WELCOME TO GREENWAY BUILDING MATERIALS INDIA PRIVATE LTD.

NUCON BLOCKS/BRICKS

ABOUT US Greenway Building Materials India Private Ltd. is solely

dedicated to the development of environmentally friendly, cost effective and energy efficient materials for new

generation buildings in India.

Led by highly educated and talented group of NRI individuals, the company plans to introduce several

innovate building materials in the Indian market to address the fast changing needs of the industry.

Our mission is to develop products that will help the India’s growth to keep the country in par with the other developed

nations while keeping in pace with industry. Our core values are social and environmental responsibility.

NUCON BLOCK

•NUCON BLOCK is an innovative product from Greenway Building Materials India Pvt. Ltd. We are located at Paritala village near VIJAYAWADA on National Highway .

•NUCON BLOCKs are ECO Friendly and is proved to be a cost effective solution by providing around 40% savings at different levels of construction.

•These blocks are manufactured from common and abundant natural raw materials producing finished product twice in volume of the raw materials used, making it extremely resource-efficient and eco-friendly.

•We make sure that we produce the high quality blocks using the state of the art production facility.

•Our automated machinery and testing process ensures high quality for each and every block that we produce.

What is AAC BLOCKSWhat is AAC BLOCKS

Autoclaved Aerated Concrete (AAC), also known as autoclaved cellular concrete (ACC), is a lightweight concrete building material invented in the mid-1920’s that simultaneously provides structure, insulation, and fire- and mold-resistance.

AAC products include blocks, wall panels, floor and roof panels, cladding (facade) panels and lintels

Composition Of AAC Blocks• AAC is produced using no aggregated larger

than sand. Quartz sand, calcined gypsum, lime (mineral) and/or cement and water are

used as a binding agent. Aluminum powder is used at a rate of 0.05%–0.08% by volume (depending on the pre-specified density).

In Our Company we are used, Fly Ash generated from thermal power plants and having silica

content is used as an aggregate. Cement 18-20%

Fly Ash 70% Aluminum 0.05 -0.08%

Lime 6% Gypsum 2 – 3%

Vegetable Oil 0.58-0.59%

AdvantagesImproved thermal efficiency reduces the heating and cooling load

in buildings.

Workability allows accurate cutting, which minimizes the generation of solid waste during use.

Durability and dimensional stability. A cement-based material, AAC resists water, rot, mold, mildew, and insects. Units are precisely shaped and conform to tight tolerances.

Applications Of AAC Blocks

High Rise Buildings

Cold Application Storages

Hospitals

Malls

Multiplex

Where Air-conditioned Offices are required

Geometry and Composition Product Physical Properties Thickness Precision in Size Compressive Strength Dry Strength Fire Resistance Sound Insulation Index Thermal Conductivity Drying Shrinkage

Measurements 100mm-225 mm +/-1 mm 3.5- 5.5 N/mm2 (As per IS 2185 Part -3 550-650 Kg /m3 (Oven Dry) 2 to 6 hrs ( Depending upon Thickness) 450 dB (For 200mm Thickness Wall) 0.16 w/mK 0.04%

Size in mm ( Wall Thickness)

No of Blocks per Cubic Meter

Masonry work in Sq Ft per Cubic Meter Blocks (respective Wall Thickness)

Weight of each one Block in (Kg)

600 x200 x 100 mm (4”)83.33 111.Sq.Ft 8.40

600 x200 x 150 mm (6”)55.56 74 Sq.Ft 12.60

600 x200 x 200 mm (8”)41.67 56 Sq.Ft 16.80

600 x200 x 225mm (9”)37.03 49 Sq Ft 18.90

Criterion AAC Blocks Clay Bricks Benefits of AAC BlocksSoil Consumption

Major use of Fly ash eliminates the use of top soil in AAC Block formation

Main ingredient in the composition is top soil resulting maximum use of top soil

Use of Fly Ash, recycling material come out of waste from thermal power plant and zero consumption of top soil make the product eco-concious and green for society

Fuel Consumption

1 Sq Ft AAC Block take approx 1 kg coal to produce itself

1 Sq Ft Clay Brick take approx 8 kg coal to produce itself

Use of Fly Ash, recycling material come out of waste from thermal power plant and zero consumption of top soil make the product eco-concious and green for society 

Co2 Consumption

1 Sq Ft of AAC block Production emits nearly 2kg of Co2

1 Sq Ft of Clay Brick production emits nearly 18kgs of Co2.

Lower Carbon Footprints leads to the clean and green environment

Production Technology

Full Automated Line Production

Inefficient worker dependent production

Automated line production leads to perfection in material quality and performance

Weight Dry Density load 550-650 kg/Cu Mtr

Dry density load 1800kg/Cu Mtr

Nearly 3 times lighter than the bricks leads to lighter beam-column structure of the building which can make noticeable cost saving in the project

Bench Marking

Bench Marking Continued…..Strength Compressive

strength of 3.5-5.5 N/mm2

Compressive strength of Clay 2.5 – 3 N/mm2

Higher strength material gives the strengthen structure with considerable low weight

Size Variation

+/- 1.0 mm +/- 5 mm Machine cut of the product gives perfect size and finished shape leads to a low cost masonry for the structure

Wastage during work

Strong material and perfect size and shape leads to near about zero wastage during work

Uneven shape, size and brittleness, it leads close to 5 % wastage during work

Cost effective due to low wastage

Overall project cost

Cut down the cost by low masonry due to perfect finished size and shape

It doesn’t contribute to cost cutting due to tedious masonry process with 2-3 layers to get the finish zero level

Contribution of less masonry use and reduced quantity of steel and concrete due to light structure, significant cost effectiveness can be noticed in the overall project cost.

Cost AnalysisDescription Accurate AAC

BlocksClay Bricks

Size 1 No of Block of size 600 x 200 x 100 mm

7.2 Nos Bricks of size 225 x 100 x 75mm

Area 1.33 Sq Ft. 1.33 Sq Ft.Material Cost Rs. 34.20 /Pc (Rs.25.71 Per Sq.Ft) Rs. 35.00 / 7Pcs. (Rs. 26.32 Per Sq.Ft)Mortar Cost Nil for Single Block – No Joints Rs. 2.50 For Filling Gap Between 7

Brick.External Plaster Rs. 24.00 @ 15mm Thickness (Rs.

15.00 Per Sq.Ft).Rs. 40.00 (First Coat of 15mm @ Rs. 15.00 & 2nd Coat of 10mm @ Rs. 10.00) (Rs. 25.00 Per Sq.Ft)

Internal Plaster Rs. 14.00 (POP @ Rs. 8.00 Per Sq.Ft) Rs. 24.00 (Cement Plaster 15mm) (Rs. 15.00 Per Sq.Ft)

Wastage 0.70 Paisa ( At standard 2% wastage on site handling and transportation)

Rs. 5.25 ( At standard 15% wastage on site handling and transportation)

Repaint Finish Internal Side NIL Rs. 2.00 Per Sq.FtTotal Cost per Sq.Ft Rs. 49.41 Rs. 70.82Savings using Blocks (B) – (A)

Rs. 21.41 Per Sq.Ft 0.00

Steel Savings Per Sq.Ft Rs. 24.00 Per Sq.Ft (As 500 Gms of steel can be saved per Sq.Ft due to light structure).

NIL

Total Savings Per Sq.Ft Using AAC Blocks (C+D)

Rs. 45.41 Per Sq.Ft Nil

Miscellaneous SavingsTime saving ( Faster

Construction)50% saving in labor

work due to Big surface area and size.

NIL

Water savings No curing required (Only joints curing required.

(Upto 60% water savings in Water labor & Costing).

NIL(Curing Required & Joints Curing Also

Required).

Electricity bill savings post construction

30% Air Conditioning bill savings. Due to high thermal insulation.

Nil ( Low Thermal Insulations)

Do’s and Don’tSl.No Do’s Sl.no Don’t

1 Surface of AAC blocks to be joined with mortar is to be wetted with brush / cotton waste or with the help of a tray filled with 25mm water

1 Don’t soak AAC Blocks in water

2 Use only compatible mortar 1:6 or 1:1:6 mortar (1 cement : 1 fly ash : 6 sand)

2 Don’t use rich mortars

3 AAC Masonry should be as per IS Code 6041 (1985) and IS Code 1905 ( 1987)

3 The mortar should not be spread much ahead of the actual laying of the blocks.

4 Chases of services in AAC masonry should be as per IS Code 1905 ( 1987)

4 Don’t deviate from the norms of chase cutting specified in the code IS 1905 ( 1987)

5 Use electro mechanical rotary tool for chase cutting

5 Don’t use chisel and hammer for chase cutting

6 Chases should be filled along with plastering and a layer of chicken mesh is to be embedded in the plaster over the width of the chase with proper overlap

6 Don’t fill the chase upto the top surface of the masonry to have a key while plastering

AAC Masonry ( Some Useful Tips) The mortar shall not be spread so much ahead of the actual laying of the units that it

tends to stiffen and lose its plasticity thereby resulting in poor bond.

Consistency as per requirement of site should be maintained at the point of laying over bed.

Laying of AAC Blocks masonry shall be in accordance with the recommendations of IS 6041 of 1985 and IS 1905 of 1987. The joint thickness shall be 10mm.

The laying of block may be started either at the corners first or it may be started from one end and proceed to the other direction.

Lay 10 mm thick cement mortar uniformly over bed. Wet the blocks on all sides by using a tray filled with 20/25 mm water and place them one by one and press it firmly to have proper bond. Fill the joints between blocks.

The first course of cellular blocks masonry shall be laid with great care, making sure that its properly aligned, leveled and plumbed, as this may assist the mason in laying succeeding courses to obtain a straight and truly vertical wall.

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