basalt rock fibre

Basalt fiber which made from fibers of basalt rock is very much similar to the carbon and the fiber glass and have better physicomechanical properties and cheaper. One Kg of basalt reinforces is equal 9.6 Kg of the steel. They have many field applications and can replace many costly and rare materials. Its manufacturing process is very simple and raw materials are found virtually in every country. Basalt fibers offer the potential to solve the largest problem in the cement and concrete industry.

1. BASALT ROCK FIBRE Submitted By, S . INDHU

2. INTRODUCTION: M aterial which is made from the extremely fine fibres of the Basalt, which composed of Pyroxene, minerals plagioclase and Olivine. Similar to the Carbon Fibre and the Fibre Glass, which is having better Physico mechanical properties than the fiber glass, but which is being significantly cheaper that the Carbon Fiber. U sed as the fiber proof textile in automotive industries and in the Aerospace and can be used as a composite to produce the products such as the tripods. Basalt Rock fibers has no toxic reaction with the air or water, are noncombustible and the explosion proof. The Basalt base composites can be replacing steel and known reinforced plastics. One Kg of basalt reinforces is equals to 9.6 Kg of the steel. There seems to be something quite poetic in using a fiber made from the natural rock to reinforce a material, which may quite reasonably being described as the artificial rock . Raw material for producing basalt fiber is the rock of a volcanic origin.

3. BASALT ROCK FIBRE - SCOPE Low cost, high performance fibers offer the potential to solve the largest problem in the cement and concrete industry, cracking and structural failure of concrete. Because of the higher performance (strength, temperature range, and durability) and lower potential cost predicted for basalt fibers. Have potential to cost effectively replace fiber glass, steel, Fiber, poly propylene, poly ethylene, polyester, aramid and carbon fiber products in many applications. Fig 1: Basalt rock and its some products  

4. BASALT ROCK FIBRE PRODUCTS : Basalt Reinforcement Rod Continuous Basalt Fiber Basalt Geotextile Basalt Reinforcing Mesh

5. 1. Basalt Reinforcement Rods: Higher specific strength and resistant to corrosion, which is chemically inert. No permanent deformation when bent. Fig 2: Basalt reinforcement rod  

6. 2. Basalt Geotextile: They are made of natural raw material (natural chemical composition provides chemical stability and resistance).They are non-inflammable and they can carry out distributed load. The cost is 4-5 lower than other geotextile material. Fig : 3 Basalt Geotextiles

7. 3. Continuous Basalt Fiber: Only one component of basalt, which is an environmentally safe. Cost of basalt raw material is very low There is no need for primary enrichment, fusion and Homogenization, as all of those was made for free by nature; to make CBF basalt should be heated up only one time; further processing of CBF into materials does not require energy; it is made with application of cold technologies. Fig 4: Continuous Basalt Fibres

8. 4. Basalt Reinforcing Mesh: Basalt reinforcing mesh is designed for reinforcing road and highway overlays to prolong the pavement lifespan by reducing the effects of reflective cracking caused by traffic loading, age hardening and temperature cycling. Pavement life between maintenance can be prolonged significantly. Basalt reinforcing mesh makes it possible to reduce thickness of asphalt concrete pavement up to 20%. Fig 5: Basalt reinforcing mesh

9. ADVANTAGES AND BENEFITS: Higher mechanical strength and modulus. More resistive to chemical aggressive environment than E-glass mesh. Lower cost and better mechanical properties than for mesh made of special glass fiber. Lower elongation before brake than for synthetic material. Easily milled using typical milling equipment. Does not stretch and pull as polymer meshes. No special equipment is required to install the reinforcement. Basalt mesh is environment friendly and based on naturally occurring material that is found worldwide They have no toxic action with air & water. Very high chemical resistance. Basalt is the best reinforcement for concrete due to its tensile strength. Noise absorption qualities. Basalt based composites can efficiently replace steel and all known reinforced plastics Water absorption

10. PROPERTIES OF BASALT FIBERS: Thermal Resistance: Basalt fibre has excellent thermal properties to that of glass fibres. It can easily withstand the temperature of 12000C to13000C for hours continuously, without any physical change, which is similar to S2 glass fibres and carbon fibres. Unstressed basalt fibres and fabrics can maintain their integrity even up to 12500C, which makes them superior compared to glass and carbon fibre. Mechanical Strength: Basalt fibre has tensile strength 3000-4840 M Pa, which is higher than E glass fibre. It has higher stiffness and strength than E glass fibre. Basalt fibre has slightly higher specific gravity, 2.6 – 2.8 g/cc, than other fibres.    

11. PROPERTIES OF BASALT FIBERS: Chemical Resistance: Basalt fibres have very good resistance against alkaline environment, with the capability to withstand pH up to 13-14 . It also has good acid and salt resistance. Corrosion and Fungi Resistance: Basalt fibre has better corrosion resistance. It does not undergo any toxic reaction with water and air or gas es also. Moisture regain and moisture content of basalt fibres exist in the range of less than 1%. Basalt materials have strong resistance against the action of fungi and microorganisms.

12. PROPERTIES OF BASALT FIBERS: Abrasion Property: Basalt material is extremely hard and has hardness values between 5 to 9 on Mohr’s scale, which results in better abrasion property. Even continuous abrasion of the basalt fiber woven fabrics over the propeller type abraders do not result in the splitting of fibre by fracture and results only in breaking of individual fibres from Woven structure which eliminates possibility of causing hazards. Ecological Friendliness: Basalt fibres have natural raw material, which is basalt rock it does not cause any damage to the health. Basalt fibre has no biological hazards and solves waste disposal problems. It does not clog incinerator as glass. Hence, it is incinerator friendly.

13. FIELD APPLICATIONS OF BASALT ROCK FIBRE: Construction Road Construction Engineering Net Work Agriculture Underground Construction Machine Construction

14. Construction: Reinforcement of bridges, Tunnels, External and internal heat and sound insulation. Insulation of panel butt joints, Directional and depressive reinforcement of concrete, Repair (healing) of cracks. L ocal damage to building, bridges, building construction, Soft roofing made of non- combustible baraltoinson and basalaltoplastic , Rigid roofing (of slate and tile type). Fig 6: Basalt reinforced bridge

15. Road Construction: Reinforcement of concrete and asphalt pavements and runways, Construction of sound-absorbing barriers for highways, railways, and underground metro lines, Curbstones, pavement linings (basalt casting), Small moulds .  Fig 7: Underground road

16. Engineering Networks: Pipelines for heating and hot water supply, Pipelines for heat supply, Canalization,Oil and gas pipelines, Cable conduit for telephone system protected against electromagnetic fields and information leakage through electronic surveillance, High efficient seals and linings for pipelines, Pipes for chemical products and transportation of aggressive media, Pumps for aggressive media. Fig 8: Pipe lines for various purposes

17. Agriculture: Land Drainage Pipes, Pipes for Irrigation and Hosting Raising Vegetable and Seeding ( Hydroponics) Basalt Super Thin Fiber Agricultural Construction, Agricultural Machine Construction.  

18. Underground Construction: Anchors, Pillars, Ceilings, Vaults, Pipelines for Various Purposes, Foundations for Buildings and Constructions, Less Laying Of Pipelines. Fig 9: Basalt rock for underground construction

19. Machine Construction: Case and body parts, Thermo constant body containers, Refrigerators, Completely incombustible thermal and sound insulation for cabins, motor compartments, Metro carriages, ships and aircraft, Electro technical and electronic circuit, boards, brake pads for automobiles, aircraft.

20. TECHNICAL PROPERTIES: High tensile strength, Quite durable. Alkali & acids resistant. High thermal conductivity. Completely inert with no environmental risks, High chemical resistance, High thermal resistance (thermo stability) and low flammability. High thermal and acoustic insulation properties. Excellent adhesion to polymer resins and rubbers. Relatively high mechanical strength, abrasion resistance and elasticity, High dielectric properties, Low water absorption. Ecologically clean and non-toxic

21. TECHNICAL PROPERTIES: Property Value Tensile strength 4.84 GPa Elastic modulus 89 GPa Elongation at break 3.15 % Density 2.7g/cm³

22. CHEMICAL COMPOSITION BASALT ROCK : Chemical Name : Basic volcanic igneous rock from calc -alkali series. CHEMICAL COMPOUND % WEIGHT OF BASALT SiO 2 49.58 TiO 2 2.08 Al 2 O 3 14.48 Fe 2 O 3 4.42 Feo 9.43 K 2 O 1.89 Na 2 O 2.10 Mgo 5.10 Cao 8.50

23. MANUFACTURE: Basalt fiber is made from a single material, crushed basalt, from a carefully chosen quarry source The basalt is simply washed and then sent to be melted down. The manufacture of basalt fiber requires the melting of the quarried basalt rock at about 1,400 °C (2,550 °F ). The molten rock is then extruded through small nozzles to produce continuous filaments of basalt fiber . There are three main manufacturing techniques, which are centrifugal-blowing, centrifugal-multi roll and die-blowing. The fibers typically have a filament diameter of between 9 and 13 µm which is far enough above the respiratory limit of 5 µm to make basalt fiber a suitable replacement for asbestos . They also have a high elastic modulus , resulting in excellent specific tenacity —three times that of steel .

24. MANUFACTURE: Fig 10: Manufacturing Process

25. CONCLUSION: Basalt can be used in manufacturing and made into fine, superfine ultrafine fibres. Basalt is an alternative raw material for fibre forming because of its relatively homogeneous chemical structure, its large scale availability throughout the world, its freedom from impurities and of course, its ability to form fibres in the molten state. Basalt Rock fibres have no toxic reaction with air or water, are non-combustible. When in contact with other chemicals they produce no chemical reactions that may damage health or the environment. So it is ecological friendly material. Basalt rock fibres have new range of material in building construction, road construction, concrete industry and agriculture field. As per case study, concrete beam reinforced with BFRP bars achieved tensile strengths that are consisting with the relevant properties of the constituent materials. Concrete beams reinforced with BFRP bars behave in ductile manner exhibiting large deflection at failure. Basalt is well known as a rock found in virtually every country round the world. Basalt rock is more in India (especially in Maharashtra). The cost of basalt is 10 times lower than that of raw materials for fiberglass. Basalt is more available than any other raw material .  

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