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An overview: basalt rock fibres-new construction material

Article · January 2014

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Acta Engineering International Aufau Periodicals

Review Article

An Overview: Basalt Rock Fibers - New Construction Material

Vishal Pandurang Kumbhar
AGTI’s Dr. Daulatrao Aher College of Engineering, Karad, India

Abstract

Glass, Carbon and polyamide fibers are commonly used in

manufacturing of reinforcing bars for concrete applications.
Recent development in fiber production technology allows
the making of basalt fibers which is made from basalt rock.
This technology mainly developed in USSR. Basalt fiber
have properties such as good range of thermal
performance, high tensile strength, good electromagnetic
properties, inert nature; and resistance to acid, radiation,
UV light, vibration and impact loading. This paper discuss
about their manufacturing processes. This paper also *Correspondence
discuss about availability of variety of forms of Basalt Vishal Pandurang Kumbhar
fibers products and their applications as new construction AGTI’s Daulatrao Aher College of
material ant technique. The average tensile strength and Engineering, India
modulus elasticity of BFRP bars were found to be about
Email: [email protected]
1090.2MPa and 42.78GPa respectively. The basalt fibers
manufactured mainly in Eastern Europe, Russia and USA,
Keywords: Basalt rock fibers, Strand,
now in Israel and China. Finally it is concluding that this is
Incinerator friendly, Fiberglass,
low cost material and possible to manufacture in India also
because large availability of basalt rock (nearly 5, 00,000 Building material
sq. km).

Introduction
In the recent days, the various fibers develop and used in the construction, industrial and highway engineering. The
steel is mainly used in that various application. Also fiber glass polythene fibers, carbon fibers, polyamide fibers are
now developed and also used in construction, industrial and infrastructure development. In that list new one fiber is
added, called, as basalt rock fibers.
Basalt originates from volcanic magma and flood volcanoes, a very hot fluid or semi-fluid material under the
earth crust, solidified in the open air. Basalt is the name given to a wide variety of volcanic rock, which is gray.
Brown or dark in colour, formed from volcanic lava after solidification.
The heavily thickened lavas contain olivine, clino-pyroxene (salite), plagioclase and opaque metal oxides.
Plageocene and pyroxene make up 80% of many types of basalts. Table 1.1 shows the results of the chemical analysis
of the basalt rock [2].
Because of good hardness and thermal properties, basalt has been used in the construction, industrial and
highway engineering, in the form of crushed rock. It is used as surfacing and filling in roads, the floor tiles in the
construction and as the lining material in the pipes for transporting the hot fluids. This can be major replacement to the
asbestos, which possess health hazards by damaging respiratory systems.
However, it is not commonly known that basalt can be used in manufacturing and made into fine, superfine
ultrafine fibers. Basalt is an alternative raw material for fiber 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
fibers in the molten state.
Basalt fiber offer prospect of completely new range of composite materials and product. Low cost high
performance fibers offer potential to solve the largest problem in the cement and concrete industry, cracking and
structural failure of concrete. They have potential to high performance and cost effectively replace of fiberglass, steel
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fiber, polyamide fiber and carbon fiber product in many applications. 1 Kg basalt fiber replaces 9.6 Kg steel
reinforcement. [6]

Fig.1.1 Volcanic magma Fig.1.2 Basalt rock

Table 1.1 Chemical Composition of Basalt Rock

Chemical %W
SiO2 52.8
Al2O3 17.5
Fe2O3 10.3
MgO 4.63
CaO 8.59
Na2O 3.34
K2O 1.46
TiO2 1.38
P2O5 0.28
MnO 0.16
Cr2O3 0.06

Fibers from Basalt

History
A French scientist in the US field the first patent revealing the technique of producing basalt fiber in the year
1923 and subsequently the research was started in the United States of Soviet Russia (USSR). The development of
basalt continues fibers (BCF) technology was conducted in the USSR; it had a status of closed scientific programs.
Therefore, there were no contacts with scientists and engineers from abroad. The main development efforts are given
by USSR for defense and aerospace applications.
The first samples of BCF were received at scientific research institute in Ukraine of USSR in 1956-61: but the
initial industrial equipment was very expensive and large energy consuming. After dismantling of USSR in 1990’s
.this research or technique made available to others. The recent efforts are taken for this technology to lower the cost
and commercial use. [4]

Fiber Forming Process

In many ways, basalt fiber technology is similar to glass fiber technology, except only one material, basalt
rock. Basalt continues filaments are made from the basalt rocks in a single step process melting and extrusion process.
Technological process of manufacturing basalt filament consists of melt preparation, fiber drawing (extrusion), fiber
formation, application of lubricants and finally winding. Basalt fibers are currently manufactured by heating the basalt
and extruding molten liquid through a die in the shape of fibers, as shown in plant layout figure 2.1. [3and7]

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Crushed rock material are charged into bath type melting furnace by a dozing charger, which is heated using
air gas mixture or electrically. Crushed rocks are converted into melt under temperature 1285 0C to 14500C in the
furnace bath. Molten basalt flows from furnace to feeder through feeder channel and feeder window communicate to
recuperate. The feeder has a window with a flange connected o slot type bushing and is heated by furnace waste gases
or by electrically. The melt flows through platinum-rhodium bushing with 200 holes which is heated electrically. The
fibers are drawn from melt under hydrostatic pressure and subsequently cooled to get hardened filaments.
A sizing liquid with components to impart strand integrity, lubricity and resin compatibility is applied, and
then filaments are collected together to form ‘strand’ and forwarded to take up devices to wound on forming tube.

1.Batch silos: raw material supply, 2. Weighing, dosing and mixing,

3. Pneumatic transport, 4. Batch box : charging,
5. Melting Furnace, 6. Feeder,
7. Bushings, (continuous filament formation), 8. Sizing application,
9. Draw plate feeder; Strand formation, 10. Lubricator,
11. Automated winder
Fig.2.1 Plant layout of basalt fiber formation

By varying the drawing speed of the fiber and temperature of the melt, fibers of wide size range could be
produced. For example, a drawing speed of 12m/s and nozzle temperature of 13250C a fiber of 7 micron were
produced while at 4m/s and 12850C a fiber of 17 micron was produced.

Cost of fiber production

The raw material required for the basalt fibers production, viz., basalt rock, single material, is inexpensive and readily
available in the world (mainly in India). The energy required to melting basalt rock in fiber formation higher than E-
glass fiber and similar to S2-glass fiber (E-glass fiber and S2-glass fiber are types of glass fiber). The bushing of
platinum-alloy used in process is very costly. And productivity of fiber is low during learning. Thus basalt fiber cost
somewhere between E-glass and S-glass fiber but should come down.

Properties of Basalt Fibers

Basalt fibers have different properties as follows-
Thermal Resistance
Basalt fiber has excellent thermal properties to that of glass fibers. It can easily withstand the temperature of 12000C
to13000C for hours continuously, without any physical change, which is similar to S2 glass fibers and carbon
fibers.Unstressed basalt fibers and fabrics can maintain their integrity even up to 12500C, which makes them superior
compared to glass and carbon fiber.

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Mechanical Strength
Basalt fiber has tensile strength 3000-4840 M Pa, which is higher than E-glass fiber. It has higher stiffness and
strength than E-glass fiber. Basalt fiber has slightly higher specific gravity, 2.6 – 2.8 g/cc, than other fibers.

Chemical Resistance
Basalt fibers 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 fiber has better corrosion resistance. It does not undergo any toxic reaction with water and air or gases also.
Moisture regain and moisture content of basalt fibers exist in the range of less than 1%. Basalt materials have strong
resistance against the action of fungi and micro-organisms.

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 fiber by fracture and results only in breaking of individual fibers from woven structure which
eliminates possibility of causing hazards.

Ecological Friendliness
Basalt fibers have natural raw material, which is basalt rock it does not cause any damage to the health. Basalt fiber
has no biological hazards and solves waste disposal problems. It does not clog incinerator as glass. Hence, it is
incinerator friendly.

Comparisons of Characteristics between Continuous Rock Fibers and Other Fibers

Table 4.1 and 4.2 shows comparison of Basalt fibers and other fibers
Table 4.1 Mechanical and Thermal Characteristics and Cost Comparison (Note: 1 Dollar = Rs.60/-)

S-glass Polyamide Carbon

Capability Basalt fiber E-glass fiber
fiber fiber fiber
Tensile strength,
3000~4840 3100~3800 4020~4650 2900~3450 3500~6000
M Pa
Tensile strength,
3000~4840 3100~3800 4020~4650 2900~3450 3500~6000
M Pa
Elastic modulus,
79.3~93.1 72.5~75.5 83~86 70~140 230~600
G Pa
Elongation at
3.1~6 4.7 5.3 2.8~3.6 1.5~2.0
break, %
Specific gravity 2.65-2.8 2.5~2.62 2.46 1.44 1.75~1.95
Diameter of
6~21 6~21 6~21 - 5~15
filament, mµ
Temperature of
-260~+500 -50~+380 -50 +300 -50~+290 -50~+700
application, °C
Melting
Temperature, 1450 1120 1550 - -
°C
Price, Rs./kg 150 90 120 1500 1800

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Table 4.2 Comparative % Weight loss after 3 hours boiling of CBF Fibers and Glass fibers in different Chemicals

CBF Fibers E-glass fiber S-glass fiber

H2O 0.2 0.7 0.05
2N NAOH 5 6 5
2N HCL 2.2 38.9 15.7

CBF Products and Its Application

Products

Figure 5.1 to figure 5.9 shows various products of basalt fibers. Continuous basalt filaments have following
primary products such as Continuous basalt fibers, Chopped fibers, CBF roving, CBF yarns [7and 8]
By using these primary products the secondary products are produced such as Basalt rebar, Basalt geo-textile,
Basalt mesh, Basalt fiber pipes, and Basalt laminates.

Fig 5.1 CBF Filaments Fig 5.2 Copped fibers Fig 5.3 CBF roving

Fig 5.4 CBF yarns Fig 5.5 Basalt rebar Fig 5.6 Basalt geo-textile
Applications
CBF products are used in various applications. They are as follows-

Nuclear power plant

Basalt materials do not absorb radioactive radiations, which makes them to consider as the potential in
production and transportation of radioactive materials, in nuclear power plants. Protective cap using geo-composites
in the waste disposal sites, incorporating the basalt materials, can offer best protection for the human health and
environment against the radioactive wastes.

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Fig 5.7 Basalt fibers pipes Fig 5.8 Basalt fibers mesh Fig 5.9 Basalt fiber fabric

Concrete reinforcement
Requirement of the moderate strengthening in the civil structures & high fire resistance can be met with basalt fibers.
Basalt filaments incorporated unidirectional rods are used as the reinforcement of concrete slabs in hydraulic
engineering and construction in seismically hazardous regions. It is also used in reinforcement for bridges, tunnels,
railway sleepers etc.
The basalt rebar consisting of 80% of basalt fiber with on epoxy binder offer better mechanical property to the
reinforced concrete & are less expensive. Basalt rebar have same coefficient of thermal expansion (8 ppm/ 0C) as that
of concrete, which increases the compatibility & performance in adverse conditions.
In the accelerated weathering tests, basalt fiber shows better results as compared to glass fibers. Exposed to
6000C for 2 hours also results in almost retention of 90% of normal strength while carbon fiber and glass fibers loss
their volumetric integrity.
Chopped fibers are used in cement concrete which increases crack resistance and fracture toughness of
concrete. It does not give any adverse effect in concrete mixing.

Building material
Basalt fibers can also be used in the interiors, partitioning of buildings, fire proof doors, and sound insulations for the
building. They have better sound insulation property. It can act as a barrier in the frequency range up to 1800Hz to the
extent of 80% to 95% [5]. It is also used as and warmed panels for construction of prefabricated houses such as
roofing. Basalt fibers have better thermal insulating properties, almost three times than the asbestos. Basalt fabrics are
used as fire blocking material in the public transport systems. Both woven as well as knitted fabrics are used for these
applications.
It is used in port construction and sea platforms because of better chemical and salt resistance property and
also for environment safety.

Road construction
Basalt geo-mesh offers a number of advantages over glass and metal mesh for the pavement reinforcement. They are
ecological safe and can withstand very high temperature of molten asphalt. The basalt geo-meshes are chemically inert
and lighter than metallic meshes. They are also safe in tunnel lining work. Basalt geo-textile is suitable for soil and
embankment stabilization and environmental and ecological safety.

Abrasion resistance basalt fiber pipes and casting

High pressure pipes can be manufactured through filament winding, using fabrics and prepegs impregnate with a
binder. These pipes are useful as components for transporting corrosive liquid and gases. Also basalt plastic pipes can
be used for a longer service life, i.e. 60 to 80 years, which is 2 to 3 times longer than the metallic pipes. These are
used in cement industries, chemical, oil and petrochemical industries.
Basalt fibers are also used in conveyor system for reinforcing the belts and coating for rollers to increase the
life span.

Agriculture
Basalt fibers can be used in the various agricultural applications like, land drainage pipes, pies for irrigation and
hosing. Also it is used in agricultural machine construction.
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Case Study
Case study shows an experimental result. Preliminary findings from recent research on concrete beams reinforced
with BFRP bars are presented by one research person. The average tensile strength and modulus of elasticity of BFRP
bars were determined from the test program and were found to be about 1090.2 M Pa and 42.78 G Pa respectively.

Beam Test
Thirteen test beams were tested over a span of 5 feet. The moment strength of concrete beams reinforced with BFRP
(Basalt Fibers Reinforced Polymer) bars was found to be consistent with mechanical properties of BFRP bars. The
design recommendations of ACI440.1R-06 are mostly adequate to predict the moment strength of concrete beams
reinforced with BFRP bars. However, research needs also exist in the area of shear strength and durability of BFRP
reinforced concrete members. The research presented in this paper was funded by Reforce Tech AS, Norway.

Test Result
It can be seen that most beams were able to achieve the moment strength that is predicted using ACI440.1R-06
method that is applicable to other common type of FRP. The preliminary research indicates that BFRP bars are
performing well than other types of common bars. A summary of test results is shown in table 6.1 [1].

Table 6.1 Summary of Tensile Properties of BFRP Bars

Bar Diameter (mm) Area(mm2) fu,ave ( M Pa) Ef,ave (G Pa)

R4 4.3 14.5 1110 41.1
R7 7.1 39.7 1084 41.4
R10 9.8 75.6 1067 45.1
(Note: fu,ave = Average tensile strength, Ef,ave = Average modulus of elasticity)

Possibility of Implement in India

Current sources of basalt fiber production are mainly in Eastern Europe, viz., Russia, Ukraine, Germany, Belgium,
United Kingdom and United states of America where technology immersed. Also these sources expanded and now in
Israel and China. Various plans for more production have been announced but these plans haven’t all materialized.
These fiber manufacturing should be closed to suitable basalt quarries and inexpensive energy. Basalt is also
available in southern part of India. This technology has possible to implement in India. Basalt rock covers (Deccan
Trap) an area of about 5,00,000 Sq. Km which is large part of the Maharashtra, Kutch, Gujarat, Madhya Pradesh, Goa,
Karnataka, Andhra Pradesh etc.

Conclusions

1) Basalt can be used in manufacturing and made into fine, superfine ultrafine fibers. Basalt is an alternative raw
material for fiber 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 fibers in the molten state.
2) Basalt Rock fibers 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.
3) Basalt rock fibers have new range of material in building construction, road construction, concrete industry and
agriculture field. They have potential to high performance and cost effectively replace of fiberglass, steel and
carbon fiber product in many applications. 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.

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4) 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.
Thus, it is possible to install this technology in India (Maharashtra).

References

[1] Dr. Patnaik Anil, “Applications of Basalt Fibers Reinforced Polymer (BFRP) Reinforcement for Transportation
Infrastructure”, Developing a Research Agenda for Transportation Infrastructure – TRB, November 2009, 1-5.
[2] Dr. Sergey Osnos, “Basalt continuous fiber: development of technologies and equipment from the past to the
present”, Basalt Fiber & Composite Materials Technology Development Company, China.
[3] Murray Allan D.,” Basalt Fibers for high-performance composites”, Allied composite Technologies LLC, 1-4.
[4] Saravanan D., “Spinning of rocks – Basalt fibers”, Institute of Engineers (India) Journal, volume 82, February
2006, 39-45.
[5] Sheldon G. L., “Forming fibers from basalt rock”, platinum metal review, 1977, 18-24.
[6] Singha Kunal “A Short Review on Basalt Fiber”, International Journal of Textile Science, volume 1 (4), 2012, 19-
28.
[7] Basaltex Pvt. Ltd., “Basalt continuous fiber: development of technologies from the past to present”, 1-6.
[8] Basalt information, “Aketoma – Basalt fabrics, tubes, Mesh, rods etc.”, (www.laseroptronix.se/exoma/
basaltinformation.pdf).

© 2014, by the Authors. The articles published from this journal are distributed to Publication History
the public under “Creative Commons Attribution License” Received 12th Nov 2014
(http://creativecommons.org/licenses/by/3.0/). Therefore, upon proper citation of Revised 08th Dec 2014
the original work, all the articles can be used without any restriction or can be Accepted 08th Dec 2014
distributed in any medium in any form. Online 30th Dec 2014

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