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Autoclaved Aerated Concrete

Autoclaved aerated concrete (AAC), was invented in the mid-1920s by the Swedish architect and inventor Axel Eriksson. It is a lightweight, precast building material with amazing properties- The highest fire rating, incredible thermal insulation in a SINGLE-WALL structure, termite proof, sound deadening, AFFORDABLE, no ant and insect infestations and mold resistant. Turn-key cost is on par with HPM and Honsador's conventional kit homes, with 10 times the value! To manufacture AAC, Portland cement is mixed with lime, silica sand, water and aluminum paste and poured into a mold. The reaction between aluminum and concrete causes billions of microscopic hydrogen bubbles to form, expanding the concrete to about five times its original volume. After evaporation of the hydrogen, the now highly closed-cell, aerated concrete is cut to size and formed by steam-curing in a pressurized chamber (autoclave). The result is a non-toxic, very airtight material which generates no pollutants or hazardous waste during the manufacturing process. The home pictured below is made from AAC blocks that are made in Thailand by an accredited factory, and each 2’ x 3’ x 4” thick block has a G-4 stamp on it which is an international measure of strength. Individual blocks are about 75 lbs each, and are glued together with polyurethane construction adhesive. Our process is proven, incredibly inexpensive, fast and easy to build with, and many homes on the Big Island have been built with this easy process that have all satisfied the Bldg Depts standards, insuring a smooth process when you work with us. (On Oahu, we are currently working on defining the specs and process that the Honolulu Bldg Dept requires, stay tuned to this page). This 3’ X 2’ X 4” block is steel reinforced, brilliantly conceived and engineered to perfection by the superblock company in Thailand. We work closely with our supplier who is the US distributor of this patented product.

Besides insulating capability, one of AAC's advantages in construction is its quick and easy installation since the material can be easily cut to size on site using an ordinary skill saw, bandsaws, sawzall, hand saws etc. Electrical wiring comes down from the attic and is placed into plastic conduit pipe which is glued inside routed out channels down the walls that are filled in easily with thinset. Supply water is brought in via C-PVC pipes that are either imbedded inside the slab, or can be brought in thru the wall from the outside. Vent pipes are situated within appropriately sized gaps between walls and filled in again with thinset mix. The drains are set in your slab. Our system utilizes blocks that are easily lifted into place by 2 people, not requiring any special lifting equipment. The AAC blocks are finished on the outside with thinset and silica sand, and finally painted. You can finish with stucco, but this system of thinset and silica sand is much cheaper. This protects and seals it against the elements. You can use waterproofing coatings on top of the thinset layer if you have concerns about moisture. Sun exposure on an AAC wall has very little effect on the temperature inside the home as AAC has amazing thermal properties derived from the billions of tiny, unconnected air bubbles. In the photo directly below, you can see the rebar reinforced concrete pour on top of all the exterior walls, and the imbedded simpson ties which hold the roof trusses. Also- you can choose to use the concrete slab as a floor by executing a fine finish on the slab, then staining and sealing it, like how Costco and others do their concrete floors. The ultimate in cost savings and easy to clean!

In the photo directly below, look at the far bottom-right corner of the concrete slab. You will see rebar imbedded in the slab. These are placed every 12 feet. We connect additional rebar so that it reaches as high as the walls, drill and install short rebar pieces into each AAC wall, wire just the slab rebar together and then pour concrete, connecting each 12’ wide section of AAC blocks with these vertical concrete pours. Drilling into the AAC blocks is a 3 second job done with the cheapest of drill bits. Screws go right into AAC without drilling, and cabinets are set by drilling and using epoxy glue with anchors. Not quite as easy as a wood frame home, but that is really minor compared to all the incredible properties of AAC! The latest evolution of our system is to do rebar pours above windows and doors instead of placing special AAC pieces called lintels. These pours are stronger than the lintels, and it is much more efficient to ship only the blocks. This system has evolved from actually building many homes and fine tuning this efficient, easy and fast process.

AAC’s excellent thermal efficiency makes a major contribution to energy conservation by sharply reducing the need for heating and cooling in homes and buildings. AAC is very green, save and accept the shipping to Hawaii. In addition, AAC’s easy workability allows accurate cutting that minimizes waste. Unlike other building materials, AAC is a single-wall system that does not require any other insulating materials or drywall. Interior walls are finished with drywall mud utilizing a very fine texture easily sprayed onto the interior walls! In the photo directly below, the vertical pours are now seen clearly. They can be flush with the blocks, or made slightly thicker than the 4” thick AAC block walls. The trussed roof system is very cost effective, and has minimal termite exposure. Just to be safe as possible, we treat the trusses with additional treatment so termites are even less attracted to the exposed eves. This combination of AAC blocks and trussed roof system is easy and quick to build, and very cost effective. Perfect for the DIY’ers on an owner-builder permit or utilizing a General Contractor if financing the home- either way, we can manage the entire job if you wish, simply consult briefly or whatever works for you. Bonding a financed job is not a problem, we have that set-up and ready to execute!

Affordable Portable Housing offers you complete design-build services with AAC and other systems also! This AAC system is perfect for owner-builders, or we can manage the job under either an owner-builder permit or utilizing a General Contractor. Call or email us for more information on this exciting building material, and to see homes and buildings in person made from this amazing material. A personal visit to one of our AAC homes will no doubt infect you with enthusiasm! There are over 30 factories world-wide, and AAC is used extensively in the Middle East, USA, Canada, Europe and Asia. It is truly revolutionizing the building industry worldwide. (Google AAC.) We provide design services with complete drafting, permitting and construction services at a very competitive price, or we can just supply the blocks, consult with you if you wish, or assist to whatever degree you desire. We do get busy, and try our best to accommodate your schedule the best that we can.

Affordable Portable Housing