thickness of Plaster for AAC block is much less
compared to
conventional bricks
29. Maintenance High Comparatively Lesser -AAC block reduces operating cost by 30% to40%.
due to its superior -Reduces overall construction cost by 2.5% as it
properties requires less jointing and reduces need for cement
and steel.
-High-insulation blocks save up to 30% in energy
costs.
-Wall painting and plastering last longer as almost
nil efflorescence affects AAC. This translates into
lower maintenance costs.
30. Wastage Due to Approximate 10 to 12% Minimal (1-2%) If any breakage in the AAC blocks, it would be into
Breakages two or three pieces which can be utilized in masonry
as "brick bat".
31. Pest & Termite Low High.AAC blocks are in AAC Blocks do not allow spread of termites and
Resistance organic, insect resistant and growth of pests and hence provides longer life to
solid wall Construction expensive wooden interiors.
material. Termites and ants do
not eat or nest in AAC
Blocks.
32. Fume Resistance Average Good. AAC Blocks are completely inorganic and hence do
not generate any toxic fumes or poisonous gases
harmful to the occupants. The air tight nature of
blocks also prevents toxic fumes from spreading into
other parts of building.

[5] www.level.org.nz
REFERENCES [6] www.aac-india.com
[1] www.westerngranite.co.za [7] Government of Madhya Pradesh public work department SOR for
[2] www.constructionworld.in building work in force of august’2014.
[3] www.biltechindia.com [8] Military Engineer Services Standard Schedule of Rates Parts – II 2010.
[4] the constructor.org/ ecofriendly building materials