Year: 2024

Avoid AAC wall cracks with the below read. As a supplier of Renacon AAC blocks for areas in & around Chennai and Conecc AAC Blocks for Bengaluru, a few of our customers have raised concerns of AAC blocks cracks. While trying to understand the issue, i had found a great post on https://www.ecorex.in/blogtopic/how-to-avoid-cracking-in-walls-with-aac-blocks-ecorex. The content below is a cut and paste of their article without any editing on our part. Hope it helps!

How To Avoid Cracking in Walls Built with AAC Blocks 

The lightweight of AAC Blocks is undoubtedly a boon for the construction industry. This feature is a blessing as it comes with numerous benefits while it also poses challenges related to the shrinkage of the masonry and movement in the structural members of the building.

After using bricks and stones for masonry construction for many years, came concrete blocks, hollow blocks, and fly ash bricks. AAC blocks have now carved their niche in the history of masonry construction.

All masonry ingredients require a particular skill so do AAC blocks. Notably, there are a few small differences between brick masonry and AAC block masonry.

Load Bearing And Non-Load Bearing Walls With AAC Blocks

The following are provisions for the construction of load bearing and non-load bearing walls with AAC blocks by IS 6041:1985 for AAC Block Masonry Construction:

• Load Bearing Walls must have an Internal wall thickness of a minimum of 150mm and an External Wall thickness of a minimum of 200mm.
• Whereas Internal wall thickness for Non-Load Bearing Walls must be a minimum of 100mm and External Wall thickness of a minimum of 150mm.

How To Avoid Cracking in Walls

The ingredients added to the AAC blocks cause the volume change and aeration in them. The volume change, in any type of concrete, is one of the most detrimental properties. One of the principal products of hydration in the cement paste is the C-S-H gel. This saturated cement paste, when exposed to ambient humidity which is below saturation, loses its dimensional stability. Also, aerated concrete retains more than 20% moisture at the end of the autoclaving cycle. Massive volume change in aerated concrete occurs due to the loss of all this moisture from the blocks. Particularly in the AAC block masonry, unsightly cracks in the masonry wall occur due to volume change. This volume change is a result of shrinkage in the wall. This shrinkage can be drying shrinkage or autogenous shrinkage.

Drying Shrinkage causes Wall Cracks

When the drying shrinkage is restrained, it creates tensile stress. The shrinkage gets restrained due to the end columns once the blocks are built in the masonry. This creates a high amount of tensile stress in the wall resulting in vertical cracks.

It is, however, difficult to make a masonry wall that does not shrink. But practicing engineers can ensure that there is minimal shrinkage. The shrinkage mainly depends on the moisture movement from the AAC blocks. AAC blocks are manufactured at a water-to-cementitious ratio of more than 1.0.

Following is an example that shows chemical water demand per cubic meter of aerated concrete:

The following figures are for uncut volume

Cement content = 101 kg/m3

Lime = 36 kg/m3

Gypsum = 6 kg/m3

Fly Ash participating in Pozzolanic reaction = 35% of the above = 50 kg/m3

Hence total cementitious solids = 193 kg/m3

Water content = 255 kg/m3

Hence w/c = 255/193 = 1.32

Following are the hydration phases of cement that denote the amount of capillary water remaining even after 100% hydration of cement on auto craving for a maximum w/c of 0.95. This water remains residual and gets trapped in the cement paste. A part of this trapped water contributes to the shrinkage of the blocks.

The significantly high pressure of about 12 bars with a 195°C steam drives the steam inside the millions of microscopic pores of the block concrete. A small amount of steam remains trapped inside the pores of the blocks when they are cooled off.

Hence as a combination of water trapped in the cement paste and the moisture left by the steam, the typical free moisture content in a block is to the tune of 25% by weight. Over the next 48 hours, the majority of this free moisture is released from the AAC blocks, the blocks begin to dry which results in major shrinkage within the first 48 hours of the autoclaving. This shrinkage results in wall cracks.

Hence, the precautions that need to be taken while building an AAC block wall so that it remains free of cracks are mentioned below. The IS code 6041:1985 also advises us on ways to avoid cracks in the wall as below: 

The alterations in length, curvature, or orientation of the structural members enclosing a wall or partition due to load settlement, thermal expansion or changes in moisture content cause the Structural Movements Cracks. In the case of framed structures, the erection of partitions and panel walls shall be delayed wherever possible until the frame has been taken up. This also affects structural deformities.

Ceiling deflection and movement – When a load falls on a ceiling above a partition wall it may deflect after its erection or through thermal or other movements.

Control of Wall Movement Accompanying Temperature and Moisture Changes – Tensile stresses which develop when wall movements accompanying temperature and moisture change and are restrained by other elements of the building result in cracking in concrete masonry walls.

Conclusion

The shrinkage and wall cracks in the AAC block masonry construction can be minimized and even avoided by careful application of the blocks and keeping in mind the temperature, load bearing, and other significant details.

[ all credits to the above article go to how to avoid cracking in walls with AAC blocks ecorex | Ecorex ]

We welcome you to visit our complete products at Products. Part of the problem solving in avoiding wall cracks is procuring good quality blocks. We recommend purchasing blocks from us as we do a strong quality control before dispatch and also provide strong customer care in construction

Let us explore how to choose & source the best brick for long lasting elevation walls.

Choosing and then sourcing a good quality brick for use in elevation walls has become a difficult task as of today. Why?

We are Premier Integrators, who are manufacturers & suppliers of wire cut bricks which we de-air, extrude and fire at our kilns in Mangalore and near Shaklespur, Karnataka.

Choosing the best brick for long lasting walls involves considering various decisions on design and structural requirements.

By following the above points, you can select the best bricks for your elevation walls that not only enhance the visual appeal but also ensure durability and sustainability.

Kindly consider our Products listed in https://premierintergrators.com/product-category/bricks/ or you could also visit our sister concern for other exclusive construction designer products – https://premierbricks.in

All the best!

What are exposed bricks?

Exposed bricks are brick walls left uncovered by plaster, paint, or other finishes. They showcase the natural beauty of bricks and can be used both indoors and outdoors.

Why choose exposed bricks?

• Aesthetic Appeal: Exposed bricks add a unique charm and texture to any space.
• Durability: Bricks are known for their strength and longevity.
• Thermal Insulation: They help keep your home warm in winter and cool in summer.
• Sound Insulation: Bricks reduce noise pollution.
• Low Maintenance: They require minimal upkeep.

Types of exposed bricks:

• Dust Pressed Bricks: Uniform shape.
• Box Bricks: Irregular shape.
• Curve Bricks: For creating curved walls or arches.
• Designed Bricks: Custom-made to your specifications.

Where to use exposed bricks:

• Interior: Feature walls, fireplaces, commercial spaces.
• Exterior: Building facades, garden walls, entrance features.

Premier Bricks:

Premier Bricks offers high-quality, durable, and aesthetically pleasing bricks for construction. Terracotta is a popular choice for its natural qualities.

Conclusion:

Our Wire-cut extruded bricks used for elevation walls that are non-plastered are a versatile and stylish option for both interior and exterior applications. They add character, durability, and insulation to your home. Consider using our bricks for a unique and timeless look.

FAQs:

• Why choose Premier Bricks? Premier Bricks offers high-quality, durable, and aesthetically appealing bricks.
• Benefits of non-plastered brick walls? Aesthetic appeal, thermal and sound insulation, low maintenance.
• Can elevation bricks be used indoors and outdoors? Yes, they can be used in various applications.
• Best types of bricks for exposed walls? Expelled, stock, curve, and designed bricks.

Premier Bricks: A leading manufacturer of high-quality bricks, including terracotta, for construction.

Visit our product page at https://premierintergrators.com/products or for a different range of elevation or premier products visit our sister concern https://premierbricks.in

Create a Striking Facade with Red Exposed Brick Cladding

Elevate Your Home with 12x4x2 Inch Cladding Bricks: A Comprehensive Guide

Introduction

Our exposed red brick claddings are the perfect solution when you are you looking to add a touch of rustic charm and timeless elegance to your home’s exterior! These versatile and durable bricks can be used to create stunning facades, accent walls, and even landscaping features.

Benefits of exposed red brick Cladding

• Durability: Cladding bricks are built to last, resisting weather, wear, and tear.
• Versatility: They can be used in various architectural styles, from traditional to modern.
• Low Maintenance: Once installed, cladding bricks require minimal upkeep.
• Aesthetic Appeal: Their natural texture and color can enhance the overall appearance of your home.

Choosing the Right Cladding Bricks

When selecting cladding bricks, consider the following factors:

• Material: Our exposed red brick Cladding are made with clay and turned into terracotta when fired.
• Color and Texture: Choose bricks that complement your home’s style.
• Installation: Ensure proper installation for optimal durability and appearance.

Popular Applications

• Exterior Facades: Create a striking facade for your home.
• Accent Walls: Add a focal point to your interior.
• Landscaping: Use cladding bricks for garden paths or retaining walls.

Inspiration

Come back again and we shall share a picture of a wall done with our exposed red brick cladding here.

Conclusion

12x4x2 inch cladding bricks offer a beautiful and practical way to enhance your home’s exterior. By carefully selecting the right materials and installation method, you can create a stunning and long-lasting feature.

Would you like to know more about specific cladding brick manufacturers in Chennai or get a quote for your project? Visit our webpage https://premierintergrators.com/products

For other products you can also visit us at https://premierbricks.in

Using exposed bricks in elevation walls can add a lot of character and charm to your building.

Here are some tips to help you make the most of in the construction of your non-plastered exposed brick wall with elevation wire cut clay bricks from Premier Integrators:

1. Choose the Right wire-cut Clay Bricks

• Quality Matters: Opt for high-quality bricks that are durable and weather-resistant.
• Color and Texture: Select bricks that complement the overall aesthetic of your building. Consider the color, texture, and finish.
• Brick Size: There are different brick sizes and types, which need to take into account based on the wall design.

2. Design Considerations for Exposed bricks

• Pattern and Layout: Experiment with different brick patterns like running bond, herringbone, or basket weave to create visual interest.
• Mix and Match: Combine exposed bricks with other materials like wood, glass, or metal for a modern look.

3. Installation Tips for Elevation Designs

• Proper Mortar: Use the right type of mortar to ensure the bricks are securely in place and can withstand environmental conditions. we recommend ready-mix bags compared to the conventional cement mix. You can also try our product http://premierintergrators.com/product-category/bag/
• Professional Help: Consider hiring a professional mason to ensure the bricks are laid correctly and evenly.

4. Exposed bricks Maintenance

• Regular Cleaning: Keep the bricks clean by washing them periodically with a mild detergent and water.
• Sealing: Apply a sealant to protect the bricks from moisture and stains. This will also help in maintaining their appearance over time.

5. Enhancing Aesthetics

• Lighting: Use strategic lighting to highlight the texture and color of the bricks, especially at night.
• Greenery: Add plants or climbing vines to soften the look and add a natural element to the elevation.

6. Weather Protect your exposed bricks

• Overhangs and Awnings: Install overhangs or awnings to protect the brick wall from direct rain and harsh sunlight.
• Drainage: Ensure proper drainage around the brick wall to prevent water accumulation and damage.

By following these tips, you can create stunning elevation walls that not only look great but also stand the test of time. If you have any more questions or need further assistance, feel free to ask! call me directly on tel: +919790927004 😊

Elevation Bricks: Where Aesthetics Meet Durability

Elevation Bricks also known as exposed bricks. People use exposed bricks in walls to create a façade or design element After constructing the brick structure, the brick wall does not need plastering. In other words, we do not need to finish it with cement mortar.

Special Clay wire-cut full bricks, different types of rock, wood panels & also engineered construction material are used to design elevation walls.

We at Premier Integrators, manufacture wire-cut bricks which are to be used for elevation or non-plastering brick walls. Our bricks are specially made to give a life-long appeal to your construction projects.

Now let’s explore the aesthetic uses of elevation bricks made and supplied by Premier Integrators and their impact on contemporary architecture:

Elevation clay wire-cut bricks are versatile and enduring. They also blend technical precision with artistic expression. Their shapes, textures & colors vary based on clay type and manufacturing process. Architects use them to create dynamic facades and structures, experimenting with placement, orientation, and material textures. 

if you are interested in constructing a non-plastered exposed brick wall with elevation clay bricks click this link to check our brick range. https://premierintergrators.com/product-category/bricks/

As a manufacturer and distributor of clay products for construction, our Sales team has mostly been asked us what is it that makes our Elevation bricks made out of clay different from the normal use plastering wire-cut bricks

THE MATERIAL

We source clay in and around the of Dakshin Kananda as for their high plasticity and its richness in oxides.

This quality clay is mostly found in the hill sections of the western ghats.  The Kerala administration has banned the mining of clay and other rock products due to the erosion of the hills resulting in landslides.  Hence, only the northern segment of the western ghats are presently the catchment zones.

This clay is seasoned for almost one year

This oxides in the clay when fired at the correct temperature results in the life time lasting red colour of the brick.

THE PROCESS

Exposed bricks (also called non-plastering elevation bricks) are manufactured using modern method.

The seasoned clay is first loaded into a crusher which removes organic plan and rock.

Water is added to this and mixed into a uniform consistent mixture.

This is then passed through a passage which sucks out the air from the clay, making it very dense.  This is called as ‘De-airing’

Relatively low moisture clay is then extruded through a die mouth piece to form a column.

The extruded column is then cut using hydraulic wire cut machine to give uniform sizes and sharp edges and straight lines.

They are now placed on racks and left in the drying chamber.  This might take around 21 days plus depending on the climate outside.

Finally, the loaded into our Offman continuous Kiln and fired at around 800 degrees centigrade.

 On completion of firing these are removed from the kiln, sorted based on their final finish

Our non-plastering elevation bricks are ready for shipping.

These are completely exposed extruded and eco-friendly.

No plastering is required and are used for beautification.

Low maintenance cost however little expensive than regular clay bricks.

We are manufacturing exposed solid extruded clay bricks in standard sizes and have variants like Copper Red and Red Orange.

Visit our products page https://premierintergrators.com/product-category/bricks/ for our bricks range

Solid wire cut bricks or Perforated wire cut bricks?

We have always had an inclination towards solid wire cut brick as against perforated or holey bricks for use in non-plastered brick walls.

In the realm of masonry and construction, wire-cut bricks are a popular choice for creating durable and aesthetically pleasing elevation walls. The choice between solid and perforated wirecut bricks can significantly influence both the structural integrity and visual appeal of the wall.

Each type of brick offers distinct advantages and disadvantages, making it important to understand their respective characteristics.

Solid Wirecut Bricks

Characteristics:

• Construction: Solid wire-cut bricks are manufactured by cutting clay with a wire into the desired shape and then firing them at high temperatures. This process results in a dense, robust brick.
• Density and Strength: The absence of perforations makes solid wirecut bricks more dense and structurally stronger. This added strength makes them suitable for load-bearing walls.
• Durability: Their solid composition provides excellent resistance to environmental stressors, including weather extremes, making them highly durable.
• Insulation: Solid bricks offer better thermal mass, which can help in regulating indoor temperatures by absorbing and slowly releasing heat. However, they are less effective in insulation compared to perforated bricks.

Applications:

• Aesthetic Appeal: Solid wirecut bricks provide a uniform and clean appearance, which can be aesthetically pleasing for elevation walls where a sleek and classic look is desired.
• Structural Requirements: These bricks are ideal for areas where high structural strength is needed, such as load-bearing walls and high-rise buildings.

Perforated Bricks (Click here to check out our Perforated Brick)

Characteristics:

• Construction: Perforated wire-cut bricks are similar in manufacturing process to solid bricks but include one or more holes or cavities. These perforations are designed to reduce the weight of the bricks and improve their insulation properties.
• Weight and Insulation: The perforations make these bricks lighter, which can reduce the load on building foundations. Additionally, they offer better thermal and acoustic insulation due to the air pockets within the brick.
• Moisture Resistance: While perforated bricks can be prone to water ingress through the cavities, they are often treated or designed to minimize moisture absorption and ensure durability.

Applications:

• Energy Efficiency: The improved insulation properties of perforated bricks make them suitable for energy-efficient building designs. They help in maintaining stable indoor temperatures, which can reduce heating and cooling costs.
• Lightweight Construction: Their reduced weight makes them easier to handle and transport, which can be advantageous in construction projects where weight considerations are critical.

Comparative Summary for elevation bricks

1. Structural Strength:
   • Solid Wirecut Bricks: Higher strength and durability; ideal for load-bearing applications.
   • Perforated Wirecut Bricks: Lower strength due to perforations; better suited for non-load-bearing applications or where lightweight construction is preferred.
2. Thermal Insulation:
   • Solid Wirecut Bricks: Good thermal mass but less effective in insulation.
   • Perforated Wirecut Bricks: Superior insulation properties due to air pockets, contributing to energy efficiency.
3. Aesthetic Considerations:
   • Solid Wirecut Bricks: Offers a more uniform and traditional appearance.
   • Perforated Wirecut Bricks: Can have a more textured appearance due to the perforations but might still achieve an attractive finish with the right design.
4. Cost and Handling:
   • Solid Wirecut Bricks: Generally more expensive and heavier, impacting transportation and handling costs.
   • Perforated Wirecut Bricks: Lighter and potentially less expensive, making them easier to handle and transport.

Conclusion

Both solid and perforated wire-cut bricks offer valuable benefits for elevation walls, and the choice largely depends on the specific needs of your project.

If structural strength and durability are paramount, solid wire-cut bricks are likely the better option. Conversely, if energy efficiency & reduced weight are more critical, perforated wire-cut bricks might be preferable.

Evaluating these factors in the context of your project requirements will help ensure you select the best brick type for your elevation walls.