The CLC blocks manufacturing industry has become an integral part of the expansive global construction market. Technological advancements in manufacturing techniques have brought about several upgrades. This has ensured that the raw materials used today are immensely strong and extremely stable, as well as being eco-friendly too.
Using CLC products is seen as the sustainable route for construction projects. If you are a manufacturer of CLC products, then this article will be helpful. Below, you will learn everything needed to know about CLC block, such as the manufacturing process, differences with AAC bricks and applications of CLC products.
Table of Contents
What are CLC Blocks?
Cellular Lightweight Concrete (CLC) bricks are also called CLC blocks. These are a type of construction material that have become increasingly popular in India and abroad in the past few years.
CLC products are normally made by mixing cement, sand, water, fly ash, a special foaming agent and CLC block hardener as additive. The foaming agent is necessary to reduce the mass and weight of the CLC products while the CLC brick hardener helps to shorten setting time. This is what gives CLC products the inherent insulation properties.
What are the Applications of CLC Blocks?
CLC bricks and blocks are one of the most versatile construction materials in use today. Here are the common applications and uses of CLC blocks in construction –
- Low-cost housing
- Air-conditioned buildings
- Eco-friendly construction
- Acoustic construction
- Waterproofing
- Roof insulation
- High-rise apartment buildings
- Pre-cast exterior walls
- Adding floors to existing structures
- Sub-terrain (underground) construction
The cost of producing CLC blocks in India is lower as compared to conventional bricks. The exact manufacturing cost of CLC products depends on their size, shape and average cost of raw materials.
To ensure economy in production, it is recommended to buy high quality CLC block hardener from expert manufacturers, such as Sakshi Chem Sciences Pvt Ltd.
What is the Difference Between CLC Block and AAC Brick?
Despite their popularity and extensive use, there are many people who believe CLC block and AAC brick are one and the same. However, the two are extremely different in every aspect.
Below is the list of differences between CLC blocks and AAC bricks –
Raw Materials
CLC blocks are made using a slurry of cement, sand, fly ash, water and pre-formed stable foam.
AAC bricks are made by mixing cement, fly ash, gypsum, lime, aluminum powder and water.
Scalability
CLC blocks have shorter curing time and take less storage space, which makes the production process faster and more convenient.
AAC bricks require installing different autoclaves and moulds to increase production volume, which is quite expensive.
Production Capacity
CLC block manufacturers have a higher production capacity as compared to conventional brick manufacturing.
AAC bricks manufacturing process have a slightly lower production capacity as compared to CLC block manufacturing.
Compressive Strength
CLC blocks have an average compressive strength of 3 N/mm². This is slightly lower than AAC bricks, but CLC products are immensely lightweight in comparison.
AAC bricks have an average compressive strength of 3.5 – 7 N/mm² but are considerably heavier as compared to CLC products of the same size.
Product quality
CLC blocks can have a highly consistent quality if made by using reliable CLC block hardener.
AAC bricks have a more consistent quality as compared to conventional bricks.
What is the Manufacturing Process of CLC Blocks?
Below is the step-by-step process of manufacturing CLC products using high-quality CLC block hardener –
1 – Preparing raw materials
The first step in manufacturing CLC products requires selecting the appropriate raw materials for producing high quality CLC blocks. These raw materials include cement, water, fly ash, foam generator and CLC block hardener.
According to experts, you will need around 5 (five) bags of OPC 53 grade cement and 500 KG of fly ash to produce 1 (one) cubic meter of CLC blocks.
2 – Foaming
The second step is the foaming process. For this, a foam generator machine is used. This machine produces stable foam using a special foaming agent, such as the one offered by Sakshi Chem Sciences.
According to experts, around 1.2 KG of foaming agent is mixed with 30 liters of water and then added to the concrete admixture. The foam produces air bubbles throughout the interior of the blocks, which reduces the mass and weight, without affecting the stability and strength.
3 – Weighing
The next step in manufacturing CLC blocks includes the weighing process. This requires taking a liter of the slurry from the mixer and measuring its density by weight. If the slurry achieves the required density, then it is sent for the next stage of the manufacturing process.
4 – Casting
Next, the foam-induced slurry is poured into pre-designed formworks or molds. These molds are usually made of plastic or steel in the form of the desired shape and size required for the blocks or bricks.
5 – Curing
The next step is the curing process. For this, the blocks are left in the mold for at least 28 days which allows them to gain the desired stability and strength. Curing can be done through two different processes – natural curing or steam curing, where each has its own advantages and drawbacks.
6 – Demolding
As soon as the curing process is complete, the hardened blocks are carefully removed from the mold/formwork. It is advisable to be very careful during demolding to avoid cracks, voids or other damage to the newly-cast blocks.
7 – Drying
The next step in the CLC block manufacturing process is drying. For this, the demolded blocks are left to dry in a controlled environment. This step is necessary to reduce the moisture content in the blocks and to enhance their inherent strength too.
8 – Quality check
The last step in manufacturing CLC blocks is the quality control process. Before the CLC blocks are ready for use they need to undergo stringent quality control checks. This step is vital to ensure that the CLC products fulfil the required specifications and quality standards.
Conclusion
CLC blocks are extremely advantageous as compared to conventional bricks or AAC bricks. The CLC blocks are made using high quality components and undergo a rigorous manufacturing process which ensures their functionality and workability.
CLC block hardener is a crucial component for ensuring higher quality products. It is highly advisable to choose CLC block hardener from renowned and reliable producers, such as Sakshi Chem Sciences, to ensure optimal product quality.
