SIPOReX

AAC BUILDING SYSTEM

1. INTRODUCTION

Siporex is lightweight Autoclaved Aerated Concrete (AAC) manufactured from the same
components as conventional concrete: cement, sand and water in addition to aluminum powder
and other additives.

The product is available as blocks with different dimensions and precast reinforced units, i.e.,
wall panels, lintels and floor/roof slabs forming a complete building system. A villa of one or two
storeys can easily be constructed using Siporex blocks, floor and roof slabs, and lintels without
the need of reinforced concrete main frame.

Industrial production of this versatile building material was started in 1929 and it has been
produced and used for building construction ever since. First in Europe and now world-wide.
Here in the Kingdom of Saudi Arabia, LCC Siporex Company was established in 1977 and has
been producing Siporex AAC material at our plant in the Second Industrial Estate, AlKharj Road.
With our continued expansion of additional manufacturing plant to sustain the growing demand,
our current total production capacity has intensified to about 350,000 cubic meters of Siporex
AAC products per year.

Siporex manufacturing plant in Riyadh, Saudi Arabia

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AAC BUILDING SYSTEM

2. CODES & STANDARDS

Various international codes and standards had been developed

to provide engineers and designers with provisions for the
analysis and design of AAC factory-produced blocks and
reinforced panels based on various research studies and
experiences on its use. These include guidelines or
recommended practice addressing the materials, manufacture
and structural design of AAC including design considerations
such as erection and construction details incorporating the use
of AAC products in conventional construction. Some of these
Codes & Standards are listed below:

CODE OR DESIGNATION
DESCRIPTION
STANDARD NO.
Guide for Low Density Precast Concrete Floor,
ACI ACI 523.2R
Roof and Wall Units
Standard Practice for Autoclaved Aerated Concrete
ASTM C1555-03A
Masonry
Standard Specification for Precast Autoclaved
ASTM C1386-98
Aerated Concrete Wall Construction Units
DEUTCH DIN 4165 Autoclaved Aerated Concrete Blocks
NORM
BRITISH BS 8110 – Part
Autoclaved Aerated Concrete
STANDARD 2, Section Six
BRITISH BS EN 771-
Autoclaved Aerated Concrete Masonry Units
STANDARD 4:2001
BRITISH BS EN Determination of the Dry Density of Autoclaved
STANDARD 678:1994 Aerated Concrete
BRITISH BS EN Determination of the compressive Strength of
STANDARD 679 :1994 Autoclaved Aerated Concrete
BRITISH BS EN Determination of the Drying Shrinkage of
STANDARD 680: 1994 Autoclaved Aerated Concrete
BRITISH BS EN
Method of test for Masonry Units
STANDARD 772-10:1999
BRITISH BS EN Determination of Moisture Content of Autoclaved
STANDARD 1353:1997 Aerated Concrete
SASO SASO 1579 Precast Autoclaved Aerated Concrete
SWEDISH BUILDING CODE Autoclaved Aerated Concrete Products
Design Procedure for Siporex Roof, Floor, Wall
COUNCIL OF AMERICAN
Panels, Masonry Blocks and Lintels of Autoclaved
BUILDING OFFICIALS
Lightweight Cellular Concrete(Report # NER-297)
RILEM Autoclaved Aerated Concrete

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AAC BUILDING SYSTEM

3. MANUFACTURING

Siporex is produced by a highly complex and advanced manufacturing process in our factory under the
careful control of chemists and engineers. Siporex is made either as steel reinforced panels using
moulds 6 meters long, 1.5 meters wide and 600 mm deep or as non-reinforced blocks using moulds 6
meters long, 1.5 (or 1.2) meters wide and 600 mm deep.

The basic raw materials are sand, water, aluminum

powder and cement. The sand is ground to required
fineness in a ball mill before mixing with other raw
materials with water to form slurry to which a trace
of aluminum powder is added as expanding agent.
Regulated amount of aluminum powder gives
accurate control of density of the final product.
Moulds are only partly filled with slurry which then
expands in a controlled reaction to fill the moulds.

When the mass is sufficiently hard, the moulds are

stripped and the cake is wire-cut to close tolerances
into blocks using high-precision cutting technology.
These are then steam cured under high pressure in
autoclaves for up to 15 hours. This completes the
chemical process, resulting in a unique crystal
structure of calcium silicate hydrate and ensuring a
stable and inert product giving AAC outstanding
qualities not found in other products.

After cooling to ambient temperature, the batches

are demoulded, and stacked for further handling
and storage. The block stacks are strapped, marked
and stored on wooden pallets. Each pallet can be
stored with up to 3 bundles of blocks (180 cm high).
At the storage area, the floor should be level to
avoid tilting of stocks.

The manufacturing of Aerated Lightweight Concrete

as blocks by LCC Siporex implements and
maintains a Quality Management System which
fulfills the requirements of ISO 9001:2000.
For final products, compressive test, shrinkage and
dry densities are carried out on a daily basis. The
finished goods inspection program ensures the
products quality. The material is now ready for
loading and delivery

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AAC BUILDING SYSTEM

4. PROPERTIES & BENEFITS OF USING SIPOREX

The manufacturing process as well as the basic ingredients used provide Siporex its unique
properties and benefits not found in other traditional building materials and will radically change
the construction practices in this industry.
Lightweight Energy Efficient
Siporex products are supplied with Siporex ensure comfortable room
nominal dry density of 550 kg/m3 and temperature without the need for
weigh less than a quarter compared additional insulation. Its thermal
to conventional concrete. Other insulation and heat retention offer a
densities such as 450 or 600 kg/m3 good protection against rapid cooling
can also be produced upon request. or heating up too much. This means
Due to the lightweight property of lower power consumption in
Siporex, foundation loads are greatly environmental management system.
reduced resulting to big savings in With a thermal conductivity (“k”
the overall cost. Its light weight also value) of 0.144 W/mºC, it is the only
means significant advantage in structural materials classified by
transportation cost. SCECO as insulating material.

Strength Workability
In relation to its dry density, Siporex Siporex products can be sawn, cut,
can withstand relatively high slot, drilled, chased and nailed with
compressive stress, which in the ordinary woodworking tools which
aspect of application is very sufficient makes them easier to install than
to take building loads. Siporex other building materials. This also
achieves its full strength during simplifies the installation of electro-
autoclaving process. Minimum mechanical services and other
compressive strength is about 35 utilities, which means more cost
kg/cm2 for nominal dry density of 550 savings.
kg/m3.

Resistance to Fire Acoustic Insulation

Siporex has remarkable fire Siporex meets the appropriate
resistance properties and is non- standards for sound insulation in
combustible. Heat migration takes house building, which means quieter
place at a slow rate due to its low and more comfortable interior. In
thermal conductivity, giving Siporex industrial construction, Siporex
excellent fire resistance. A 15 cm minimizes industrial noise pollution.
thick panel will resist fire for seven The sound absorption of untreated
life-saving hours. Siporex is ideal for Siporex surface is better than that of
firewall application and as protection dense concrete. A 20 cm thick
for structural steel construction. Siporex wall with 3mm surface finish
will have STC rating of about 48 dB.

Non-toxic Durability
Siporex itself is ecologically Siporex products do not contain any
harmless, since it neither contains organic matter subject to
gases nor fibers, it is neither deterioration and will not degrade
dangerous to ground-water nor does even under severe weather
it releases any radioactive radiation. conditions. Structures built several
No pollutants or toxic by-products are decades ago are still in active use
produced in the manufacturing today.
process or even when subjected to
fire.

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AAC BUILDING SYSTEM

5. PRODUCT DATA

5.1 Product Application & Characteristic Data

Siporex solid blocks are used as load-bearing and non load-bearing walls and as thermally insulating
roof tiles in addition to being used as Hordi blocks or infills for ribbed slabs. The production process
guarantees the accurate dimensions with slim tolerance of ±3mm for thickness & width and ±5mm for
length. This allows for a straight and plumbed walls resulting in less on-site trimmings and reduces the
quantity of mortar and finishing materials required.

5.2 Masonry Blocks Dimensions

For the past decades, LCC Siporex had been supplying AAC blocks with a standard face size of 25 cm
high x 60 cm long only in various thicknesses. However, due to the increasing demand and growing
popularity of the use of AAC blocks, LCC Siporex have started the production of new dimensions of
blocks in line with the continued expansion of additional manufacturing plant to sustain the market
requirements. Siporex blocks are now produced at the following standard sizes:
Standard face size: 25 cm high x 60 cm long: Thickness: 10, 15, 20, 25 and 30 cm
Standard face size: 20 cm high x 60 cm long: Thickness: 10, 15, 20, 30 and 40 cm
5.3 Hordi Blocks
Hordi blocks or infill blocks for ribbed slabs can be
produced in various dimensions to form lightweight
infill between in-situ reinforced concrete ribs
designed to span in one or both directions. Due to
their excellent bondage to in-situ concrete, Siporex
Hordi blocks are easily arranged to form permanent
part of the slab, providing excellent thermal
insulation as well as fire resistance material. Hordi
blocks are produced with density of 450 kg/m3
according to the following dimensions:
Length : 60 cm
Width : 37/38 cm or 40 cm
Thickness : 20, 25, 30, 35 cm
Other sizes may be produced upon request only.
Hordi blocks are not available in stock and are
manufactured against order only.
Hordi blocks application

5.4 Thermal Insulating Tiles

Roof insulation of existing conventional roof can still be improved with the use of Siporex thermal
insulating tiles available at the following dimensions:
60 x 60 x 7.5 cm
60 x 25 x 7.5
60 x 25 x 5 cm
Other dimensions can be produced upon request.

5.5 Box Type Lintels (LB)

Box type lintels are designed with special steel reinforcement
arrangement produced with depth equal to the height of Siporex
blocks for ease of construction. This eliminates shuttering and cast-
in-situ works as well as avoids thermal bridges caused by the use
of traditional concrete lintels.
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AAC BUILDING SYSTEM

5. PRODUCT DATA
5.6 Maximum Clear Span of Box Type Lintels with Various Design Loads (Height = 25 cm)
Thickness of Box Type Lintel (mm)
Design Load
100 150 200 250
500 kg/m 200 cm 350 cm 360 cm 360 cm

1000 kg/m 150 cm 250 cm 260 cm 265 cm

1500 kg/m 75 cm 200 cm 210 cm 210 cm

5.7 Packing Data for Siporex Blocks

Siporex blocks are delivered ready for use and packed in easily
transportable wooden pallets. The pallets should be unloaded at the site
by construction-site cranes, forklifts or other suitable hoisting
equipments. For ease in unloading of materials, it is suggested to order
Siporex blocks in whole bundle or pallet volume to avoid handling loose
quantities. Following table is an easy reference in making order of some
standard sizes of Siporex blocks in bundles or pallets.

No. of No. of
No. of No. of
Blocks Bundle m3 per m3 per
Block Dimensions Blocks Blocks
per per Bundle Pallet
per m3 per m2
Bundle Pallet
10 x 25 x 60 cm 66.66 6.67 75 2 1.125 2.25
15 x 25 x 60 cm 44.44 6.67 50 3 1.125 3.375
20 x 25 x 60 cm 33.33 6.67 35 3 1.05 3.15
25 x 25 x 60 cm 26.66 6.67 30 3 1.125 3.375
30 x 25 x 60 cm 22.22 6.67 25 3 1.125 3.375

10 x 20 x 60 cm 83.33 8.33 72 3 0.864 2.592

15 x 20 x 60 cm 55.55 8.33 48 3 0.864 2.592
20 x 20 x 60 cm 41.67 8.33 36 3 0.864 2.592
30 x 20 x 60 cm 33.33 8.33 24 3 0.864 2.592
40 x 20 x 60 cm 27.78 8.33 18 3 0.864 2.592

SIPOREX ROOF TILES:

5 x 25 x 60 cm 133.33 6.67 150 2 1.125 2.25
7.5 x 25 x 60 cm 88.89 6.67 100 2 1.125 2.25
7.5 x 60 x 60 cm 37.04 2.78 40 3 1.08 3.24

SIPOREX HORDI BLOCKS:

20 x 37/38 x 60 cm 22.22 4.4 21 3 0.945 2.835
20 x 40 x 60 cm 20.83 4.17 18 3 0.864 2.592
25 x 37/38 x 60 cm 17.78 4.4 18 3 1.013 3.038
30 x 37/38 x 60 cm 14.8 4.4 15 3 1.013 3.038
30 x 40 x 60 cm 13.89 4.17 12 3 0.864 2.592
35 x 37/38 x 60 cm 12.7 4.4 12 3 0.945 2.835

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AAC BUILDING SYSTEM

6. INSTALLATION / PLASTERING

6.1 Block Laying

The first course should be laid on cement-mortar bed of
thickness about 1 to 3 cm depending on the evenness of
the base and should maintain a correct level for fast
installation progress in the following courses. It is
recommended to spray the mortar face of the block
before installation to keep damp at erection time
especially during the hot seasons. After installation,
spray with water twice a day for 3 consecutive days for
curing of the mortar. Three types of Mortars can be
applied on the succeeding courses:

6.1.1) Siporex Glue (for thin joints):

Pre-mixed mortar – only water is to be added. Thickness of glue should not exceed 3 mm in
horizontal and vertical joints in order to achieve the ideal consumption rate as follows:
• 7 kg/m2 for Siporex blocks 25 cm thick
• 6 kg/m2 for Siporex blocks 20 cm thick
• 5 kg/m2 for Siporex blocks 15 cm thick
6.1.2) Ordinary Mortar with Gesol
1:6 Cement : Sand respectively in addition to water (with 10% of Gesol). The erection can be
carried out normally as for conventional blocks. (Gesol is a liquid material used as bonding
agent and retardant for the mortar especially during hot weather. Gesol is available at Siporex
factory in 3 kg and 25 kg plastic containers).

6.1.3) Ordinary Mortar with Lime:

1:1:10 Cement : Lime : Sand

6.2 Plastering of Siporex Block Wall

Before plastering, dirt and loose particles should be removed from walls. Spray walls with water and
follow one of the two methods mentioned below:
6.2.1) Traditional Plastering:
Similar to plastering of conventional block walls with the following
mix:
• Splattering (3mm): Use 1 cement : 3 sand mixed with
solution of water and Gesol (20% of the volume). Spray
with water twice a day.
• Ordinary Plastering Mortar: (1 – 1.5 cm thick, apply 24
hours after the splattering)
Use 1 cement : 6 sand mixed with solution of water and
Gesol (10% of volume).
6.2.2) Plastering with Pre-mixed Mortar (Serpo Prime)
Water is added to the pre-mixed plaster supplied in bags of
25 and 50 kgs. Surfaces should be thoroughly cleaned and
wetted without any splattering. Apply plaster directly with a
thickness ranging between 0.5 to 1 cm.
In both above methods, walls should be watered twice a day after
plastering for three consecutive days.
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AAC BUILDING SYSTEM

6. FIXINGS / CONNECTIONS
6.1 Bolts and Fixings
Special types of fixings can be used with Siporex structures such as galvanized cut nails, bolt fastenings and wall
plugs. The type of anchoring method to be used depends on the holding capacity required. These types of fixings
are used in installation of doors and windows, as well as wall accessories with weights not exceeding the allowable
loads of the type of fixing used. Ordinary wire nails should not be used since their anchoring ability to Siporex is
low. Through-bolts should be used in case of heavy fixtures such as water heater and hanging lavatories. Some of
the types of fixings and anchors suitable for use with Siporex AAC materials are as follows:

Galvanized Cut Nails Hilti HGN Anchors Fischer Anchors

Galvanized Cut Nails comes in HGN Gas Concrete Anchors, Also available with plastic plugs
different lengths and are available at manufactured by Hilti Company is a suitable for light to medium weight
our Siporex Factory. Cut nails are Cadmium-free Polyamide anchor fixings in aerated concrete. It has
hammered directly into Siporex walls specially suitable for AAC concrete fins providing grip as well as
and do not need to be pre-drilled They base. Available in various sizes, it resistance to rotation. This type is
can be used to fasten light to moderate provides high pressure per unit of also available in various sizes to
weight items to Siporex. area. suit the particular needs.

6.2 Cladding with Marble or Artificial Stone 6.3 Connection with dissimilar material

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AAC BUILDING SYSTEM

7. SIPOREX BUILDINGS

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AAC BUILDING SYSTEM

8. LIST OF SOME PROJECTS

S. # Client / Contractor Name of Project Location Year

1. Saudi Petrochemical Co. 136 Housing Units Jubail 1987
2. A.K. Group Aziziyah Housing 208 Villas AlKhobar 1992
3. ABV Rock Group SSSP Residential Cmpd 120 Units Madinah 1992
4. ABV Rock Group SSSP Residential Cmpd 110 Units Abha 1993
5. ABV Rock Group SSSP Residential Cmpd 110 Units Buraidah 1993
6. Kimma Construction Yanpet Housing Project 200 Villas Yanbu 1993
7. ABV Rock Group ABV Compound Jeddah 1993
8. A. K. Group Tabuk Gardens Village – 60 villas Tabuk 1994
9. Sata Engineering Blocks Taiwan 1994
10. Saudi Real Estate Co. D.Q. Housing Project Riyadh 1994
11. M.S. AlSuwaidi Cont. Est. Yanpet Housing Proj. Ph. II 300 Villas Yanbu 1994
12. AMERAB-ECO- Tawam 89 Villas & B. Walls AbuDhabi 1995
13. AlMobti for Trad. & Cont. 273 Villas Compound Djibouti 1996
14. A.K. Group R.S.L.F. Housing Tabuk 1996
15. International Center Co. YCC – 40 Villas Yanbu 1997
16. C C C (ARAMCO) Residential & Industrial Compound Shaybah 1997
17. Gen. Presidency for Girls Educ. 16 Colleges Buildings Diff. sites 1997
18. AlSwayeh Co. Hyatt Regency Hotel Riyadh 1998
19. Developed Building Co. Landmark Shopping Mall Proj. Qatar 1999
20. REDICO Tabuk Gardens Village – 2A Tabuk 2000
21. Developed Bldg. Co. Al Ittihad & Al Rayyan Stadiums Qatar 2001
22. Saudi Wiemer & Tracte Al Rushaid Village 2 Alkhobar 2001
23. Saudi Binladin Group King Abdullah Multi-storey Hotel Madinah 2001
24. Nasser Al Hajri Yanpet Housing Proj.-Ph.3 Yanbu 2002
25. Modern Villas Real Estate Housing Compound Riyadh 2002
26. Al Someie Real Estate Housing Compound Riyadh 2002
27. Abdullatif AlIssa Group Al Issa Compound Riyadh 2003
28. Al Marasem Contg. Residential Compound Shouaiba 2003
29. Bin Jarallah Group Gizan Housing Jizan 2003
30. Al Marasem Cont. Housing Compound Tufail 2003
31. Al Mashrab Co. Abha University Abha 2004
32. Al Ali Engineering 108 Villas Qatar 2004
33. Al Ali Engineering Villaggio Qatar 2004
34. King Abdullah Foundation 2,500 villas – Dev. Housing Project Diff.sites 2004-2006
35. EMECO Al Amar Gold Mine – Housing Quayyiah 2004
36. Al Ali Engineering 30 Villas Qatar 2005
37. Al Ali Engineering 84 Villas Qatar 2006
38. Assad Said Corporation ASC Housing Compound Jubail 2006
39. Al Ma’awdah Const. 25 Villas Bahrain 2006
40. Saudi Binladin Group Al Haram Shopping Center Madinah 2007
41. Al Ali Engineering The Pearl Qatar Qatar 2007
42. Al Ali Engineering 58 Villas Qatar 2007
43. Makkah Co. Supply of Blocks Kuwait/Iraq 2007
44. Al Mabda Rezayat Housing Compound Jubail 2007
45. Saudi Binladin Group Dar Al-Qibla Complex Madinah 2007
46. Sinoma Hofuf Cement Factory Hofuf 2007
47. Al-Marasem Co. Charity Housing Diff. sites 2007
48. Al-Othman Agri. Prod. Housing Compound Hofuf 2008
49. Danash Co. Al Jouf Cement Factory – Housing Turaif 2008
50. S.M.A. Proj. & Devt. Co. Khartoum College of Med. Science Sudan 2008
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