Thin bed Mortar for AAC blocks

KANERIA PLAST PVT LTD

Surat, Gujarat.

Mo       :  + 91  787  8811196

Email   :  ankitdesaisurat@gmail.com

KANERIA PLAST PVT. LTD  is (ISO-9001:2008 certified) company in manufacturing of Ready Mix Mortars base at Surat, Gujarat, India with one of its kind manufacturing facility with total operation in automatic mode, Full fledged Quality testing Laboratory & team having extensive experience in ready mix mortars. For more information about company and products visit our website- www.kaneriaplast.com.

We are always committed to deliver our high quality and best-in-class products & services at reasonably low price by Eliminating avoidable costs & With Concept of Mass production. 

Our motto is to provide solution that matches all basic factors -Quality, Price, Service for highly demanding participants in Construction Industry.

All We believe in Speaking by doing so that finally customer receives solution they expect with delightful experience of the product and company.

Block Jointing Mortar (Thin bed Mortar) for 

AAC blocks:

Thin bed Mortar for  AAC Block  is a Cure Free high quality mortar mix;

Specifically designed to provide strength and adhesion to walls constructed by AAC blocks, fly ash bricks, concrete blocks etc. Thin bed mortar is combination of cement, graded sand ; blended with polymers to impart high strength & water retention properties.

Key Features of product & Benefits:

·   -  Thin Bed mortar (Block Jointing Mortar) is ready to use & only water to be added.

·       Highly suitable to AAC blocks:

- - Since low water absorption per cubic metre of AAC material ultimately cause drying up of conventional mortar on application. This leads to separation at joints if not provided on time curing. While in case of Cure free thin bed mortar no such a dry shrinkage is observed.

·       - No shrinkage cracks.

·       - Required bond strength.

·       - No curing required.

·       - Excellent workability as compared to conventional mortar.

·       - It is cost effective / Minimal wastage.

·       -  It is premixed so saves considerable time & labour.

·       - Consistent product quality.

·       - Easy to store & no hassle to procure loose & unprocessed raw material for masonry.

     Methodology

      There are two types of mortar needed for AAC construction
(i) leveling bed mortar and
(ii) thin set mortar ( Block Jointing Mortar)

Uses: Thin bed mortar is cement based adhesive used for both exterior/interior wall, may be load bearing/non load bearing made of unit as AAC blocks (light weight blocks)

The advantages of thin bed mortar:

Operational Benefits:

• Reduce space for storage since thin bed system gives more coverage in less given material.
• Reduces time of construction since initial setting time is 3.5 hrs and final setting time about 48 hours.
• Reduce cost limited by the minimum amount of the excess mortar for construction.
• Keep clean and tidy on site.
• Easy to carry and handle.
• Easy to apply with conventional tools.
• Easy to control quality as well as quantity of construction.
• No curing required.
• Pre-mixed factory product ensures quality.

Functional Benefits:

• Makes masonry light weight.
• Gives excellent bond strength and adhesion specially for wall subjected to vibration.
• Enhances thermal resistance, seepage resistance, sound insulation property of wall.

Application method for thin bed mortar (Block Jointing Mortar) in AAC masonry:

The leveling bed mortar is only used under the first row of AAC. It is never used between or on top of AAC blocks.
       Thin set mortar or thin bed mortar cement based adhesive is used to glue AAC blocks together. Builder or engineer always should  use the thin set mortar for better construction formulated specially for the AAC block masonry.

Names prevailing in market for this product are block fix , premixed chemical for AAC (Autoclaves aerated concrete) block, Block Jointing Mortar, aac block bond, block adhesive, Cure free mortar etc.

       This is normal method used to install light weight blocks by Thin bed mortar supplied by most of the manufacturer.

* entire bag or half of the bag is used at one time for consistent mixture.
* water is normally 35 % of volume of material or added in such quantity to prepare highly thick paste.
* thin paste with excessive water shall lead to poor strength.
* Variable speed drill with stirrer and Bucket is advisable
* the water and thin set mortar is thoroughly mixed for 5 to 10 minutes to give thick paste.
* Then it is allow to settle for 5 minutes. after that it is ready to used.
* the surface of block receiving thin set mortar must be cleaned and free from loose material, grease
, oil, dirt or other residues.
*pre- wetting with water is required as per Indian environment.
* Using notched trowel mortar is applied on block.
* after any interval of time mixture should be always stirred before use.
*then other block unit is placed and proceed for leveling. wooden mallet is used for stroking and pushing blocks toward under-layer block.
* about 10 minute is allowed for adjusting block and movement. if decided to remove block for other adjustment then for replacing new block or other way out old mortar is scrape of and new mortar is applied.
*prepared mortar should be used within 1 hour.

This block jointing Mortar/gluing system is prevailing in following geography in India
Gujarat: Surat, Rajkot, Ahemadabad, Vadodara, Bharuch, Valsad, Vapi, Umergaon, Navsari
Maharastra: Mumbai, Navi Mumbai, Thane, Pune, Nashik, Dahanu, Boiser
Haryana: Faridabad, Jaipur, Panipat
Delhi, New Delhi, Noida, Gurgaon, Chandigarh
Rajasthan: Jaipur, Udaipur,

READY MIX PLASTER

PRODUCT-USE 

Kaneria-Ready Mix Plaster is ready to use sand/cement base pre-packed-dry-mixed plastering material used For Durable plastering on internal as well external wall.

CONTAINS:  Cement, Silica (graded-sand, Fly- ash, other forms), additives- Binders, SRA, special additives, water retaining agents.

Color     : Grey

Packing:  40 kg

FEATURES OF KANERIA READY MIX PLASTER

• Durability-Long life

• Best in class particle size distribution

• Single component,  ready  to mix with water & use

• No need of monitoring mortar ratio

• Less curing requirement

• Less rebound loss-Minimal wastage

• Enhanced Impermeability

• Superior Protective property & adhesion

• Easy reconciliation of cost and estimates

PREPARATION

• Surfaces need to be flat & free from loose material/patches, Dust, oil, grease, paints, etc.

• If RCC surface it is advisable to make surface rough by Hacking or one day old chat-plastering

• Pre-wetting is essential of surface till saturation but top surface should be dry for start plastering.

• For Plaster-mixture water 7-8 litres potable water by with 1 bag Kaneria-RMP.

• Do not dilute with cement/ sand for best performance.

• Mix thoroughly to achieve consistent & uniform mixture.

• Allow Mixture to start reaction properly for at least 2-3 minutes 

• Mix every time before usage.

APPLICATION

• Apply prepared plaster mix to arranged surface manually or with spray.

• Allow mortar mixture for sufficient time (depends on climate) so that able to cut properly for leveling.

• Curing: Curing can be start after 24 hrs for daily 2-3 times for 5 to 7 days. While for high humid climate one can reduce daily frequency.

CAUTION:

• Avoid prolong skin, respiratory contact of any such cement based alkaline products. Use mask, gloves, goggles

• In case of eye contact rinse with clean water.

TECHNICAL PARAMETER of KANERIA - RMP

PHYSICAL          :  FORM FREE FLOW GREY POWDER

AGGREGATES    :  Well graded, dry, silt free sweet water sand

BASIC BINDER   :  Ordinary Portland cement

ADDITIVES         :  Water retaining agents, SRA, Binder, workability improvers

POT-LIFE            :  60-120 Minutes

WATER RATIO    :  17-19 % by weight

BULK DENSITY : 1600 to 1900 kg/ M³

COMPRESSIVE STREGNTH : as per IS-4031-Part-6

Coverage: 

* Approx 16-17 Sq.Ft for 12-10 mm thickness.

* Coverage may very upon surface undulation

TILE ADHESIVE - Non Slip Adhesive (NSA)

Kaneria- NSA or Tile adhesive is premixed mortar consist of Cement, Silica (graded-sand, Fly- ash, other forms), polymers, Binders, SRA, special additives to match high performance adhesion for various cladding of tiles, marbles, stone cladding on internal, external wall as well floor and ceiling.

FEATURES OF KANERIA TILE ADHESIVES

• Polymer-modified, cement-based, with special additives
• Single component,  ready to use
• Self curing, Non slip, Non shrink
• Superior Mechanical property & adhesion
• Long life
• Suitable to Thin Layer application

   Kaneria- Tile Adhesive Variants
   PREPARATION

    PREMIUM : For High performance on internal as well external wall Tile on Tile, Any cementious surface to fix Large format, dense, low porosity stone/Tile cladding like Vitrified tiles, Ceramic tiles, Porcelains, Mosaics, Granites, Marbles. ( Type II as per IS-15477 ) 

  GRAND : For reliable performance on Internal as well external wall, Any cementious surface to fix medium format- dense, low to medium porosity stone/ large format Tile cladding like Vitrified tiles, Ceramic tiles, Granites, Marbles.     (Type I as per IS-15477 )

    SUPREME: ( Type II as per IS-15477 ) but whitish in colour.

* Surfaces need to be flat & free from loose material/patches, Dust, oil, grease, paints, etc. Pre-wetting is essential of surface till saturation but top surface should be dry.

* For Mortar-mixture, always add KTA powder (3.5 parts) to potable water (1 part).

* Do not dilute with cement/ sand for best performance.

* Mix thoroughly (speed stirrer is recommended) to achieve consistent, uniform and air bubble free mixture.

* Allow Mixture to start reaction properly for at least 5 min.

* Mix every time before usage.

APPLICATION

* Apply Prepared Tile adhesive on surface through towel.

* Place and Install tiles one by one immediately; strictly within 10 to 15 min (OPEN TIME).

* Stroke/Tap the tiles properly (use rubber mallet) to make sure no air-space left on back side.

* Remove excess material tiles’ surface using damped cloth.

* Always use all prepared-mixture within 60 minutes after preparation (POTLIFE- 60mins).

CAUTION:

* Avoid prolong skin, respiratory contact of any such cement based alkaline products. 
   Use mask, gloves, goggles

* In case of eye contact rinse with clean water.

COVERAGE:

* Coverage may vary due to surface undulation 

2.10 Sq.Ft per kg for 3 mm thickness

1.05 Sq.Ft per kg for 6 mm thickness

0.70 Sq.Ft per kg for 9 mm thickness

PHYSICAL          :  FORM FREE FLOW GREY/ or White POWDER

OPEN TIME        : 15 Minutes

POT-LIFE            :  60 Minutes

WATER RATIO    :  3.5 Parts Powder: 1 Part Water

BULK DENSITY : 1600 to 1900 kg/ M³

• KANERIA-Block Jointing Mortar  :  Thin Bed Mortar for Jointing AAC blocks (lightweight blocks). commonly called chemical for AAC blocks which work like glue to install AAC masonry quickly with excellent binding strength with each other and no need of water curing to acquire sufficient strength within week. packing: 40 kg.

• KANERIA-Ready Mixed Plaster:  Ready mixed plaster is sand+cement+fiber+polymers+additives for plastering on  all kind of masonry wall made of bricks,  Lightweight (AAC) block, stone, concrete etc.This can be used as manual as well spray machine application.  packing: 40 kg.

• KANERIA-Tile adhesives: Non skid adhesive used for tile on tile, vertical tile, stone (Natural as well synthetic) on wall gluing/ fixing/installing as well mixing with mortar for best and reliable adhesion.  packing: 30, 40 kg. premium variant such as WHITE as well Eco variant for FLOOR also available.

• KANERIA-Wall Putty: Specially designed for coating plaster to give smooth, lustrous, white & silky finish that helps decorative paint to result higher coverage & long lasting performance.

AAC  blocks

Intoduction:

Autoclaved aerated concrete (AAC) blocks, also known as autoclaved cellular concrete (ACC) blocks, autoclaved lightweight concrete (ALC) blocks,  or Lightweight concrete block  autoclaved concrete, cellular concrete or Cellular lightweight concrete (CLC) was invented in 1923 by Swedish Inventor Johan Axel Eriksson as a cost effective and eco-friendly substitute of red clay bricks as walling material.  

Even though regular sand + cement mortar can be used to join this blocks, most of the buildings erected with AAC blocks use thin bed mortar or thin set mortar in thicknesses around 1/8 to 1/16 inch. 

 It is a lightweight, precast building material that simultaneously provides light weight structure, heat (thermal) & sound insulation, fire resistance, mold-resistance walling solution. one of its advantages in construction is its quick and easy installation, because the material can be routed, sanded, or cut to size on site using standard carbon steel power tools.

AAC blocks is porous concrete with tobermorite cellular structure. It contains 80% Air and 20% solids by volume. This makes AAC blocks lightweight building material for wall construction.

Due to this feature-porosity other features comes hand in hand.

Like it can be cast in larger shape still doesn't bring much pain in handling. And construction becomes faster.

Porous structure not only brings thermal insulation feature but also sound insulation, seepage resistance.

As in table following proportion of raw material are used along with water in manufacturing of lightweight blocks.

   

Content	Proportion
Fly Ash	68.0%
Cement	14.0%
Lime	14.0%
Gypsum	3.5%
Other	0.5%

With All in one kind of wall construction building material the AAC block is believed to be innovation of century in construction industry.

Manufacturing Process

Aluminum powder along with Fly ash, cement, lime, gypsum, surfactants in slurry form is mixed in high speed –Automatic batch mixer resulting in AAC slurry; which is poured in to Mold. Reaction of aluminum with lime, water, silica releases Hydrogen gas (H₂ ↑) when escapes from slurry, it rises to give porous structured to Calcium silica Hydrate (C-S-H, Concrete).  This risen mold is cut in to blocks of require size by wire cutting machine; which are again steam cure under high temperature 

(180⁰ C) and pressure (1.2 bars).

This gives High strength and precise sized but lightweight AAC blocks; are green building material perfect for wall of all kind.

Technical Parameters of AAC blocks              (Lightweight blocks)

Parameter	Unit	Value
		Blocks	Brick
Size: length x height	mm	600x200 or 625x240	225x75
Size: thickness	mm	50, 75, 100, 150, 200, 225	105
Dry Density:	Kg/M3	550-650	1900-2000
Compressive Strength:	Kg/cm2	> 3	> 3
Thermal Conductivity	W/K0M	0.16 to 0.18	0.81 to 0.96
Size Variation	mm	+ 1 mm	+ 10 mm

AAC blocks Sizes and Per Cubic meter Pcs Calculation

Sizes					Volume (Cu.M)	Pieces / Cu.M	Face Area (Sq.ft)
L		H		T
600	x	200	x	50	0.006	166.67	1.29
600	x	200	x	75	0.009	111.11	1.29
600	x	200	x	100	0.012	83.33	1.29
600	x	200	x	125	0.015	66.67	1.29
600	x	200	x	150	0.018	55.56	1.29
600	x	200	x	200	0.024	41.67	1.29
600	x	200	x	225	0.027	37.04	1.29
625	x	240	x	50	0.0075	133.33	1.61
625	x	240	x	75	0.01125	88.89	1.61
625	x	240	x	100	0.015	66.67	1.61
625	x	240	x	125	0.01875	53.33	1.61
625	x	240	x	150	0.0225	44.44	1.61
625	x	240	x	200	0.03	33.33	1.61
625	x	240	x	225	0.03375	29.63	1.61

Gujarat:

Rajkot Bhavnagar Amreli Junagadh Jamnagar palanpur Himmat Nagar Patan Mehsana Gandhinagar Ahemedabad Sabarmati Maninagar Khambhat Nadiad Anand Vadodara Gorwa Makarpura Dahod Godhara Bharuch Ankleshwar Surat Varachha Adajan Dindoli Bhatar Bardoli Vyara Navsari Valsad Vapi Umbergaon Daman Silvassa Dahanu

Maharastra:

Mumbai Navi Mumbai Virar Thane Andheri Mulund Nashik Jalgaon Aurangabad Nandurbar shahda dhuliya

Rajasthan: Udaipur, Jodhpur, Jaypur

Madhya Pradesh: Indore, Bhopal

Advantages of AAC blocks to House-Holder

Safety in Earthquake:

‘During Earthquake; Lightweight building is always more safe then heavy building’. Since lightweight AAC block Reduces 60 % of dead weight of building; safety of building in earthquake increases.

 Gives High Thermal Insulation:

Because of Superior thermal insulation property of rating R30, AAC blocks do not allow effect of outer heat/cold on interior of building. This saves A/C cost by more than 30%.

Gives High Sound Insulation:

AAC blocks falls in STC-44 (sound transmission class) which make it very low cost & good sound barrier material for residential and social buildings.

Allows No Water seepage: Due to lowest “Water absorptive material”/ “Volume of block” ratio (only 20% in block compare to 65 % in brick) and absence of capillaries (So No capillary action), AAC blocks do not allow water seepage of from exterior to interior of wall.

No efflorescence: Due to seepage resistance as well Absence of any salty material in production of blocks there is no chance of efflorescence in AAC blocks wall.

Pest resistance: Anjali AAC blocks are Pest resistance since humidity, nutritional material and such Environment required to grow mold, insect, pest is not available in it.

Fire resistance: AAC blocks falling into fire rating of 4 hrs makes it fire resistance wall material for building.

Advantages of AAC blocks to Builder

Ease of Working:

Lifting, Drilling, cutting, chiseling, rasping are very easy and convenient with AAC blocks and can be done with conventional tools.

Faster Construction: Along with ease of working, accurate & bigger size of AAC block (more than 7 times) speed of construction of wall increases 2 to 3 fold.

Best finishing: Accurate size of AAC blocks brings better finishing of building without compromising on speed of construction

Carpet area: Wall made of AAC blocks having Accurate size & surface; can be finish with single coat plaster that saves ½” inch of space throughout length of wall, increases carpet area.

Saves steel & concrete: Lowest dry density (550-650 kg/M³) of AAC blocks reduces dead load by 50 % saves Steel and cement noticeably.

Cost effective: Although AAC blocks is costlier than red bricks; Cost of wall per square feet of wall reduces since

•              Saves joining mortar material by 60%
•           Saves Plastering material by 40%
•           Reduces over all wastage by 70%

Advantages of AAC blocks to Society

Saves Fertile Land:

AAC blocks uses fly ash wastage coming from thermal power don’t require fertile clay, Unlike red bricks manufacturing.

Recycling Fly ash waste: 

After hydra power we are still largely depend on thermal power which has huge problem of fly ash waste being pile up in million tones. This is major raw material for AAC blocks.

Energy efficient As well Reduces Carbon Emission:

AAC blocks manufacturing is most energy efficient process compare to other walling material which again helps to reduce carbon emission.

Saves Fuel for Transportation:

AAC blocks Being lightweight more volume of walling material (almost 3 times) can be transfer in same carrier saves fuel for transportation by 66%.

Green Building Material:

Because of above social and environmental benefits it is material of choice for green building certifying organizations like LEED, IGBC, BREEAM, DGNB, CASBEE etc. 

To learn more about AAC Blocks (light weight blocks)- 
http://www.understanding-cement.com/autoclaved-aerated-concrete.html

below list may help you out for acquiring AAC blocks at various locations in India.
LIST OF AAC BLOCK  PLANTS MANUFACTURERS IN INDIA

Madhyapradesh	Raipur	Ecorex	Ecorex Buildtech Pvt Ltd
Tamilnadu	Chennai	CELL O CON	Methra Industries
West Bengal	Kolkatta	Biltech	Biltech Building Elements Limited
West Bengal	Howrah	ICON	Inspira Group
West Bengal	Howrah	UAL-Koncrete	UAL Industries Ltd.
Assam	Guwahati	brickOlite	K D Group of Industries
Hariyana	Faridabad	RICHA	Richa Infrastructure Ltd.
Hariyana	Faridabad	Ecocrete	FUTURE ECOCRETE PVT. LTD.
Hariyana	Greater Noida (NCR)	Superlite	Kannav Builders Private Limited
Hariyana	Jhajjhar (NCR)	SMARTBLOX	J K Lakshmi Cement
Hariyana	Jhajjhar (NCR)	Magicrete	Magicrete Building Solutions
Hariyana	Jhajjhar (NCR)	Aerocon	HIL
Hariyana	Palwal (NCR)	Biltech	Biltech Building Elements Limited
Hariyana	Panipat	Instablock	Indo-Bhutan Construction Solutions Pvt. Ltd.
Himachal Pradesh	Solan	RS	R.S Green Infra (India) Pvt. Ltd.,
Andhrapradesh	Bangalore (Tumkur)	Siporex	B G Shirke Group
Andhrapradesh	Hyderabad	Reliconz	Reliconz Brixs Pvt. Ltd.
Andhrapradesh	Hyderabad	Superblok	Aarush Building Materials
Andhrapradesh	Hyderabad	Xtralite	Ultratech
Andhrapradesh	Krishna- Kanchikacherla	Nucon	Greenway Building Materials India Pvt. Ltd.
Andhrapradesh	Vijaywada	PRIME AAC	ECO-CARE Building Products Pvt Ltd
Tamilnadu	Chennai	Aerocon	HIL
Tamilnadu	Chennai	Renacon	Renaatus Procon Pvt. Ltd.
Gujarat	Ahmedabad	Brixo	Brixo Industries
Gujarat	Ahmedabad	Surya	Suryshree Wellness Pvt Ltd.
Gujarat	Ahmedabad	Wonder	N J AAC Blocks
Gujarat	Baroda	Iolite	Iolite Cube Inframaterial Pvt. Ltd.
Gujarat	Bawla	EFCON	Phenix Procon Pvt. Ltd.
Gujarat	Gandhinagar	Ecogreen	Eco Green Products Pvt Ltd
Gujarat	Gandhinagar	Float	Yash Associates
Gujarat	Morbi	Pravin	Pravin Buildtech Pvt. Ltd.
Gujarat	Rajkot	Aercon	Aercon India
Gujarat	Surat (Golan)	Aerocon	HIL
Gujarat	Surat	Ascolite	Aswani Construction Pvt. Ltd.
Gujarat	Surat	Biltech	Biltech Building Elements Limited
Gujarat	Surat	Litecon	Litecon Industries
Gujarat	Surat	Magicrete	Magicrete Building Solutions
Gujarat	Surat	FNL	FNL AAC BLOCKS PVT LTD
Gujarat	Surat	Anjali	Anjali Infracrete
Gujarat	Surat	Eracrete	Eracrete Buildcon
Gujarat	Surat	Globcon	Globcon Industries
Gujarat	Surat	Laxmi	Laxmi Blocks Building Pvt Ltd.
Gujarat	Umargaon	NXTBLOC	Mohit Industries Limited
Maharastra	Bhigwan (Pune)	Biltech	Biltech Building Elements Limited
Maharastra	Kolhapur	Neolite	Neolite Buildcon Pvt. Ltd
Maharastra	Nashik (Sinnar)	Ecolite	JVS Comastco
Maharastra	Nashik	Flyocrete	Flyocrete Green Concrete LLP
Maharastra	Palghar (Mumbai)	Biltech	Biltech Building Elements Limited
Maharastra	Pune	Siporex	B G Shirke Group
Maharastra	Wada (Mumbai)	Xtralite	Ultratech
Maharastra	Nashik	U-CRETE	Urjayant Engineering Pvt.Ltd