Fusion Mortar (AAC Blocks joining mortar or Thin bed mortar or AAC Blocks Adhesive or AAC Blocks Glue ) is a ready to mix, self-curing cementitious mortar for laying of AAC Blocks, CLC Bricks, Hollow concrete blocks and bricks.
It’s a factory made premixed mortar blended with carefully selected raw materials such as graded sand, mineral binders and ordinary Portland cement (OPC) in combination with selected polymeric additives which help in providing mechanical bond and adhesion between the blocks and block to surface.
Designed for use with water to produce high strength thixotropic mortar, Fusion Mortar is manufactured by following strict quality norms and is in compliance with C 1660-09 ASTM standards (www.astm.org), a worldwide standard followed for thin bed mortar for autoclaved aerated concrete masonry that meets the requirements of National and International standards.
- Highly suitable to AAC blocks : Since low water absorption per cubic metre of AAC material ultimately cause drying up of conventional mortar on application. This leads to separation at joints if not provided on time curing. While in case of Cure free thin bed mortar no such a dry shrinkage is observed.
- High Strength (Tensile Splitting Strength): Optimally polymerized Fusion Mortar provides additional bonding strength apart from the mechanical sand-cement bonding due to hydration retainer compounds which gives solid robust wall with long lasting durability.
- Self Curing: No curing required after block work is done, thus saving critical resources like water.
- Flexible: Improved Workability: due to added polymers it results in improved quality, water retention.
- Less Storage Space: Fusion Jointing Mortar is ready to mix product there by eliminating need for bulk storage of sand and cement.
- Construction Accuracy: Due to measured application and thin bed, the wall construction is accurate.
- Fast Construction and Higher Productivity: Fusion Jointing Mortar is a timely setting mortar which allows uninterrupted block mounting, which is far lower in time than conventional and ordinary mortars. Combined with qualities of good workability, spread of material and no need of curing, Fusion Jointing Mortar increases speed of construction – only 24 to 48 hrs required before next stage like plastering.
- Withstand Hammering and Chiseling: Fusion Jointing Mortar is able to withstand the hammering and chiseling required to be done for window, door frames and conducting for electrical wiring after 48-72 hours.
- ASTM Complaint: It is specially formulated and tested to be in compliance with ASTM C 1660 -09 and gives the confidence to the consumer of a product based on researched standards.
- BASE: Cement with modified polymer powder
- COLOR: Grey powder
- POT LIFE: Approximately 2hr 28oC
- DENSITY: 2.0 gr/cm3
- WATER DEMAND: 12 to 13 Liters per 40Kg bag
- SELF-CURING: Yes
- TENSILE ADHESION STRENGTH: 1.0 N/mm2
Coverage* (walling area) from 40 Kg Bag considering 3 mm joint thickness
100 mm thick wall: 166 Sq Ft
125 mm thick wall: 132 Sq Ft
150 mm thick wall: 110 Sq Ft
200 mm thick wall: 83 Sq Ft
230 mm thick wall: 72 Sq Ft
(* Assuming Fusion AAC Block length = 600 mm and Depth = 200 mm)
Area of Application
→ For interior and exterior use for fixing AAC Fly ash, CLC, Hollow, concrete blocks & bricks.
→ Parapet walls and jointing of cement windows and doors.
→ Jointing of panels and pre-stressed concrete slabs.
→ Boundaries and garden walls.
Comparison of Fusion Mortar with Traditional Mortar
|Parameters||Traditional Mortar(Cement & Sand)||Fusion Mortar|
|Cost Comparison||Cement (0.5 kg @ Rs 330 per bag) = Rs. 3.3
+ Sand (0.045 cft @ Rs 30.5 per cft) = Rs. 1.37
Total = Rs. 4.67 per sq. ft.
|Approx. Rs. 3.60/sq. ft|
|Joint thickness||10 mm – 15 mm||3 to 4 mm|
|Plastering possible||Minimum 7 days curing required||After 24 hours|
|Height of build||Restricted||No Restriction|
|Strength||Joints are weak points||Joints are stronger|
|Shrinkage||More shrinkage cracks||No|
|Stability||Less Stable||More Stable|
|Aesthetics||Uneven, with variations||Even and better laying|
- The base surface should be properly cured prior to application of Fusion Jointing Mortar
- The surface must be cleaned thoroughly, with no loose particles or dust.
- The surface must be structurally sound, clean and free from dirt, oil, grease, efflorescence and any other contaminant which could impair the natural bond.
- Surface defects such as cracks, holes or voids should be repaired prior to application
- It is very important that Fusion Jointing Mortar is mixed with water properly and thoroughly before use. It is advisable to use a mechanical stirrer for uniform and thorough mixing to save time, labour and for maximum workability.
- Take a clean vessel/bucket, add water to it and put required quantity of Fusion Jointing Mortar in it.
- Mixing Ratio – Clean potable water (approximately 25%-30%) of the weight of the powder is required to be mixed depending upon the thickness of the product to be applied. Water is to be incrementally added in stages to get a smooth, uniform and workable mix. Allow ample of time for initial mixing.
- Ensure that no powder is left unmixed at the bottom of the vessel. The Fusion Jointing Mortar is now ready for application.
- The first course of blocks are always laid in thick bed mortar mix made of 1:4 (by
volume) cement: sand added to it a bonding agent @ 10% of water with a thickness of levelling bed is ½” to 2”. This serves as a leveling pad for the first course of blocks. Care must be taken at this stage to ensure the blocks are plumb and level so further construction up to ceiling height will be fast
and accurate. Corner blocks are laid first and the first course should be completed before second course installation.
- The specially separated scoops ensure a mortar bed of 3 to 4 mm with minimum effort. Choose the correct width of scoop to suit the blocks thickness. For wider blocks, two or more lines of mortar may need to be applied using a narrow scoop.
- Fill the scoop with mortar and hold the scoop at an angle so that the wings of the scoop are not against the block.
- Wiggle scoop as you go up or along the bed face to ensure good coverage across the face. Rinse the scoop in water to prevent build-up & clogging.
- All mortar joints and perpends must be fully filled.
- Present a mortared perpend to a dry perpend and tap firmly into position with a rubber mallet
- Tap the block firmly with rubber mallet to get a tight fit between the blocks & clean off excess mortar squeezed out of the joint.
- Check for horizontal and vertical level and adjust as necessary. The mortar begins to adhere strongly after approximately 5-10 minutes!
AAC Blocks introduction
Autoclaved Aerated Concrete (AAC Blocks) is one of the eco – friendly and certified green building materials. AAC is porous, non-toxic, reusable, renewable and recyclable. Autoclaved Aerated Concrete, also known as AAC Blocks , is a lightweight, load-bearing, high insulating, durable building product, which is produced in a wide range of sizes and strengths. AAC offers incredible opportunities to increase building quality and at the same time reduce costs at the construction site. The Autoclaved Aerated Concrete material was invented by a Sweden Architect, Johan Axel Eriksson in 1924. It has become one of the most used building materials in Europe and is rapidly growing in many other countries around the world. AAC Blocks are produced out of a mix of quartz sand or pulverized fly ash, lime, cement, gypsum/anhydrite, water and Aluminum and is hardened by steam-curing in autoclaves. Due its excellent properties, AAC Block is used in many building constructions, such as in residential homes, commercial and industrial buildings, schools, hospitals, hotels and many other applications. AAC replaces clay bricks which are environmentally unsustainable. Being aerated, it contains 50 – 60 % of air, leading to light weight and low thermal conductivity. The characteristic of AAC is helpful in green housings and saves fertile lands and a solution for fly ash disposal.
ADVANTAGES OF AAC
AAC products are made using slurry mix containing cement, sand, lime and aerating agent. The slurry is poured and moulded to form lightweight blocks, panels and lintels upon which are cured in autoclave. The high-pressure steam-curing mechanism in the autoclave facilitates the curing process of the moulded lightweight concrete, producing physically and chemically stable products that weigh about 1/5 of normal concrete. AAC products contain millions of tiny non-connecting air pockets yielding superior thermal insulation property. AAC products are typically installed to form walls, floors and roofs.
AAC products are becoming the preferred building products for constructing residential, hotel, industrial and public buildings because of its natural composition and non-toxic property, saves energy and environmental friendly. AAC products possess the durability characteristics similar to normal concrete or stone, yet with workability better than wood.
Thermal Comfort & Energy Saving
Save up to 25% of Foundation Cost
Wall Installation Speed
FUSION PRODUCTION PROCESS
Put the sand or fly-ash with water into a ball mill to produce sand slurry. Other dry materials (lime, cement, gypsum & additives) are transported to the silos located in the mixing tower. After mixing 3~4mins, using automatic scale system to do with the aluminum powder for maximum safety and dosing precision and then continue mixing 40s. Once weighed and dosed, the mixer ensures perfectly homogeneous distribution of raw materials in the mix. Once using the pouring mixer to cast the slurry into the freshly mould cleaned and oiled, the mixer is vibrated to eliminate air pockets to ensure the quality of end products.The whole cycle is 5~7min.
For the panel production line, a reinforcement station is installed. Before introducing the steel reinforcement in the mix, an assembled steel mesh (for partition panels) or ready cage (for reinforced panels and elements) is dipped into anti-corrosion treatment. After a mix is poured into a mould the reinforcement is immediately inserted into a mould. Precise AAC formula design and control over the cake rising process are especially important in panel production.The greatest advantage of AAC panel production in the Keda system is that it realize the automatic welding system for wire-mesh cages of panels without manual operations for welding work, the special circulatory system of saddle base and automatic packing system can reduce handling, cake cracks and other damages (mainly sticking) the element can suffer during the production process and also can save the plant area and labor costs .
After that, put the mould box into the curing room with 40～70℃. After 2-3 hours curing,the blocks become solid, using our special de-moulding crane to separates the cake from the mould and put the cake onto ferry car after 90 degree overturning to transport cutting zone. The cutting frame is made with oscillating and pneumatically spanned steel wires resulting in a precise cut. A recent innovation is design of sloping cross cutting machinery with strength steel wire fixed on the sloping main beams which can avoid the gravity cracking and realize the minimum cutting size of 50mm. After vertical cutting & cross cutting the cake turns into blocks (L ± 2mm ~ W ± 1mm ~ H ±1mm) 100% of the rest material is mixed with water and used in the next cycle.The curing car transports the cakes into autoclave with temperature 200℃ and steam pressure 1.2MPa, autoclaving cycle is 11H. The tail steam of the autoclave will be recycled into other autoclaves and/or to pre-curing zone by pipe for completely utilization.
In the unloading area an automatic system takes the complete white cake and one-by-one transfers it from the frame onto the pallet table. Elements are then automatically placed on the pallets and transported by a conveyor system to the quality inspection and sorting place. After this station the pallets are ready for final packaging e.g. stretch hood and eventually strapping.In a similar manner, reinforced wall, floor, roof panels and lintels can be packed and strapped automatically or manually. Keda plants can have different packing line designs depending on the sales market.
WHERE TO APPLY FUSION PRODUCTS?
Autoclaved Aerated Concrete is ideal for load-bearing and non-load bearing applications. In addition, Fusion AAC products are suitable for various types of buildings such as:
- Residential Units
- Commercial Units
- Schools / Universities
- Shopping Malls
- Public Transport
- Intersection Buildings