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AAC Wall Panels

AAC Wall Panels

Magicrete AAC Wall Panels is the quintessential green building material incorporating features long been desired by builders, engineers, and architects in the building construction industry. Their advantages surpass traditional construction methods, such as red clay bricks and concrete blocks, in several key aspects: strength, acoustics, thermal insulation, fire resistance, and installation efficiency. These panels, reinforced with corrosion-protected steel, strike a balance between lightweight design and heavy-duty performance.

Having achieved substantial success in global markets, AAC Wall Panel technology embodies the pinnacle of durable and high-quality construction, achieved within remarkably short timelines.

These panels boast the industry's highest thermal rating, boasting a K-value of 0.16 W/(m⋅K). Their cellular structure guarantees a well-insulated interior, ensuring cooler interiors during summer and warmer spaces in winter. Studies reveal a remarkable 30% reduction in air-conditioning bills, highlighting the panels' exceptional energy efficiency.

Resource efficiency remains a hallmark of Magicrete AAC Wall Panels, emphasizing minimal environmental impact. The closed air pockets within the panels create outstanding sound insulation, reaching an STC rating of 44 dB, effectively dampening external noise. Furthermore, their impressive 4-hour fire rating permits thinner wall sections, maximizing floor space for end-users. Available in full-height lengths from floor to ceiling, with varied thicknesses and a standard width of 600 mm, these panels offer versatility in design and application.

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Features

Thermally Insulated

Thermally Insulated

Walls constructed of AAC Wall Panels provide sustained energy savings in both hot & cold climates. Its unique cellular structure contribute to a highest thermal rating in the industry, R30. Significant savings up to 30% in air conditioning has been observed.

Fire Resistant

Fire Resistant

AAC Wall Panels has unique cellular structure provides best in class rating of 4 hours. Its melting point is over 1600 degree Celsius, more than twice the typical temperature in building, which is 650 degree Celsius.

Earthquake Resistant

Earthquake Resistant

Microscopic structure of AAC Wall Panels does not allow for capillary action making it impervious to water.

Noise Pollution Resistant

Noise Pollution Resistant

AAC Wall Panels closed air pockets can provide very good sound insulation with an STC rating of 44.

Water Resistant

Water Resistant

Microscopic structure of AAC Wall Panels does not allow for capillary action making it impervious to water.

Green Building

Green Building

AAC Wall Panels are Recyclable, inert & non-toxic, Energy saving, Manufacturing through occupancy, and has excellent life-cycle cost. They are durable, natural finish options. And supports LEED credits.

Technical Specification

PARAMETERS SPECIFICATIONS
Weight 55 Kg/m2 (75 mm Thickness) 70 Kg/m2 (100 mm Thickness)
Density ~ 600 Kg/m3
Compressive Strength > 4 N/mm2
Thermal Conductivity 0.115 W/m-K
Fire Resistance 4 hrs (100 mm Thickness)
STC Rating 40 db
Coefficient of Thermal Expansion 8x10-6/K
Modulus of Elasticity 2190 Mpa

Knowledge Base

FAQs

Cost comparison of AAC Panels with other walling materials - AAC Blocks, Panels and Dry wall System

Drywalls will be the most expensive out of the three options, and overall if we talk about the construction, AAC panels and AAC blocks will be at par. AAC panels and AAC blocks will be at par, considering there will not be any requirement of plaster for internal walls, no coping required, and saving in labor cost.

How to reduce the construction cost in conventional method and what are all additional amenities required for budgeted apartments?

Construction cost is mainly bifurcated into two parts: Material Cost and Labour Cost. The best option for budget homes is to reduce the labor cost by utilizing techniques that can reduce the project timelines. Trying to reduce the material cost might have an implication on the quality.

What is the life of AAC Products?

As per a few reports and studies, AAC blocks have an estimated life of almost 100 years. So, for residential houses, which are designed for a span of 50 to 80 years, AAC blocks will last up to the designed life of the structure.

As a flat purchaser, what should we prefer, external walls with red bricks or the one with AAC Panels?

Opting for AAC Panels is environmentally advantageous and aids in decreasing energy consumption by lowering HVAC loads, thanks to their lower U-Value compared to red clay bricks.

What is lead period of procurement of Panels?

It typically takes around 20 days from the design approval or approval of the panel layout.

How does AAC Wall Panels help in saving space?

AAC Wall Panels, equipped with superior water barrier, insulation, fire resistance, and sound-resistant properties, provide a more efficient alternative by enabling the use of thinner walls (75 mm or 90 mm) rather than a 100 mm wall. Consequently, this leads to a space saving of at least 2%.

Are AAC Wall Panels Reliable?

The system and product exhibit a high level of reliability and are widely utilized on a global scale, with common applications in countries such as Australia, the USA, Germany, Netherlands, China, Thailand, Singapore, UAE, and more.

Is it environment friendly. Does it help for ECBC or Green Building Certifications?

AAC boasts lower embodied energy than Red Bricks. Additionally, AAC is a material that can provide the necessary U-value for ECBC or any Green Building Certification. It is non-toxic, contains recycled content, and has a low U-Value, making it eligible for earning credits toward green certification.

What is the maximum height and thickness of these AAC wall panels?

The maximum height varies depending on the thickness. For a 75mm wall, the maximum height is 3 meters; for a 100mm wall, it is 4 meters, and for a thickness of 150mm and above, the maximum height extends to 6 meters.

Is it possible to customize the panel size?

Certainly, the panel size can be customized based on the project's quantity requirements. However, it's important to note that the width (600 mm) remains constant.

What is the maximum allowable bend in walls, and how is warping prevented?

The panels are reinforced, offering enhanced flexural strength to the product. This reinforcement ensures that even at larger heights, there are no issues with deflection, warping, or buckling effects.

What constitutes the base material of AAC Wall Panel?

The base materials of AAC Wall Panels include Sand, Cement, Aeration Agent, Lime, Gypsum, and Polymers.

Which type of joining mortar is most suitable for AAC Wall Panels and how should it be applied?

There is a specific thin-bed mortar designed for securing AAC materials, such as Magic bond from Magicrete, which is recommended due to its high cement content. It is advisable to use a 3 mm thin-bed mortar applied with a specialized notched trowel for precise results.

Can AAC Panels be utilized alongside sturdier materials like Solid/Hollow blocks or RCC Walls or Precast Panels?

Yes, they can. Since these materials have distinct characteristics and will experience different rates of expansion and contraction, it is recommended to leave a 10 mm gap at all T and L joints. This gap should be filled with PU Foam capable of absorbing vibration deflection.

Are AAC Panels equipped with pre-cut openings for doors and windows? If not, is it permissible to create them, and does this process impact the structural integrity?

While it is feasible, careful wall planning is necessary in advance. The alternative involves performing necessary cut-outs, possibly at the production plant before shipping to the site. However, a preferable approach is to cut and install windows on-site. After panel installation, it is advisable to wait 2-3 days to allow the thin-bed mortar between panels to achieve maximum strength before pursuing any additional cutting. This will not compromise the structural strength.

In a project where there is an approximate height variation of +/- 20 mm due to beam deflection or RCC undulation, can standard panels be employed?

Yes, the panels are typically 15-20 mm shorter than the wall height. The vacant space is filled with Backer Rod and PU Foam. For walls exceeding 6 meters in length, it is essential to incorporate an expansion joint or column stiffener to address deflection effectively.

What is the standard allowance for wastage when dealing with these panels?

The normal wastage considered is 5%. Nevertheless, any excess cut panels, up to the maximum wastage, can be effectively utilized for constructing lintels or other smaller sections.

How can joints be concealed effectively?

One method involves filling the joints with slurry and subsequently rubbing them. Alternatively, a fiber mesh tape is applied over the joints, followed by the application of polymer-based putty. Before this process, sandpaper is used to eliminate excess thin-bed mortar.

How is the gap between wall and ceiling taken care of?

Addressing the gap between the wall and ceiling involves the use of a 10x10 mm Backer Rod along with PU foam. This not only absorbs vibrations but also mitigates any deflection present.

Can the panels be subjected to cutting, and will it impact their strength?

Yes, it is possible to cut the panels using appropriate tools and following basic guidelines. The strength of the panels will not be compromised in the process.

How is the process of installing lintels carried out?

Lintels can be fabricated using the same reinforced panels. To ensure proper support, it is essential to create suitable bearing by cutting the wall panels upon which the lintel will be positioned. Subsequently, L clamps can be affixed beneath the lintels for added stability.

If the wall's height is 6 meters, is a single panel sufficient?

For a 100 mm wall, two 3-meter panels can be installed one above the other with coping in between. Alternatively, the panels can be installed in a staggered manner.

Can water penetrate AAC walls in the rainy season?

In AAC, water does not pass through due to discontinuous air pores. While in red clay brick, due to high capillary suction, water penetrates through it.

How are two panels connected, and what is the level of safety in these connections?

The connection between the two panels is highly secure. The top and bottom joints are secured using GI L-clamps, and between the two panels, Magicrete thin-bed mortar is applied. Additionally, the panels are designed with a tongue and groove feature to ensure proper alignment.

Is it feasible to pursue chasing and nailing?

Chasing and nailing can be executed similarly to the process used with AAC Blocks. For nailing in particular, a special AAC Fastener must be utilized.

How long can we construct an AAC Wall?

We suggest you give a control joint after every three-meter interval, and the joint has to be filled with resilient material or backer rod and sealed with caulking.

Is plaster necessary for a smooth finish after chiselling, or is there a way to achieve a good finish without resorting to plaster?

Following the completion of MEP work, an alternative approach involves applying thin-bed mortar and securing fibre mesh over it. This can then be concealed with two coats of coarse putty, followed by a layer of thin putty, eliminating the need for traditional plaster while maintaining a satisfactory finish.

Can a 75mm depth be chased into a 100mm wall for the installation of a DB Junction Box?

Yes, it is feasible, and it will not compromise the overall strength of the wall.

How are electrical switches installed in the panel?

The process closely mirrors the approach used for AAC Blocks. A concrete cover of at least 40 mm is provided, allowing for straightforward chasing during installation.

How can cracks be managed when beams deflect in the context of AAC Wall Panels?

A minimum gap of 20 mm is introduced between the beam and the panel, and this space is filled with a backer rod and PU foam. This setup allows for the accommodation of deflection and vibration, minimizing the risk of cracks.

Could you provide more details on the soundproof properties of AAC panels?

AAC panels, being a porous concrete material, offer a sound insulation value of approximately 40 dB for a 100 mm wall.

What is the product's density and fire resistance?

Density: 550 to 650 kg/m2

Fire Resistance: Up to 4 hours for a 100 mm thickness.

How do these structures fare against wind loads?

They have been demonstrated to withstand wind loads equivalent to category 5 tropical storms. The wall panels can endure wind loads of up to 180 kg/m2. Aside from wind loads, AAC Wall Panels are not subject to any other dynamic loads.

Is the product suitable for use in areas prone to high seismic activity?

The impact of earthquake forces is directly correlated with the weight of the building. Given that AAC Panels are lightweight, they contribute to enhanced stability in the structure of buildings. AAC products, by reducing the dead load on buildings, specifically the weight of the building, ultimately improve safety against earthquakes. The critical connections primarily involve thin-bed mortar and L-clamps. Once the thin-bed mortar attains strength, it also provides earthquake resistance.

Is there a risk of seepage in AAC Wall Panels?

The AAC Wall Panel's cellular structures consist of numerous independent, closed, tiny, and dispersed air spaces. This distinctive composition effectively prevents water penetration. For applications in external surfaces and wet areas, it is advisable to apply a plaster.

Is it possible to utilize AAC Wall panels for external walls?

Certainly, AAC Wall panels can be employed for external walls. However, it is advisable to apply plaster or a waterproof coating to prevent seepage or leakage. Additionally, there will be significantly fewer joints compared to conventional blockwork.

What is the weight-bearing capacity of AAC Panels, and can cabinet or kitchen units be installed on the wall panels?

Certainly, this is achievable. It's essential to utilize anchors specifically designed for AAC to ensure proper installation. The holding capacity is superior to AAC blocks due to reinforcement. However, it's crucial to use AAC fasteners with the necessary capacity. With four AAC Fasteners, it can easily support up to 200 kgs.

Is skilled labor necessary for installing these panels, and what is the installation time frame?

AAC Wall Panels can be easily installed by semi-skilled laborers. A team of 3-4 individuals can complete the installation of 30-40 sq. meters of wall in a day.

What is the maximum weight of these panels, and do we need specialized equipment for handling, or can it be done manually?

The weight varies with the panel thickness; for a 100 mm panel, the approximate weight is 80 kg/m2. An efficient method involves lifting the entire pallet, containing 6-7 panels, using a tower crane and placing it on platforms on each floor. Alternatively, the pallet can be transported to higher floors using a P&M lift.