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Instructions for

Aerocon Blocks Masonry Construction

Dear Customer

Thank you for choosing to build with AEROCON Blocks- Autoclaved Aerated Concrete
(AAC) blocks. These blocks are light weight, easy to handle and have high thermal
insulation and Sound absorption properties.

We suggest you adhere to the following instructions to realize all the product advantages for
high quality construction and best performance. The information is based on relevant IS
codes and good construction practices. Make sure that your site supervisor or contractor
follows the instructions to get the full benefits of Aerocon Blcoks.

GENERAL

Unload blocks on a dry level surface raised above ground and cover them to prevent
exposure to rain or severe weather conditions. For some reason if the blocks are get
Wet, allow them dry before use.

It is recommended to use 200 mm thick blocks for external walls. Lower thickness
blocks may also be used in external walls when these Walls are suitably designed.
For internal walls use minimum 100 mm thick blocks for non-load bearing walls.

Blocks can be easy cut/sawn, drilled, nailed and routed at site using recommended
tools. Cutting of blocks can be done by using a handsaw or Sabre saw of BOSCH
make (GSA1300). For bigger projects cutting wheel can be mounted on table and
blocks are pushed towards wheel for cutting.

MORTAR FOR CONSTRUCTION

The recommended mortar mix for construction (proportion by volume) is 1:1:6


Cement, Lime and Sand or 1:6 Cement, Sand. Preferably use PPC cement for best
results.
The mortar shall not be spread so much ahead of the actual laying of the blocks as it
tends to stiffen and lose its plasticity there by resulting poor adhesion and bond.

Mortar consistency to be maintained at the time of laying block masonry.

Thin bed mortar manufactured by reputed companies also can be used for blocks
laying .Pl follow the manufacturer recommendations for laying of block masonry.

LAYING OF BLOCK MASONRY

Do not soak the blocks during laying. All surfaces of the blocks are to be moistened,
using wet brush or sponge, to prevent absorption of water from mortar. Best way to
dip and remove the blocks.

For walls above ground floor, provide bed cement mortar 1:8, before starting the first
course of blocks.Pl check the height of masonry and distribute the same along the
joints, If the gap is more same can be adjusted in bed mortar.

Blocks should be laid true to level and plumb on a firm bed of mortar. The thickness
of horizontal and vertical joints should be limited to 10 -12 mm. The joints shall he
struck off flush and compressed as the mortar stiffens.

Lay the first course of block masonry with care and laid with water level, ensuring it is
properly aligned, leveled and plumbed. This will assist in laying succeeding courses
to obtain a straight and truly vertical wall.

Maintain a regular bond pattern, based on minimum overlap of 100 mm or quarter


block, whichever is more.

Horizontal & Vertical Joints to be filled properly without gaps/cavities to avoid air
entrap, the best way to do this is sliding of block after placing on mortar surface.

Once the masonry erected the curing shall be done for one week, brick masonry,
unlike brick masonry AAC blocks require curing mortar joints.

BOND BEAMS OR BED JOINT REINFORCEMENT:

As for all masonry materials. The AAc block work is subjected to movements and this
may lead to development cracks. These may be due to shrinkage and non uniform
loading of the walls.

To minimise the effects of shrinkage , tensile & diagonal cracking and to enhance
stability , It is recommended to provide bed joint reinforcement or nominal bond
beams as given below.

Cross walls shall be bonded to the long walls in alternate courses. For any non-
standard gap, cut the blocks to the required size to fill up the same.. Avoid filling the
gaps using dissimilar materials.

Provide bed joint reinforcement or RCC Bond beam of thickness 80 mm with two
nos of 8 mm dia rods and 6 mm stirrups at 200 mm c/c these are recommendations
of IS 6041 and IS 1905 -1987. Ensure that reinforcement rods to be inserted into
surrounding columns for load transmission as shown in below fig. A for Bond beams
& fig. B for Bed joint reinforcement .
Fig A

Fig B

MOVEMENT JOINTS
For continuous walls in excess of 6.0 M a 10 mm wide movement joint running
through the wall shall be provided starting at 3 M from a corner. The joint shall be
filled with resilient material and the ends shall be sealed to prevent rain water
penetration. We have to provide dummy / stub columns depend on thickness of
blocks.
JOINING OF DISSIMILAR MATERIALS:

All the contact surfaces should preferably be separated from those of dissimilar materials
like concrete or steel , by filling with a resilient material along the contact area and edges
filled with sealant. Provide chicken/ synthetic mesh firmly over all dissimilar joints of
concrete/block masonry prior to plastering. For external wall joints need to be grouted or
properly treated to avoid water ingress and crack formation.

SERVICE LINES

For concealed or piping, block wall can be chased using hand or electric router.
Depths of vertical chases should be Limited to one-third of the wall thickness and
horizontal chases to one-sixth of the wall thickness. Holes in block wall can be made
with a standard hand or electric drill.

The chases shall be refilled with leaner mortar and chicken mesh shall be applied on
that area and cured.
JOINERY & FIXINGS

Doors and window frames can be fixed to a block wall using wall pIugs and wood
screws. The screws are to be penetrated into the block to a minimum depth of 50 mm

Light weight fixtures like skirting boards, cladding battens etc., Can be fixed using cut
nails screw-driven into the block wall. For all other type of fittings like cupboards,
washbasins etc., suitable plugs with screws may be used.

As a general rule, fixings should not be closer to the free edge of block than the depth
of embedment.

The diameter of the hole drilled should be one size smaller than the screw to ensure
that the plug fits in tightly before the screw is driven. Follow recommendations of the
manufacturer

All nails and screws are to be inserted into the blocks and not along the joints.

Conventional method like providing Holdfast 3 nos embedded in concrete on each


side for door and window frames can be provided as shown in fig.
LINTELS

Precast or cast in-situ concrete lintels can be used in block masonry, over all
openings.

Lintels shall always rest on full block with minimum bearing as under.

Upto 900 900 to 2000 2000 to 3000 Above 3000


Opening Size
mm mm mm mm
Minimum
bearing 150 mm 200 mm 300 mm To design
(each side)

Below the openings provide bond beam with reinforcement to avoid diagonal tension
cracks. The bond beam to be extended up to 300 mm from window corners both the
sides.

PLASTERING

Do not soak the wall before plastering. The wall shall be moistened evenly before
applying the plaster. A fog spray is recommended for this purpose.

For external plastering has to be carried out in two coats, apply SBR coating with
sand on block surface will enhance the bonding and minimize thickness of plastering.

It is recommended to use cement mortar 1:6 for internal & external plastering works
and preferably use PPC cement for masonry and plastering works to minimize
shrinkage cracks.
Plastering thickness can be minimized to 10 mm & 15 mm for internal and external
walls.

PRECAUTIONS TO BE TAKEN FOR LAYING OF AAC MASONRY:

The cracks occurring in block masonry and in plastering are of any structural problem
involving stability and safety to the structure. But it is advised to minimize the same to have
good appearance and maintenance free.

Do not store the blocks on un leveled surface


Do not use wet blocks for masonry construction
Do not make the holes on block masonry for scaffolding supports
Do not soak the blocks before use
Do not hammer the block masonry for service lines, chases etc
Do not completely wet the block masonry before plastering works
Do not chase the blocks back to back for lesser thickness blocks.

LIST OF RELEVANT STANDARDS

Code of practice for application of cement and cement-lime plaster


IS: 1661
finishes.
IS: 1905
Code of practice for structural use of un reinforced masonry

IS: 2185 Specification for concrete masonry units ( Auoclaved cellular


Part 3 concrete blocks)

IS: 2250 Code of practice for preparation and use of masonry mortars

Code of practice construction of autoclaved cellular concrete block


IS: 6041
masonry
BS : 5628
Part 1,2 & 3 Code of practice for use of masonry