Benefits of CLC Bricks

Reduction of dead load of building elements Optimization of floor space or coverage Reduction in usage of building material & costs Reduction in cost of superstructure steel Fire resistant Sound Proof Thermal insulation Eco friendly Suitable for seismic Zone housing projects Compared with conventional concrete, Cellular Lightweight Concrete (CLC) has many benefits .

The tremendous savings described when using CLC are manifold, continuing with substantialsavings in raw material (no gravel required), in dead load of high-rise reducing by almost half. Considering that a substantial amount of steel is necessary only to carry the weight of the structure, steel requirement might reduce by hundres of ton in high rise.

Weight reduction is obvious in transport, where almost double of volume of building material can be produced, it has an impact on craning, where either larger panles can be taken, or the full capacity in span. Alternatively less re-location of the crane is necessary.

Thermal Insulation increasingly turns to be the most important issue in the planning and construction of buildings. There are many costly ways of insulation on sandwich structure of a wall, adding the one or another rigid insulation material, with a satisfactory result by computation but not always a sound solution in safety, health or enviroment. The best solution is, to incorporate thermal insulation in the mix of a concrete, such offered in aircured CLC.

The air-embedded in the CLC is also instrumental for the high fire-rating. In 1200 kg/m density a 13-14 cm thick wall has a fire endurance of 5 hours. The same delay occurs with a 400 kg/m layer of CLC in only 10 cm thickness. CLC is otherwiese non-combustible.

Over the efforts to keep on increasing the thermal capacity of building members, other aspects have been neglected, such as sound insulation. Sound is experienced as air-borne or foot-fall sound (impact ). Airborne it is a rule of density and therefore CLC offers superior protection than very light concrete (ACC). In impact sound it is superior to conventional concrete. Hitting a wall with a hammer, will let you feel the full force on the other side, whilst the air embedded in CLC will not allow the blow to pass through. At the most it will suffer a small dent and therefby prevent any greater damage.

As the impact force will not transmit, slabs produced of CLC or topped with a layer of CLC floor screed will prevent any sound being no-ticed in the room below. Walls of CLC will also serve as sound retaining walls on roads or railway tracks therefore, absorbing the sound and preventing it from bouncing to the other side.

Adding fibers to CLC is a further important benefit, increasing bending stress substantially and most of it impact strength. The three dimensional acting fiber (e.g. polypropylene) will further reduce shrinkage, therefore reducing water absorption and increasing strength (up to 25 %. This is appreciated most when producing slender building components.

Using only sand, cement, water and foam, the cost for one m of CLC in most cases is less even than for the equivilant volume of conventional concrete. Adding all the described highly appreciated benefits (comprising CLC) to regular concrete, if at all possible, the cost for such regular concrete would probably double but still not reach the overall quality of CLC.

Our system can be readily integrated into existing concrete and prefab works, by just installing the inexpensive, simple but fully automatic foam generator. Over 300.000 buildings have been completed in the past 30 years in over 50 different countries, either using blocks of CLC, steel-reinforced prfab and slabs but mostly casting complete houses in one pour, using vertical formwork. This way one building is completed each day with every set of moulds, frames for doors and windows - or openings therefore, cast-in, the same as facility pipes/tubes for power and sanitary.

CLC becomes increasingly popular also in such countries, where the use of clay will be prohibited to conserve is for the agricultural industry only. A starter-kit is available for less than 10.000 Euro ex works.

:: CLC + Fly Ash Lightweight concrete utilizing in excess of 25% of fly-ash CLC is an air-cured lightweight concrete that can be produced at project site, utilizing equipment and molds normally in use for conventional concrete. The density recommended is 800 kg /m (oven-dried) for blocks and 1.200 kg/m to produce prefab

elements and walls cast in-situ. The typical mix for a 1.000 kg/m density CLC to be used in blocks is as follows (to produce 1 m) Cement (Portland): 190 kg = 61 liters Sand (0 - 2 mm or finer): 430 kg = 164 liters Fly-Ash: 309 kg = 100 liters (approx) Water: 250 kg = 250 liters Foam (600): 423 liters Wet density 1.179 kg/m Total volume (submerged in water) 1.000 liters (= 1 m) Expected (oven-dry) density. approx. 1.000 kg/m Content of air in concrete approx. 43% Content of Fly-Ash in solid material (929 kg): 33% Content of Fly-Ash in oven-dry material: 31 % Benefits of CLC blocks/elements Tremendous weight reduction High thermal insulation Optimum fire rating Substantial material savings: no gravel used little cement less steel in structure and foundation Easy and fast production No primary energy and reduced transportation costs Boon for remote areas with only sand available

CLC, like conventional concrete ages well, increasing its strength by as much as 50% (!) between 28 and 90 days after pouring, As long as CLC draws humidity from the atmosphere it will keep on increasing its mechanical properties. Only 1 kg (1 Itr) of 600 foaming agent is essen tial to produce 1 m of CLC for instance in a density of 1.200 kg/m: A 200 kg/liter drum of lasts for more then 200 m of CLC. Molds or design to produce inexpensive molds locally. Costing In view of fly-ash - an enviroment pollutant industrial waste - being a major ingredient of CLC, and this being a good subst itute for ordinary clay bricks (which use high primary ENERGY and precious agricultural top - soil), the Government of India for instance has given special Import duty concessions. CLC is an excellent and competitive material for low -rise, load-bearing construction and outside walls aswell as partitioning work in multi -storeyed blocks. Popular block sizes as per IS : 2185 (Part-4) : 2008 Length : 400, 500, 600 mm Height :250 or 300 mm Width : 100, 150, 200 or 250 mm or as desired Blocks are cast in vertical position to offer equally accurate sides, given by the mold. Only one side (the top when cast) is not given by the mold as open-top, which is screeded. This side will face the next block in masonary anyhow. Curing of CLC takes place within the same period as conventional concrete. If ca st in the evening, the

concrete can be demolded next morning. Curing can be speeded up by either heat, steam or chemical (accelera - tors). - As in conventional concrete CLC may also be coloured (adding pigments).

:: Range Of Densities Density 100 kg/m the only system world-wide to produce a solely mineral-based insulation board offering the same lambda as man-made polystyrol, poly-urethane or mineral wool, however without any hazardous behaviour for health, environment or fire. This density requires autoclaving. Complete plants are available to produce up to 500 m daily (or more). Density 300-600 kg/m This density is primarily applied for thermal insulation or fire protection. It uses only cement (or little sand), water and foam and can easily be pumped. foam generators allow the production of stiff foam for slopes to be applied on roof-tops. Density 700-800 kg/m Is also used for void-filling, such as an landscaping (above underground construction), to fill voids behind archways and refurbishing of damaged sewerage systems. It is also been used to produce building blocks. Density 900-1100 kg/m Serves to foremostly produce blocks and other non-load bearing building elements such as balcony railings, partitions, parapets and fence walls etc. Density 1200-1400 kg/m Are the most commenly densities for prefab and cast in situ walls, load-bearing and non-load-bearing. It is also successfully used for floorscreeds (sound and insulation plus weight reduction). Density 1600-1800 kg/m would be recommended for slabs and other load-bearing building elements where higher strength is obligatory.

CLAY BRICKS

CLC BLOCKS

Environmental Impact Consumption of Soil - 3.2 kgs. of top Soil Consumption of clay brick One sq ft of carpet area walling will consume of top soil -25.5 kgs One sq ft of carpet area with clay bricks will consume of coal - 8kgs One sq ft of carpet area will emit of CO2 -17.6 kgs No top soil consumed Uses fly ash which is a thermal power plant waste product & thus no consumption of top soil One sq ft of carpet area with CLC blocks will consum0.96 kgs of coal One sq ft of carpet area will emit of CO2 -2.13 kgs

Social Impact Organised sector. Nation building through Corporate Governance, Statutory Labour and HR practices

Unorganisad sector (child labour rampant in unorganised sector)

Does not contribute to government exchequer (taxes)

Contributes to government taxes in form of Centrale Excise. VAF & Octroi

Unhealthy working conditions, a major health hazard due to Organised sector with state-of-the-art Factory facility toxic gases