LESS WASTE SHARPER DESIGN

Designing out Waste: design detail sheet

Aerated concrete blocks

with thin joint mortar

Standard: Concrete blocks with cement mortar

Aerated concrete blocks with thin joint mortar

Conventional joint

10mm joint

AAC blockwork
Thin joint mortar

3mm joint

The best opportunities for improving

materials resource efficiency in construction
projects occur during the design stage.
Implementing these opportunities can provide
significant cost savings, reductions in waste
disposed to landfill, and carbon reductions.
This sheet is part of a series highlighting
alternative design details which use less
materials or result in less waste being created
than standard details used in construction.
The benefits provided by the alternative design
detail are quantified, and technical
considerations presented.

Potential benefits:

70% lighter than standard concrete

blocks.

Up to 80% less mortar sets within

20 minutes.

Construction times can be equivalent to

off site methods.

Modest extra cost of materials is off set

by low waste and waste disposal.

21% less embodied carbon than

standard blocks of the same size.

Halving
Waste to
Landfill

02 Designing out Waste: design detail sheet

Photo source: H+H UK Limited

Aerated autoclaved concrete (AAC) blocks,

together with thin joint mortar, represent a
fast and efficient construction method. They
are strong, durable and time-tested.
Manufactured to exacting dimensional
tolerances, they can also be easily cut where
necessary.

Further information

Major materials resource efficiency savings

come from the light weight of the blocks and
low mortar requirements. In addition most
AAC blocks include recycled content, in the
form of PFA.

Can be used in load-bearing walls up to

five storeys.
High levels of durability. Resistant to
damage by insects, sulphates, frost and
water.
Can be easily cut and shaped by hand.
Thin mortar improves thermal bridging, air
tightness and sound insulation.
Care must be taken to avoid damage to
AAC blocks during construction.

The autoclaving process ensures strength,

rigidity and dimensional stability.
Thin joint mortar is a cement-based product
that only requires the addition of water and
allows joints of 3mm or less, although
thickness can be varied to allow perfect
levelling. It is quick-setting allowing rapid
construction.

WRAP has produced a range of guidance and

tools to help design teams with designing for
resource efficiency in construction projects.
These resources are freely available at
www.wrap.org.uk/construction

Designing out Waste: design detail sheet 03

Potential benefits*

Materials/waste

Cost

Time

Carbon

High strength-to-weight ratio reduces materials use.

Low mortar requirement also results in low waste.

Highly efficient manufacturing process.

Off cuts can be easily reused.

Exposed finish is feasible, eliminating plaster/plasterboard.

Low weight building structure allows reduced foundations.

Modest extra cost of 2/m2 off set by labour/programme savings.

Value of wasted materials can be reduced by 44%.

Waste disposal costs can be reduced by 50%.

Further cost savings for foundations and transportation due to

light weight.

Large block sizes available allowing rapid construction.

Quick setting mortar.

Buildings are watertight early internal works can start before

external leaf is finished.

Consistent wall surfaces speeds up finishing trades and reduces

snagging.

21% less CO2e compared to equivalent sized standard blocks.

Excellent thermal properties can help reduce operational carbon

emissions.

Typically contains 85% PFA (a by-product from coal fired power

stations).

Blocks are 100% recyclable.

Precise dimensional tolerances.

Lightweight and easy to handle; easy laying and levelling.

Blocks are easy to cut, shape and sand.

Mortar is easily and accurately applied using simple application tool.

Mass market solution; readily available in the UK.

Can be used for single leaf, external solid wall construction.

Recycling

Constructability

Replicability

*All stated benefits are provided as guidance only and may vary from project to project.

Design stage of implementation:

RIBA Stage D/E (Design Development/Technical Design)
Relevant standards:
BS EN 771-4 (relates to AAC Block units)
BS 8110 Concrete
Eurocode 2
NBS Ref:
F10 (Brick/Block Walling)

WRAP and Faithful+Gould believe the content of this report to be correct as at the date of writing. However, factors such as prices, levels of recycled
content and regulatory requirements are subject to change and users of the report should check with their suppliers to confirm the current situation. In
addition, care should be taken in using any of the cost information provided as it is based upon numerous project-specific assumptions (such as scale,
location, tender context, etc.). The report does not claim to be exhaustive, nor does it claim to cover all relevant products and specifications available on
the market. While steps have been taken to ensure accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage
arising out of or in connection with this information being inaccurate, incomplete or misleading. It is the responsibility of the potential user of a material
or product to consult with the supplier or manufacturer and ascertain whether a particular product will satisfy their specific requirements. The listing or
featuring of a particular product or company does not constitute an endorsement by WRAP and WRAP cannot guarantee the performance of individual
products or materials. This material is copyrighted. It may be reproduced free of charge subject to the material being accurate and not used in
misleading context. The source of the material must be identified and the copyright status acknowledged. This material must not be used to endorse or
used to suggest WRAP's endorsement of a commercial product or service. For more detail, please refer to WRAP's Terms & Conditions on its web site:
www.wrap.org.uk.

Waste & Resources

Action Programme

The Old Academy

21 Horse Fair
Banbury, Oxon
OX16 0AH

Tel: 01295 819 900

Fax: 01295 819 911
E-mail: info@wrap.org.uk

Helpline freephone
0808 100 2040

www.wrap.org.uk/construction