How to Avoid Cracking in AAC Block Wall

Mukund Joshi

(An Excerpt from “AAC Blocks for Superior Masonry Construction” –

available on Amazon)

Within Infinite Truths lies the Eternal Truth. Who sees it all?
Varuna has but a thousand eyes Indra, a hundred And I, only two.
Devdutt Patnaik

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 Copyright: Mukund Joshi

B-2, Yash Heights, Govind Nagar, Nashik

No part of this book may be reproduced or transmitted in

any form or by any means, electronic or mechanical,
including photocopying, recording or by any information
storage and retrieval system, without written permission
from the author.

About the Author

Mukund Joshi is a concrete technologist by profession and has an

extensive experience in the field of manufacturing of AAC blocks. He
has presented technical papers in various conferences in the field of
concrete technology in various countries. He works as an adviser on
many construction projects and AAC block plants in India.

I will be more than happy to answer your questions – just

drop me an email.

Email: mukund.joshi@outlook.com

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Chemistry of Hydration in AAC

We have seen numerous benefits of the AAC blocks due to

its lightweight nature. On the other hand, it also poses
challenges related to the shrinkage of the masonry and
movement in the structural members of the building.

In any type of concrete volume change 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 does not remain dimensionally
stable when exposed to the ambient humidities which are
below saturation. In addition to this, aerated concrete
also retains more than 20% moisture at the end of the
autoclaving cycle. The loss of all this moisture from the
blocks can create massive volume change in aerated
concrete. Particularly in the AAC block masonry the
volume change leads to unsightly cracks in the masonry
wall. This volume change happens primarily due to
shrinkage in the wall. This shrinkage can be drying
shrinkage or autogenous shrinkage.

The drying shrinkage creates tensile stress when it is

restrained. Once the blocks are built in the masonry the
shrinkage gets restrained due to the end columns. This
creates high amount of tensile stress in the wall resulting
into vertical cracks. Of course it is difficult to make a
masonry wall that does not shrink, however a practicing
engineer can put in every effort to ensure that the
shrinkage is limited to a minimum. The shrinkage mainly
depends on the moisture movement from the AAC blocks.
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As we all know, AAC blocks are manufactured at a water
to cementatious ratio is almost 1.50.

Following is an example that shows chemical water

demand per cubic meter of aerated concrete:

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 cementatious solids = 193 kg/m3

Water content = 288 kg/m3

Hence w/c = 288/193 = 1.49

Following are the hydration phases of cement that denote

amount of capillary water remaining even after 100%
hydration of cement on autoclaving 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.

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Water trapped in the capillary structure of C-S-H Gel at high w/c

In addition to the above, Aerated concrete is

manufactured in an autoclave at a pressure of about 12
bars with a 195’C steam. This is a significantly high
pressure which drives the steam inside the millions of
microscopic pores of the block. As the blocks are cooled
off, a small part of the moisture formed from steam
remains trapped inside the pores of the blocks.

Hence as a combination of water trapped in the cement

paste and the moisture left by the steam, a typical free
moisture content in a block is to the tune of 25% by
weight. As the majority of this free moisture is released

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 over the period of the next 48 hours of manufacturing of
the AAC blocks, the blocks begin drying which results into
major shrinkage within the first 48 hours of the
autoclaving.

This shrinkage results into cracks and following are the

precautions to be taken while building an AAC block wall
so that it remains free of cracks.

The IS code 6041:1985 also advises us on ways to

avoid cracks in the wall as below:

Structural Movements - Cracks may occur due to 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. In the case of
framed structures, erection of partitions and panel walls shall
be delayed wherever possible until the frame has taken up, as
much as possible, any deformation occurring due to structural
movements.

Ceiling deflection and movement - A ceiling above a

partition wall may deflect under loads applied after its
erection, or through thermal or other movements.

Control of Wall Movement Accompanying Temperature

and Moisture Changes - Cracking in concrete masonry walls
is often due to tensile stresses which develop when wall
movements accompanying temperature and moisture change
are restrained by other elements of the building, or when
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 concrete masonry places restraint on the movement of
adjoining elements.

The work instructions given in the following section are

recommended while undertaking AAC block masonry
construction to minimize cracking in the walls.

Work Instructions for Masonry with AAC Blocks

1.0 Please make sure that the starter bed is in zero tolerance level. A starter beam of
lean concrete of height 100mm is advised to take care of undulations in the floor.
This ensures that the AAC block masonry remains in true line and level.
It is worth noting that the joint thickness of AAC block masonry is typically 3mm –
and hence it is called thin bed jointing masonry. With such thin joints, the masons
find it difficult to maintain the level unless the starter beam is in exact line and level.
2.0 For each upper layer, fix the blocks by uniformly applying a thin layer of 3mm
jointing mortar on the course. Spread the mortar as you go along. Do not spread the
mortar far ahead which will result in earlier setting.
3.0 It is not required to soak the AAC blocks completely in water. Only slight wetting of
surface is enough.
4.0 Use a tray filled with 30 to 40mm of water. Before laying each block, immerse it in
the tray from all sides and make it slightly wet on four sides. Then place the block
firmly in position to have proper bond.
5.0 The first course of the masonry shall be laid with proper attention and should be
uniformly aligned, levelled and plumbed. This ensures that the upper layers remain
in true plumb and uniform level.
6.0 Apply the mortar on the side of a block as you move ahead. Ensure that mortar is
uniformly spread over the block. None of the joints shall be left with a gap.
7.0 It has been observed that when the joints are not filled fully with mortar, it leads to
cracking of blocks or gypsum plaster due to movement in blocks.
8.0 Fill the gap at the top between the wall and the beam bottom with 5-10mm
coarse aggregates. This packs the masonry and takes care of the unevenness
of the beam bottom. The top beam gets uniform bearing with the masonry

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 avoiding any stress concentration on the wall. This ensures that cracks do not
develop in AAC blocks wall due to stress concentration from the vibration of
loads of the upper slab. Any mortar has to be filled ONLY AFTER the wall is
packed with coarse aggregates.
9.0 We can apply the gypsum plaster on the inner wall surfaces and then paint the
walls.
10.0 You can drill a screw or carve an electrical conduit in an AAC wall. The AAC
blocks have excellent workability. Just use proper tools for the work. Avoid using
hammer and chisel – instead use mechanised cutting tools or saw for shaping the
blocks.
11.0 You need to put a patali beam if the wall height is more than 10 feet
12.0 You need to put a vertical stiffner if the length of the wall is more than 15 feet.

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 How to apply External Polymer Plaster on a
masonry wall of AAC Blocks
1.0 Rake the joints.
2.0 The beam-masonry joint and the column-masonry joint must be treated with chicken
mesh and polymer adhesive. Apply a bonding coat of polymer adhesive over the
entire length of the joint.
3.0 Do the wetting of the wall with water for 2 hours only before you begin the
plaster. If you do the wetting for longer period, it may result in weaker bond of
plaster.
4.0 Use Readymix Plaster available in 40 kg bags. Add typically 5.50 litres of water with
40kg of plaster bag.
5.0 You have an option to finish the external plaster in two layers with a total thickness
of 18mm. But the thickness of plaster should not be more than 12mm in case of first
layer.
6.0 A continuous curing for 7 days is very essential for a high quality bonding of
plaster free of cracks. It has been seen on numerous sites that this last step is
ignored and all the good work done before goes in vain.
Cover the vertical plastered surface with hessian cloth and keep it moist all the time. In
this way we can ensure good curing of the plaster.

You can order my book from Amazon – it covers all the aspects of AAC block masonry
construction
“AAC Blocks for Superior Masonry Construction”
Click this link to order the book
https://www.amazon.in/dp/B07NPG21S5/ref=cm_sw_r_em_apa_i_ItPRDb824ZYGA

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Frequently Asked Questions and Answers

We cannot solve our problems with the same thinking we used when we created them.
Albert Einstein

1) The AAC block has cracked at some places in the wall. What is the reason?

There could be several reasons for cracking of the blocks.

1. Packing of coarse aggregates below the top beam is essential as it fixes the wall
in place and does not allow vibration from loads of the upper slab in the blocks.
2. If the joints are not properly filled, it leads to uneven settlement. It may lead to
stress concentration and cracking. A uniform 3mm to 4mm joint thickness is
mandatory.
3. Take care to use only mechanised cutting tools to cut the blocks – do not use
chisel and hammer. Because cutting the block in perfect right angle is important.

2) My gypsum plaster shows a moist surface at the bottom of the wall. How to
prevent it?

Begin the block masonry with a starter bed of 3 to 4 inch at the bottom of the wall.
Begin the AAC masonry work on this starter bed.

3) How many days to cure Polymer Readymix Plaster?

Minimum 7 days with continuously moist hessian cloth

4) Is chicken mesh necessary before plaster?

Yes – Chicken mesh should be fixed at all block and RCC joints.

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5) What is usage time for plaster and mortar products?

Both the products must be used within 40 minutes of mixing with water.

6) Can the AAC blocks take load of our furniture?

7) How to check compressive strength of AAC blocks?

In the CTM machine, the blocks should be given the load perpendicular to the
direction of rising – which is length of the blocks.

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8) How can I fix door frame in the AAC block wall?

Use long holdfasts embedded in wall for stronger support to frames.

9) How are the blocks loaded in the truck?

The blocks are loaded with a Robotic grabber crane and the block packages are
directly placed in the truck

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 10) Can I get coloured AAC blocks?

Yes – colour blocks are also produced custom-made as per the colour choice.

11) What is the Comparison Between AAC Blocks and Bricks

Technically what is the difference between masonry in AAC blocks and in

conventional bricks

Difference in Weight

1.0 For similar size, Weight of One Brick (1600 kg/m3) = Weight of Two and Half
AAC Blocks (650 kg/m3)
2.0 This means AAC blocks are very very light in weight
3.0 This helps to make a much bigger size of AAC blocks = about 8 bricks in one
AAC block
4.0 This results into huge saving in cement and sand as the number of joints get
reduced by 6 times!!
5.0 This also means that a mason can do the masonry much faster – almost 50%
more output in a day.

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Difference in Heat Transfer

• AAC blocks have very low rate of heat transfer compared to burnt clay bricks –
less than 1/3rd.
• AAC Blocks = 0.24 W/m’K against 0.81 W/m’K
• This results in massive savings in air conditioning costs – by more than 25% in
AAC block homes

Difference in Water Seepage

• The pores in AAC blocks are not connected to each other. Therefore AAC blocks do
not allow seepage of water through them by capillary reaction.
• Whereas the pores in burnt clay bricks are connected to each other. Therefore they
have a high rate of seepage of water due to capillary reaction.

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Perfection in Size

• AAC blocks have a maximum deviation in height and width of 3mm. This ensures a
much thinner plaster and thinner joints.
• This results in substantial saving in sand and cement.
• The block work looks aesthetically pleasing with neat and clean joints.

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 12) What causes cracks in AAC Blocks wall?

You see buildings after buildings without a crack in AAC masonry and then you see a
project that is full of cracks in the masonry walls. Why is it so?

The number one culprit is drying shrinkage.

AAC blocks during the process of manufacturing, as they come out of autoclave,
contain high amount of residual moisture to the tune of 25%. This residual moisture
leaves the blocks predominantly in the first 48 hours. As the moisture leaves the blocks
they shrink. Imagine you have installed these blocks in a masonry wall within the first 48
hours and then the shrinkage happens inside the wall. The shrinkage is a massive force
which tears the wall vertically resulting into a crack at the centre of the length of the
wall.

On the other hand if the blocks are allowed to “dry down “for a period of 48 hours to 72
hours before they go in a masonry wall, then you will find that the cracks in your building
would reduced by 80%.

Now what about the remaining 20% of the cracks? There are two reasons for these
remaining 20% cracks. The first one is workmanship. You need to pack the wall with the
upper beam before you put any mortar in that gap. This can be done by using 10 mm
down aggregates. Our RCC beam is never in ‘line and level’. This leaves variable gaps
between the top of the wall and the bottom of the beam. This gap creates a point load
on the wall due to deflection in the upper beam. Once the wall is packed with the
aggregates then the point load from beam gets converted into a udl and stress
concentration in the wall is reduced eliminating the cracking in the wall.

The other reason for cracking is the strength of the blocks which needs to be minimum
4Mpa which brings down the drying shrinkage value to less than 0.05%.

For a detailed treatment of this subject, please refer to my book “AAC Blocks for
Superior Masonry Construction“ which is available on Amazon.

13) Are AAC Blocks successful in India?

Yes. Massively successful.

Market penetration

Year 2008 = Just 2% penetration in metro cities

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Year 2018 = 70% penetration in metro cities

2. Economical in Use

Saves reinforcement steel, mortar, plaster, labour,… and even curing water

3. Factory made product

Consistent strength, high dimensional accuracy

These and a number of other benefits have made AAC Blocks immensely successful in
India.

Does this mean there are no drawbacks? Surely there are some - but the benefits by far
outweigh the drawbacks.

AAC Blocks have taken the construction industry by storm in Asia with Africa set to
follow the course. Of course, the journey had begun in Europe hundred years ago.

The popularity of AAC blocks is due to the immense advantages it offers - like economic
construction, thermal insulation, superior behaviour in earthquake, sound insulation etc.

But this question is about disadvantages - right? Although the advantages of AAC
blocks far outweigh its disadvantages, it does have following notable disadvantages:

Cracking in walls: we need to take precautions to eliminate drying shrinkage cracks

and stress concentration cracks. See above the answer on cracking of AAC block wall.

Not perfectly suitable for Load bearing walls: the lightweight-ness becomes a
disadvantage for load bearing structures and use of AAC blocks has to be done
judiciously for load bearing structures.

Nailing vs drilling: If you need to fix furniture in the AAC Blocks wall, you need to use
a drill bit and a rawal plug. You CAN’T just put a nail.

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