AAC WALL PANELS - Magicrete

AAC WALL PANELSLITEMAGIC

MANUALTECHNICAL

1 . Introduction- 1.1 About Magicrete- 1.2 What is AAC- 1.3 AAC Panel Manufacturing Process- 1.4 Magicrete AAC Panel- 1.5 Walling Technologies Comparison- 1.6 Scope- 1.7 IS Code 6072

2 . Advantages3 . Material Properties4 . System Performance

- 4.1 Structural- 4.2 Fire Resistance- 4.3 Thermal Conductivity- 4.4 Acoustic Performance- 4.5 Energy Efficiency- 4.6 Deflection - 4.7 Ultimate Load- 4.8 Load Test

5 . System Components6. Installation Guidelines

- 6.1 Installation Guide- 6.2 Door and Window Installation- 6.3 Lintel Installation- 6.4 Plumbing & Electrical Services- 6.5 Panel Cutting Instructions

7 . Control Joints- 7.1 Horizontal Control Joints- 7.2 Vertical Control Joints

8 . Delivery, Storage & Handling- 8.1 Delivery- 8.2 Storage and Handling

9 . Health & Safety10. Sustainability11. Common FAQ's12. Contact Us

Table of Content

THE NEXT BIG SHIFT

IN WALL CONSTRUCTION

1.1 About Magicrete

Magicrete Building Solutions is India's frontline manufacturer of Lightweight concrete (AAC) blocks, a technology that has turned over a new leaf in the construction industry. A pioneer in green building materials, we were founded with a vision of introducing prefabricated construction technologies to the Indian construction and infrastructure industry and over the years, we have regarded as a frontline producer of these blocks with two manufacturing units in Gujarat and Haryana covering the strategic markets of west and north India respectively. Magicrete was founded in 2008 by Alumni of some of the most prominent technical institutes in India including IIT Delhi, IIT Kharagpur, and IIM Lucknow. With 800,000 CBM per annum production capacity and nationwide presence in AAC Fly Ash Blocks Market. With our mission of helping people build their homes better, faster and cheaper with innovative construction technologies we are ready to take the next step by introducing AAC Wall Panels which we feel would be the next big thing in Walling Construction.

1. Introduction Our Core Values

INTEGRITY We do and live up to what’s “right”.

PASSION We demonstrate Zeal & Zest in whatever we do.

AGILITY We are quick, decisive and efficient in our response.

OWNERSHIP We are responsible & accountable for our actions.

INNOVATION We anticipate change andshape it to fit our purpose.

CLIENT FOCUS We deliver high-quality, cost-effective solutions.

The launch of Precast, finishes a 2000sft villa in 7 days, and also constructs 1200toilets in AP for TCS under the Swachh Bharat Scheme.

2015

Introduces Modular Buildings; pilot project of 9 office pods in 2500 sqft area delivered.

2017

Constructs 252 homes in Bhilai under PMAY (Urban) with monolithic construction, Celebrated a decade of innovation by Magicrete.

2018

Magicrete wins the GHTC organized by the MoHUA. Where we build 1000+ homes in 12 months with our MagicPod Technology inRanchi.

2019

Launch of Drymix mortar products MagicBond Wall Panels joining mortar & Tile laying adhesive, MagicPlast Ready mix plaster and PuttyPlus.

2014

Sourabh Bansal, Puneet Mittal and Sidharth Bansal, Co-founders, Magicrete, spot a promising market for AAC Wall Panelss to replace the `. 50,000 Cr. industry of Red Clay Bricks.

2008

Magicrete starts its commercial production at Surat plant with an annual capacity of 150,000 CBM.

2009

Magicrete increases its annual capacity to400,000 CBM, making the Surat plant India’s Largest single location AAC plant.

2012

Motilal Oswal Private Equity invested `. 35 Crores in Magicrete.

2013

Growth story Wall Panels JOINING MORTAR

TILE ADHESIVE

BONDMAGIC

READYMIX PLASTER

PLASTMAGIC

WALL PUTTY

PLUSPUTT Y

1.2 About AAC Wall Panels

Autoclaved Aerated Concrete (AAC) blocks were developed in the 1920s to resolve the mounting pressure on forestry resources for construction purposes in the post First World War Europe. Gaining popularity globally for the last several decades, today the technology has scaled up to address the complex infrastructural challenges of the 21st century.

Its Lightweight reduces the dead-weight of the structure drastically. Studies show a reduction in foundation steel by 15% and cement by 10% if AAC Blocks are used.

Best in class thermal insulation results in significant savings in HVAC cost.

1.3 AAC Panel Manufacturing Process

The raw materials are mixed into slurry state and poured into a mould (a very large cake tin). The expanding agent (aluminium powder) instantly initiates a chemical reaction to create numerous tiny and finely-dispersed hydrogen air bubbles. Meanwhile, it causes the mixture to expand to almost twice its original volume. Once the mixture turning is hard enough (semi-solid) to be wire cut into required panel sizes in a heated room, it will be transported into the cutting machine. Then the sliced semi-solid material will be cured with high-pressure steam in autoclaves for up to 12 hours.

During this curing process, the hydration of the concrete is accelerated by the high-pressure steam. The combination of the expanding chemical reaction and autoclave curing process gives AAC its unique properties that are beneficial to buildings.

FIRE RESISTANT

THERMALLY INSULATED

NOISE POLLUTION RESISTANT

EARTHQUAKE RESISTANT

WATERRESISTANT

HIGH STRENGTH

Reduces air conditioning cost by upto 30%

Microscopic structure doesn't allow for capillary action

making it impervious to water

Best in class fire rating of 4 hours with a melting

opoint over 1600 C

Excellent Sound TransmissonClass (STC) rating of 44db

Excellent resistance to earthquake forces due to its lightweight properties.

Incomparable Strength to Weight ratio. 2Compressive strength of >4N/mm

1.4 MagicLite AAC Wall Panel

MagicLite Wall Panels is lightweight, corrosion protected steel reinforced, durable,sand based Autoclaved Aerated Concrete (AAC) wall panels. They are ideal for both external and internal non-load bearing walls.

Some of the benefits include:

MagicLite wall panels are manufactured using the latest state-of-the-art production technology and plant. Made from cement, fine aggregates, lime and water, an expansion agent is added to the mixed slurry which causes it to rise like dough containing closed air pockets that results in its lightweight and energy efficient benefits. The material is molded and wire-cut into dimensioned panels and cooked with steam (autoclaving).

AAC has been used in Europe for more than 70 years and continues to be widely accepted in India since its introduction over 10 years ago.

Building homes with MagicLite wall panels will deliver a quieter, cooler and more comfortable “home living” experience. With atleast two times times greater thermal resistance than standard house bricks, the amount of energy required to heat or cool is greatly reduced thus resulting in cost savings to homeowners.

Environmentally friendlyno toxic gases or hazardous waste

Energy efficient high thermal mass and thermal isolation

Quick installationReduced time and labour costs

Excellent soundproofingReduces noise transmission significantly

Fire resistantHelps prevent spreadof fire

Durability Not affected by harsh climatic conditions

MagicLite wall panels are lighter than other concrete and masonry products allowing for faster installation, easier handling and more flexible solutions to external wall system requirements.

MagicLite wall panels are available in the following dimensions and steel reinforcement.

Thickness: 75mm / 100mm / 125mm / 150mm

Width: 600mm

Length: 2000 mm to 4000 mm

250

0 m

m u

pto

4000

mm

(i

nter

val o

f 10

0 m

m)

600 mm

75, 9

0, 1

00, 1

25...

...20

0 m

m

GROOVE

TONGUE

Corrosion protected Steel Reinforced

No Plaster Required4 X Faster Construction

No Coping / Bond Beams Required

All the benefits of AAC Wall Panelss and much more…

AAC WALL PANELSLITEMAGIC 1.5 Walling Technologies Comparison

Parameters / Material

Weight

Dry Density

Fire Resistance

Thermal Conductivity (W/K-m)

Mortar Consumption per M3

Sound Reduction Index (dB)

MEP Installation difficulty level

Savings in Structural Cost

Easy Handling

Speed of Installation

(1 Mason + 1 Helper)

Size

Compressive strength

Installation Speed

AAC Wall Panelss

270 kg/m (100 mm)

3550-650 kg/m

220 m /day

2 Hrs (100 mm)

0.16

0.5 bag of cement

44 dB (200 mm)

Very Easy

Yes

Yes

625x240x100mm

625x240x150mm

625x240x200mm

230-45 Kg/cm

High

Hollow Core Wall Panel

2 110 kg/m

(100 mm)

31550 kg/m

240 m /day

2 Hours (100 mm)

0.4

Minimal

44 dB (100 mm)

High

Yes

Yes

Custom Made

240-50 Kg/cm

Low

No

Solid Precast Wall Panel

2 240 Kg/m

(100 mm)

32400 kg/m

230 m /day

2 Hrs (100 mm)

0.38

Not Required

40 dB (100 mm)

High

No

Custom Made

240-60 Kg/cm

Low

Aerocon Panels

239 kg/m (50 mm)

254 kg/m (75 mm)

31000-1200 Kg/m

240 m /day

2 Hours (75 mm)

0.21

Not Required

36 dB (75 mm)

High

Yes

600x3000x50mm

600x3000x75mm

240-50 Kg/cm

High

Yes

Rapicon Walls

2 42.8 kg/m (50 mm

258.2 kg/m (75 mm)

3892 kg/m

240 m /day

2 Hours (75 mm)

0.12

Not Required

40 dB (75 mm)

High

Yes

600x3000x50mm

600x3000x75mm

240-50 kg/cm

High

Yes

Burnt Clay Bricks

2185 kg/m (115 mm)

31950 kg/m

210 m /day

2 Hrs (200 mm)

0.81

1.40 bag of cement

50 dB (230 mm)

Medium

No

230x75x115 mm

225-35 kg/cm

Low

No

255 kg/m (75 mm)

260 kg/m (100 mm)

3550-650 kg/m

240-50 m /day

4 Hrs (for 100 mm)

0.16

0.2 Bag

40 dB (100 mm)

Very Easy

Yes

AAC WALL PANELSLITEMAGIC

Custom Made

240-45 kg/cm

Very High

Yes

Dry Wall

220 kg/m

3600-800 kg/m

240-50 m /day

1 Hours (100 mm)

0.25

Not Required

40 dB (100 mm)

High

Yes

600x3000x100mm

230-35 Kg/cm

High

Yes

1.6 Scope

MagicLite AAC Wall Panels can be used for various kind of applications irrespective of climate and location for the project

Industrial

Commercial Residential Hospitality

Healthcare Institutional

Warehouses

1.7 IS Code 6072

Code: Conforming to IS Code 6072 Class D (Density 550 kg/m2 to 650 kg/m2)

The major materials for the manufacture of autoclaved reinforced cellular concrete wall slabs are:

Cement- Cement conforming to IS : 269-1967 or IS : 455-1967: or IS : 1489-1967.

Lime- Lime Class C lime as specified in IS : 712-1964

Sand- Finely ground silica our sand conforms to the requirements of fine aggregates in IS : 383-1970 except for the grading.

Fly Ash- Fly ash conforming to IS: 3812 (Part I)-1966: except that the loss on ignition shall not be more than 6 percent.

Granulated Blast furnace Slag - Conforming to Notes 1 and 2 of 4.2 of IS : 455 19674 may be used.

Water- Water Conforming to the requirements given in 4.3 of IS:456-1964

Reinforcement- Conforming to relevant IS Codes

Properties as per IS Codes:

• Drying Shrinkage - not more than 0.09 percent.

• Residual water content at the time of delivery to the user -

not more than 6 percent by weight.

• Compressive strength and thermal conductivity - not more than

6 percent by weight.

• Fire resistance - not less than two hours

Table 2 Compressive strength and thermal conductivity

Class of slab

Compressive strength min

3(kgf/cm )

Thermal conductivity in air dry condition,

oMax (K cal/m/h/ c)

Class E

Class D

Class C

Class B

Class A

20

35

50

60

70

0-18

0-21

0-26

0-32

0-36

Note - The compressive strength shall be the average of three sample cubes tested and the lowest individual value shall not be less than 85 percent of the required average value.

Structural Requirements

• Loading - The slab is designed for loading in accordance with IS : 875-1964. for the

purpose of calculating dead load, the weights of the materials shall be taken as specified

in IS : 1911-1967. However, the dead load of the slab proper shall be assessed in

accordance with densities specified in 4.1 plus the weight of reinforcement.

• Design load and deflection - The deflection of the slab under the horizontally applied

design load not be more than 1/3000 of the effective span.

• Ultimate Load - The ultimate load of the panel will be more than:

Ultimate Load = 2.5 x Design load

2. Advantages

Fire ResistanceFire-resistant properties and non-combustible (4 hours for 100 mm)

Eco-friendlyToxic-free and can achieve energy savings to tune of 30%

Acoustic InsulationExtraordinary acoustic insulation material by building a defense against external noise pollution by more than 40 dB

Thermal InsulationThermal efficiencies reduce energy costs by eliminating the original reliance on cooling and heating appliances.

Light Weightth th Weigh 1/4 of bricks and 1/5

of standard concrete. Savings on structural steel

Time Saving16 times faster construction as compared to traditional masonry

Space SavingBetter option to use thinner internal walls (75 mm or 90 mm) instead of 100 mm and as a result there is an increase in floor space area between 1 - 2 %.

Strong & DurableMagicLite steel reinforced panels have that solid feel of traditional bricks. With an approved external render finishMagicLite is not affected by our harsh Indian climatic conditions and will not degrade under normal conditions.

Cost EffectiveMagicLite lightweight panels are easy to handle on-site with standard construction tools and quick to build with resulting in lower labour costs.

SafeMagicLite does not contain any toxic substances or odours, and will not harbour or encourage vermin.

Energy EfficientMagicLite has a closed aerated structure which gives it superior thermal insulation properties compared to concrete or brick veneer. MagicLite is therefore a smarter choice for lower heating and coolingenergy consumption.

SustainableMagicLite is a cleaner, greener and more sustainable choice. On a volume comparison, MagicLite has manufacturing, embodied energy and greenhouse gas emission impacts significantly less than those of concrete and bricks.

Wall Installation Speed

AAC Wall Panels vs Brick (m2 / worker / day)

Save upto 25% of Foundation Cost

Bricks AAC Productsvs

Building using Bricks

Building using AAC Products

25% less foundation

required

Thermal Control

Night time Exterior Air temperature 20°C

Note: Building uses approx.30% less energy for cooling and heating the interior air space.

Day time Exterior Air temperature 33°C

8" AAC Wall

Desired interior air

temperature 24°C

Cost - Saving benefits

Wall installation (1 Mason + 2 Helpers)

60

50

40

30

20

10

0

Red clay brick

AAC Blocks

AAC Wall Panels

2m

/da

y

Parameters AAC Panels

Basic Raw Material

Dry Density

Compressive strength

Weight

Fire Resistance

Thermal Conductivity (W/K-m)

Modulas of Elasticity

Sound Reduction Index (dB)

Cement, Lime, Fine Silica Sand & Autoclaved

550-650 kg/m3

40 kg/cm2

55 kg/m2 (75 mm)

75 Kg/m2 (100 mm)

4 Hrs (for 100 mm wall)

0.115

2190 Mpa

40

3. Material properties

600 mm

173mm

173mm

173mm

866 mm

867 mm

80 mm

80 mm

3000mm

80 mm

40 mm

867 mm

40 mm

973 mm

974 mm

973 mm

40 mm

260 mm

260 mm

40 173 173 173 40

35 mm

30 mm

35 mm

100 mm

100 mm

40 mm

40 260 260 40

All bars are 6mm in diameter

Sr. No. Height in mm

Thickness in mm

1 3000 100

Reinforcement Details

4. System performance

4.1 Structural

The MagicLite AAC Wall Panels are non-loadbearing walls and are designed in accordance with IS: 6072. MagicLite Wall panels comes with single and double reinforcement depending upon the thickness.

4.2 Fire Resistance

AAC material has earned a reputation for its outstanding fire-resistant properties. It is non-combustible and offers the best fire-resistant performance among any building material currently on the market. MagicLite Wall Panels construction, without any additional finishing materials, provides a fire rating of 4 hours for a 100 mm thick panel wall. This exceptional rating meets even the most stringent requirements.

4.3 Acoustic Performance

MagiclIte AAC Wall Panel being a porous concrete material, provides a sound insulation value greater than other building materials of the same weight per surface area. MagicLite Wall Panel's high surface mass coupled with the mechanical vibration energy damping within its porous structure produces a construction material with exceptional sound insulation properties. 100 mm Panel absorbs sound insulation of upto 40 dB.

4.4 Energy Efficiency

MagicLite Wall Panels provides exceptional energy efficiency by a very low thermal conductivity (U-value) along with the thermal mass effect. This is a distinct benefit of the aerated concrete construction over other conventional building systems such as bricks or concrete. These thermal efficiencies reduce energy costs by eliminating the original reliance on cooling and heating appliances.

4.5 Deflection

As per the IS Code, The total design load is kept in position for half an hour after which the sample shall be examined for any cracking and maximum deflection at mid-span of the slab for the full load (design imposed load + self-weight of slab) shall be measured. The maximum measured deflection is less than l/300 of the effective span which is acceptable as per the code.

4.6 Ultimate Load

The load is applied until the specimen fails or terminal deflection level 1.5 times the allowable deflection as per IS: 6072.1971 is reached. Also the specimen testes sustain loads of 1.5 times the self-load before cracking.

4.7 Load Test

MagicLite Wall Panels have good load bearing capacity. The static hanging weight in a single point is around 50 kg. With 4 AAC Fasteners of sufficient capacity can support around 200 kg weight.

Compatible Fastener*

AAC Wall Panel

Cabinet

AccessoriesTools for Installation

Slings Hammer

Drilling Machine

Notch Trowel Small Hand Brush

Crow Bar

Bucket

Electrical Stirrer

Plumb LineRubber Hammer

Hand Trolley Ladder

GI Angle

PU Foam Wedges

Fasteners for AAC and Concrete

Backer Rod

Fibre Mesh Tape for flat joints Sand Paper #200

Panel Cutting Machine

Thin Bed Mortar

6. Installation

Step 1Panel lifting car

Step 2Panel pick up

Step 3Panel transport

Step 4Panel lifting

Step 7Panel positioning

Step 1 Clean and Mark the wall

alignment. Clean the floor and

ceiling without dust or dirt before

making the line by the chalk tape.

Step 4 Drill 8 mm hole of depth 40mm at the marked points in column and insert measured pre-cut steel reinforcement bars into these holes.

Step 5 Lift the wall panel and push it to attach the column (keeping 10 mm gap for Backer Rod and PU Foam)

Step 6 Use lever to l i f t MagicLite wall panel until top of the panelreach the upper floor then insert a wood wedge under the panel.

Step 7 Use GI L-clamp to fasten the panel with floors on both upper and lower side of the panel by using fasteners.

Step 8 Apply thin-bed mortar on side of the first panel then lift the next wall panel to attach and do the same as the previous steps.

Step 2 Apply Sand Cement

Mixture (1:6) on ground where

the panels are going to be

placed.

Step 3 Clean MagicLite AAC

Wall Panel and move to the

marked point.

Use Dowels

Drill 8mm hole

Use DowelsUse Wedges Use Wedges Use Thin bed Mortar

Lift the wall panelwith wedges

Use GI L - clamp with fasteners in the panel

Apply thin bedmortar on side

PANEL PANEL PANEL

Backer Rod PU FoarmSand Paper Fiber Tape

Continue installing panels and fill gap with backer

Rub with sandpaperfor smooth finish

Application of Glass fiber tape on the joints

Fill the gap by PU Foamand give it to finish

PANEL PANEL PANEL PANEL

Step 9 Continue to install wall

panels until the gap can be closed

by the last panel.

Step 12 Rub with sandpaper for smooth finish and removal of excess thin bed mortar.

Step 13 Application of Glass Fibre tape on the joints between panels and covering it with polymer based putty.

Step 14 Fill the gap if any between beam / top slab and top of Wall Panel by PU Foam and remove excess of it.

Step 15 Fill the gap under the panels and in between the panels with sand-cement mortar and allowit to dry.

Step 16 Finish MagicLite AAC wall panel installat ion by application of Putty and Paint.

Step 10 Insert Backer Rod in the

gap between beam / top slab

and top of Wall Panel.

Step 11 All the control joints (T-

joints and L-joints) needs to be

filled with 10*10mm Backer Rod

and PU Foam.

Through Anchor System

Accessories

Steel Frame

PU Foam

AAC Wall Panel

SealantPlan View

Steel Frame

PU Foam

AAC Wall Panel

SealantPlan View

12

3

4

Exterior Door Jamb Interior Door Jamb

1

3

3

2

1. 6mm Plywood2. Door Jamb3. AAC Wall Fasteners4. AAC Wall Panels

6.2 Door and Window Installation

Door Frame InstallationHold Fast Method

6.3 Lintel Installation

RCC roof slab

Panel Panel

2 3

1

Thin Bed Mortar

L-Clamps

Through Anchor System

RCC Slab/Ream

Lintel Level

Slip Membrance

Column

Floor Level

Cement Mortar

Elevation

Bed jointreinforcement

Bed jointreinforcement

Window opening

6.5 Panel Cutting Instructions

Cross Cut

1/3 Width (Max) No Limit

Notch Cut (Field Cut)

Diagonal Cut

No Limit1/3 Width (Max)

Opening (Field Cut) Ripping - Fitted Panel

12' (Min)

6.4 Plumbing / Electrical Chasing

Step 1 : Mark the chase width vertically with cutter on panel

Cut the marked width diagonally at equal distance (100mm)Step 2 :

Remove the material by the chisel to create the chase Step 3 :

RCC roof slab

8. DELIVERY, STORAGE & HANDLINGPlease read the following instructions to insure proper handling and installation of Autoclaved Aerated Concrete (AAC). Damage may occur if AAC is moved or handled several times

Unload panels using pallet forks (either forklift, nylon straps, slings or pallet fork on a crane cable)

Stored or staged materials should always be set on flat, load-bearing, stable grade on pallets

7. Control JointsControl joints allow the movements of discontinuous building materials and prevent excess stress in the panels. They must be installed to minimise the risk of damage. PU sealant / PU Foam and backing rod forming a 10x10mm joint must be used in all installations.

Vertical control joints between the AAC wall panels must be installed in the following locations:

• At a maximum of 6.0m centres• Near or at all comer intersections • At all changes in wall height and • At the location of movement control joints in the supporting structure

7.1 Vertical control Joints

Horizontal control joints between the AAC wall panels must be installed in the following locations:

• At the top of each panel

7.2 Horizontal Control Joints:

PU Foam at Horizontal Control Joint

PU Foam at VerticalControl Joint

RCC COLUMN

L Clamp

L Clamp

PANEL PANEL

RCC roof slab

9. Health And SafetyMagicLite AAC Panels, like all concrete members, contain crystalline silica (also known as silica dust). Prolonged exposure via inhalation can cause silicosis in the long term, among other possible conditions. As such, proper PPE usage during construction is necessary to create a safe work environment.

While AAC panels are left undamaged and intact, there is no potential health risk. As such, touching the material with bare skin is not an immediate problem. Protection may be suitable however, to prevent abrasion from skin contact. However, when the material has been broken down by any process such as cutting, drilling, chasing or sanding silica dust is generated. As such, this generates an increased risk of health problems. Long term exposure increases this risk, so it is advised that precautionary measures are taken.

Either protective masks or dust extraction are recommended for usage as a preventative measure during any process that breaks down the panels. Wet cutting of the panels is not recommended. Protective respirators are recommended for dust, at a minimum.

Other preventative measures not related to the inhalation of silica dust may include:

• Eye protection• Safety Shoes• Safety Helmets• Safety Gloves• Safety Belts for working at heights

SAFETY ALWAYS COMES FIRST, WEAR PPE!

Before delivery of MagicLite AAC Panels on site, an appropriate unloading area should be designated. The unloading area should be:

8.1 Delivery

• Capable of supporting the weight of the MagicLite AAC Panel packs. • K ept dry either by storing inside or protected from the rain (e.g. by use of plastic wrapping). • L arge enough to contain all panels for the construction stage without stacking packs on top of each other. • A s close as possible to the installation or lifting area, to minimise the movement. This may mean designating additional unloading areas depending on the project size.

Wherever possible, MagicLite AAC Panels should have the faces, corners and edges protected from damage. Whenever moving panels, the following precautions should be taken:

8.2 Storage & Handling

• Before lifting packs, ensure that the panels are securely strapped. • P ersonnel operating lifting machinery (e.g. forklifts, cranes, trolleys) must use the appropriate techniques and equipment. • W hen opening packs, appropriate measures should be taken to prevent panels from falling. • A ny opened packs are protected from the weather and secured while not in use. • A ll workers have appropriate personal protection equipment (PPE) for the worksite conditions. Recommended PPE includes but is not limited to:

- Hearing & eye protection - Safety clothing (e.g. safety boots, safety helmets, safety gloves etc) - Respiratory protective equipment

All workers are trained in an appropriate manner for the tasks undertaken. For example, proper equipment maintenance and usage, material safety and good lifting techniques would fall into this category.

The sequence of installation should be planned to minimise panel movements and ensure installers will have appropriate room to lift the panels. Also, whenever manually lifting single panels, a minimum of two people should carry each panel and the panel should be carried on its side (not flat).

9. . FAQ's

Seepage Issues?The cellular structures of

Magiclite AAC Wall Panel are

comprised of many independent,

closed, tiny and dispersed air

spaces. Such a unique structure

enables the panel to effectively

prevent water from penetrating

through it.

Cracks?Cracks are created mainly because

of drying shrinkage, quality of

workmanship, height, and use of a

high ratio of cement mortar. Such

problems are avoided by using

reinforced Magiclite AAC Wall

Panels.

Space Saving?AAC Wall Panels offers excellent

water barrier & insulation properties,

giving better options to use thinner

internal walls (75 mm or 90 mm)

instead of 100 mm and as a result

there is an increase in floor space

area between 1 - 2 %.

Is it reliable?The system is highly reliable and

is being commonly used in countries

like China, Australia, Thailand and

across various South Asian Countries.

Load Capacity?

Magiclite AAC wall panels have

good load-bearing capacity, the

static hanging weight in a single

point is around 50 Kgs.

Chasing and Nailing?Both chasing and nailing

can be done in a similar way as in

AAC Blocks.

Productivity?

16 times faster than conventional

bricks and can easily be installed

by groove and tongue panels

impact to labor capacity more

than 9.71 sq.m./man/day.

10. SustainabilityAutoclaved aerated concrete offers sustainability in terms of material and performance. It uses approximately one quarter of the concrete raw material and incorporates large quantity of air resulting in fewer raw materials used per square meter than many other building materials. It also has superior insulation properties compared to concrete and conventional masonry and is about one-fifth of the mass of concrete. The air-tightness in the system creates an energy efficient envelope and prevents unwanted air losses compared to conventional frame construction thus reducing energy use.

Environmental Impact (Raw Material)

Features

Labor

Cost

Environmental Impact (Manufacturing Process)

Use of Land

• Soil spread over 50,000 acres is used every year for manufacturing bricks in India. • AAC Blocks are made up of Flyash. Approx. 1 bn tons of flyash is lying as waste in ponds near thermal power plants with 200 mn tons being generated every year (utilization ~53%). Switching to AAC Blocks may help Government achieve the target of 100% fly ash utilization.

Remarks

• 4X more efficient in labor usage. • With labor cost increasing in the last 3 years, the economics has become unfavorable for clay bricks.

• Developer saves on structural steel costs (upto 15%) because of lightweight design of structure in AAC Blocks.• Its exceptional thermal insulation properties aid in reducing air conditioning loads by upto 30% which leads to further cost savings in electricity bills.

• Energy consumption is low in the manufacturing process (225 KWh/CBM) compared to bricks (900 KWh/CBM). • AAC Blocks have a carbon footprint of 2.2 kg of CO2 per sq. ft. of construction area as against 17.6 kg per sq. ft. for clay bricks. Nation can save upto 4.5 Billion Tons in carbon emissions per annum, thereby helping to achieve National Goals set under Paris Climate Treaty.

• AAC plant of 400,000 cu.um. requires 10 acres of land to produce walling material equal to 80 kilns with requirement of over 400 acres of land (40X more efficient in land usage).

BricksAAC

Inflection point of AAC