Basalt fibers are produced from basalt rocks by melting them and converting the melt into fibers. Basalts are rocks of igneous origin. Basalt fibers are classified into 3 types:
- Basalt continuous fibers (BCF), used for the production of reinforcing materials and composite products, fabrics, and non-woven materials;
- Basalt staple fibers, for the production of thermal insulation materials; and
- Basalt superthin fibers (BSTF), for the production of high quality heat- and sound-insulating and fireproof materials.
Manufacturing process
The technology of production of basalt continuous fiber (BCF) is a one-stage process: melting, homogenization of basalt and extraction of fibers. Basalt is heated only once. Further processing of BCF into materials is carried out using "cold technologies" with low energy costs.
Basalt fiber is made from a single material, crushed basalt, from a carefully chosen quarry source. Basalt of high acidity (over 46% silica content) and low iron content is considered desirable for fiber production. Unlike with other composites, such as glass fiber, essentially no materials are added during its production. The basalt is simply washed and then melted.
The manufacture of basalt fiber requires the melting of the crushed and washed basalt rock at about 1,500 °C (2,730 °F). The molten rock is then extruded through small nozzles to produce continuous filaments of basalt fiber.
The basalt fibers typically have a filament diameter of between 10 and 20 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 high specific strength—three times that of steel. Thin fiber is usually used for textile applications mainly for production of woven fabric. Thicker fiber is used in filament winding, for example, for production of compressed natural gas (CNG) cylinders or pipes. The thickest fiber is used for pultrusion, geogrid, unidirectional fabric, multiaxial fabric production and in form of chopped strand for concrete reinforcement. One of the most prospective applications for continuous basalt fiber and the most modern trend at the moment is production of basalt rebar that more and more substitutes traditional steel rebar on construction market.
Properties
The table refers to the continuous basalt fiber specific producer. Data from all the manufacturers are different, the difference is sometimes very large values.
| Property | Value |
|---|---|
| Tensile strength | 2.8–3.1 GPa (410–450 ksi) |
| Elastic modulus | 85–87 GPa (12,300–12,600 ksi) |
| Elongation at break | 3.15% |
| Density | 2.67 g/cm3 (0.096 lb/cu in) |
Comparison:
| Material | Density (g/cm3) | Tensile strength (GPa) | Specific strength | Elastic modulus (GPa) | Specific modulus |
|---|---|---|---|---|---|
| Steel rebar | 7.85 | 0.5 | 0.0637 | 210 | 26.8 |
| 2.46 | 2.1 | 0.854 | 69 | 28 | |
| C-glass | 2.46 | 2.5 | 1.02 | 69 | 28 |
| E-glass | 2.60 | 2.5 | 0.962 | 76 | 29.2 |
| 2.49 | 4.83 | 1.94 | 97 | 39 | |
| Silicon | 2.16 | 0.206-0.412 | 0.0954-0.191 | ||
| Quartz | 2.2 | 0.3438 | 0.156 | ||
| Carbon fiber (large) | 1.74 | 3.62 | 2.08 | 228 | 131 |
| Carbon fiber (medium) | 1.80 | 5.10 | 2.83 | 241 | 134 |
| Carbon fiber (small) | 1.80 | 6.21 | 3.45 | 297 | 165 |
| Kevlar K-29 | 1.44 | 3.62 | 2.51 | 41.4 | 28.7 |
| Kevlar K-149 | 1.47 | 3.48 | 2.37 | ||
| Polypropylene | 0.91 | 0.27-0.65 | 0.297-0.714 | 38 | 41.8 |
| Polyacrylonitrile | 1.18 | 0.50-0.91 | 0.424-0.771 | 75 | 63.6 |
| Basalt fiber | 2.65 | 2.9-3.1 | 1.09-1.17 | 85-87 | 32.1-32.8 |
[citation needed]
| Material type | Elastic modulus (E) | Yield stress (fy) | Tensile strength (fu) |
|---|---|---|---|
| 13-mm-diameter steel bars | 200 GPa (29,000 ksi) | 375 MPa (54.4 ksi) | 560 MPa (81 ksi) |
| 10-mm-diameter steel bars | 200 GPa (29,000 ksi) | 360 MPa (52 ksi) | 550 MPa (80 ksi) |
| 6-mm-diameter steel bars | 200 GPa (29,000 ksi) | 400 MPa (58 ksi) | 625 MPa (90.6 ksi) |
| 10-mm-diameter BFRP bars | 48.1 GPa (6,980 ksi) | - | 1,113 MPa (161.4 ksi) |
| 6-mm-diameter BFRP bars | 47.5 GPa (6,890 ksi) | - | 1,345 MPa (195.1 ksi) |
| BFRP sheet | 91 GPa (13,200 ksi) | - | 2,100 MPa (300 ksi) |
History
The first attempts to produce basalt fiber were made in the United States in 1923 by Paul Dhe who was granted U.S. patent 1,462,446. These were further developed after World War II by researchers in the US, Europe and the Soviet Union especially for military and aerospace applications. Since declassification in 1995 basalt fibers have been used in a wider range of civilian applications.
Schools
- RWTH Aachen University. Every two year RWTH Aachen University's Institut für Textiltechnik hosts the International Glass Fibers Symposium where basalt fiber is devoted a separate section. The university conducts regular research to study and improve basalt fiber properties. Textile concrete is also more corrosion-resistant and more malleable than conventional concrete. Replacement of carbon fibers with basalt fibers can significantly enhance the application fields of the innovative composite material that is textile concrete, says Andreas Koch.
- The Institute for Lightweight Design Materials Science at the University of Hannover
- The German Plastics Institute (DKI) in Darmstadt
- The Technical University of Dresden had contributed in the studying of basalt fibers. Textile reinforcements in concrete construction - basic research and applications. The Peter Offermann covers the range from the beginning of fundamental research work at the TU Dresden in the early 90s to the present. The idea that textile lattice structures made of high-performance threads for constructional reinforcement could open up completely new possibilities in construction was the starting point for today's large research network. Textile reinforcements in concrete construction - basic research and applications. As a novelty, parallel applications to the research with the required approvals in individual cases, such as the world's first textile reinforced concrete bridges and the upgrading of shell structures with the thinnest layers of textile concrete, are reported.
- University of Applied Sciences Regensburg, Department of Mechanical Engineering. Mechanical characterization of basalt fibre reinforced plastic with different fabric reinforcements – Tensile tests and FE-calculations with representative volume elements (RVEs). Marco Romano, Ingo Ehrlich.
Uses
- Heat protection
- Friction materials
- Windmill blades
- Lamp posts
- Ship hulls
- Car bodies
- Sports equipment
- Speaker cones
- Cavity wall ties
- Rebar
- Load bearing profiles
- CNG cylinders and pipes
- Absorbent for oil spills
- Chopped strand for concrete reinforcement
- High pressure vessels (e.g. tanks and gas cylinders)
- Pultruded rebar for concrete reinforcement (e.g. for bridges and buildings)
Design codes
Russia
Since October 18, 2017, JV 297.1325800.2017 "Fibreconcrete constructions with nonmetallic fiber has been put into operation. Design rules, "which eliminated the legal vacuum in the design of basalt reinforced fiber reinforced concrete. According to paragraph 1.1. the standard extends to all types of non-metallic fibers (polymers, polypropylene, glass, basalt and carbon). When comparing different fibers, it can be noted that polymer fibers are inferior to mineral strengths, but their use makes it possible to improve the characteristics of building composites.
See also
- Pele's hair
- Mineral wool
- Glass wool
- Beta cloth
References
- "Research surveys for basalt rock quarries | Basalt Projects Inc. | Engineering continuous basalt fiber and CBF-based composites". Basalt Projects Inc. Retrieved 2017-12-10.
- De Fazio, Piero (2011). "Basalt fibra: from earth an ancient material for innovative and modern application" (PDF). Energia, Ambiente e Innovazione. 3: 89–96. Archived from the original (PDF) on 2021-09-18. Retrieved 2021-09-08.
- Schut, Jan H. (August 2008). "Composites: Higher Properties, Lower Cost". www.ptonline.com. Retrieved 2017-12-10.
- Ross, Anne (August 2006). "Basalt Fibers: Alternative To Glass?". www.compositesworld.com. Retrieved 2017-12-10.
- "Basalt Fibers from continuous-filament basalt rock". basalt-fiber.com.
- Soares, B.; Preto, R.; Sousa, L.; Reis, L. (2016). "Mechanical behavior of basalt fibers in a basalt-UP composite". Procedia Structural Integrity. 1: 82–89. doi:10.1016/j.prostr.2016.02.012.
- Choi, Jeong-Il; Lee, Bang (30 September 2015). "Bonding Properties of Basalt Fiber and Strength Reduction According to Fiber Orientation". Materials. 8 (10): 6719–6727. Bibcode:2015Mate....8.6719C. doi:10.3390/ma8105335. PMC 5455386. PMID 28793595.
- "Some aspects of the technological process of continuous basalt fiber". novitsky1.narod.ru. Retrieved 2018-06-21.
- "Basalt Continuous Fiber". Archived from the original on 2009-11-03. Retrieved 2009-12-29.
- Ibrahim, Arafa M.A; Fahmy, Mohamed F.M; Wu, Zhishen (2016). "3D finite element modeling of bond-controlled behavior of steel and basalt FRP-reinforced concrete square bridge columns under lateral loading". Composite Structures. 143: 33–52. doi:10.1016/j.compstruct.2016.01.014.
- "Basalt fiber". basfiber.com (in Russian, English, German, Korean, and Japanese). Retrieved 2018-06-21.
- (the main work is the book "Konstruieren mit Faser-Kunststoff-Verbunden" of Helmut Schürmann)
- B. Jungbauer, M. Romano, I. Ehrlich, Bachelorthesis, University of Applied Sciences Regensburg, Laboratory of Composite Technology, Regensburg, (2012).
- Albarrie - BASALT FIBER
- Neuvokas
- Henderson, Tom (December 10, 2016). "Neuvokas raises the bar on manufacture of rebar". Crain's Detroit Business. Retrieved 17 December 2018.
Bibliography
- E. Lauterborn, Dokumentation Ultraschalluntersuchung Eingangsprüfung, Internal Report wiweb Erding, Erding,bOctober (2011).
- K. Moser, Faser-Kunststoff-Verbund – Entwurfs- und Berechnungsgrundlagen. VDI-Verlag, Düsseldorf, (1992).
- N. K. Naik, Woven Fabric Composites. Technomic Publishing Co., Lancaster (PA), (1994).
- Bericht 2004-1535 – Prüfung eines Sitzes nach BS 5852:1990 section 5 – ignition source crib 7, für die Fa. Franz Kiel gmbh&Co. KG. Siemens AG, A&D SP, Frankfurt am Main, (2004).
- DIN EN 2559 – Luft- und Raumfahrt – Kohlenstoffaser-Prepregs – Bestimmung des Harz- und Fasermasseanteils und der flächenbezogenen Fasermasse. Normenstelle Luftfahrt (NL) im DIN Deutsches Institut für Normung e.V., Beuth Verlag, Berlin, (1997).
- Epoxidharz L, Härter L – Technische Daten. Technical Data Sheet by R&G, (2011).
- Quality Certificates for Fabrics and Rovings. Incotelogy Ltd., Bonn, January (2012).
- Nolf, Jean Marie (2003). "Basalt Fibres-Fire Blocking Textiles". Technical Usage Textile. 49 (3): 38–42.
- Ozgen, Banu; Gong, Hugh (May 2011). "Yarn geometry in woven fabrics". Textile Research Journal. 81 (7): 738–745. doi:10.1177/0040517510388550. S2CID 138546738.
- L. Papula, Mathematische Formelsammlung für Naturwissenschaftler und Ingenieure. 10. Auflage, Vieweg+Teubner, Wiesbaden, (2009).
- Saravanan, D. (2006). "Spinning the rocks-basalt fibres". IE (I) Journal-TX. 86: 39–45.
- Schmid, Vinzent; Jungbauer, Bastian; Romano, Marco; Ehrlich, Ingo; Gebbeken, Norbert (June 2012). The influence of different types of fabrics on the fibre volume content and porosity in basalt fibre reinforced plastics. Applied Research Conference. pp. 162–165.
• Osnos S, Osnos M, «BCF: developing industrial production for reinforcement materials and composites». JEC Composites magazine / N° 139 March - April 2021, p.19 – 24.
• Osnos S., Rozhkov I. «Application of basalt rock-based materials in the automotive industry». JEC Composites magazine / N° 147, 2022, p. 33 – 36.
External links
- The production of basalt fibers Information from the Uzbekistan state scientific committee
- Basalt Continuous Fiber - Information and Characteristics
- Basalt Roving Dome Video demonstration of concrete construction reinforced with basalt fiber
- Generation 2.0 of Continuous Basalt Fiber Comparing the technologies used in CBF production
- Compressive behavior of Basalt Fiber Reinforced Composite
- Product range of Basfiber products offered by Kamenny Vek
- Extruded Acrylic Sheet - Excellent Thermoforming Capabilities
- Some aspects of the technological process of continuous basalt fiber CBF
- Video demonstration of production of continuous basalt fiber at Kamenny Vek
Basalt fibers are produced from basalt rocks by melting them and converting the melt into fibers Basalts are rocks of igneous origin Basalt fibers are classified into 3 types Basalt continuous fibers BCF used for the production of reinforcing materials and composite products fabrics and non woven materials Basalt staple fibers for the production of thermal insulation materials and Basalt superthin fibers BSTF for the production of high quality heat and sound insulating and fireproof materials Basalt fiber right compared to glass fiber left Manufacturing processThe technology of production of basalt continuous fiber BCF is a one stage process melting homogenization of basalt and extraction of fibers Basalt is heated only once Further processing of BCF into materials is carried out using cold technologies with low energy costs Basalt fiber is made from a single material crushed basalt from a carefully chosen quarry source Basalt of high acidity over 46 silica content and low iron content is considered desirable for fiber production Unlike with other composites such as glass fiber essentially no materials are added during its production The basalt is simply washed and then melted The manufacture of basalt fiber requires the melting of the crushed and washed basalt rock at about 1 500 C 2 730 F The molten rock is then extruded through small nozzles to produce continuous filaments of basalt fiber The basalt fibers typically have a filament diameter of between 10 and 20 mm which is far enough above the respiratory limit of 5 mm to make basalt fiber a suitable replacement for asbestos They also have a high elastic modulus resulting in high specific strength three times that of steel Thin fiber is usually used for textile applications mainly for production of woven fabric Thicker fiber is used in filament winding for example for production of compressed natural gas CNG cylinders or pipes The thickest fiber is used for pultrusion geogrid unidirectional fabric multiaxial fabric production and in form of chopped strand for concrete reinforcement One of the most prospective applications for continuous basalt fiber and the most modern trend at the moment is production of basalt rebar that more and more substitutes traditional steel rebar on construction market PropertiesThe table refers to the continuous basalt fiber specific producer Data from all the manufacturers are different the difference is sometimes very large values Property ValueTensile strength 2 8 3 1 GPa 410 450 ksi Elastic modulus 85 87 GPa 12 300 12 600 ksi Elongation at break 3 15 Density 2 67 g cm3 0 096 lb cu in Comparison Material Density g cm3 Tensile strength GPa Specific strength Elastic modulus GPa Specific modulusSteel rebar 7 85 0 5 0 0637 210 26 82 46 2 1 0 854 69 28C glass 2 46 2 5 1 02 69 28E glass 2 60 2 5 0 962 76 29 22 49 4 83 1 94 97 39Silicon 2 16 0 206 0 412 0 0954 0 191Quartz 2 2 0 3438 0 156Carbon fiber large 1 74 3 62 2 08 228 131Carbon fiber medium 1 80 5 10 2 83 241 134Carbon fiber small 1 80 6 21 3 45 297 165Kevlar K 29 1 44 3 62 2 51 41 4 28 7Kevlar K 149 1 47 3 48 2 37Polypropylene 0 91 0 27 0 65 0 297 0 714 38 41 8Polyacrylonitrile 1 18 0 50 0 91 0 424 0 771 75 63 6Basalt fiber 2 65 2 9 3 1 1 09 1 17 85 87 32 1 32 8 citation needed Material type Elastic modulus E Yield stress fy Tensile strength fu 13 mm diameter steel bars 200 GPa 29 000 ksi 375 MPa 54 4 ksi 560 MPa 81 ksi 10 mm diameter steel bars 200 GPa 29 000 ksi 360 MPa 52 ksi 550 MPa 80 ksi 6 mm diameter steel bars 200 GPa 29 000 ksi 400 MPa 58 ksi 625 MPa 90 6 ksi 10 mm diameter BFRP bars 48 1 GPa 6 980 ksi 1 113 MPa 161 4 ksi 6 mm diameter BFRP bars 47 5 GPa 6 890 ksi 1 345 MPa 195 1 ksi BFRP sheet 91 GPa 13 200 ksi 2 100 MPa 300 ksi HistoryThe first attempts to produce basalt fiber were made in the United States in 1923 by Paul Dhe who was granted U S patent 1 462 446 These were further developed after World War II by researchers in the US Europe and the Soviet Union especially for military and aerospace applications Since declassification in 1995 basalt fibers have been used in a wider range of civilian applications Schools RWTH Aachen University Every two year RWTH Aachen University s Institut fur Textiltechnik hosts the International Glass Fibers Symposium where basalt fiber is devoted a separate section The university conducts regular research to study and improve basalt fiber properties Textile concrete is also more corrosion resistant and more malleable than conventional concrete Replacement of carbon fibers with basalt fibers can significantly enhance the application fields of the innovative composite material that is textile concrete says Andreas Koch The Institute for Lightweight Design Materials Science at the University of Hannover The German Plastics Institute DKI in Darmstadt The Technical University of Dresden had contributed in the studying of basalt fibers Textile reinforcements in concrete construction basic research and applications The Peter Offermann covers the range from the beginning of fundamental research work at the TU Dresden in the early 90s to the present The idea that textile lattice structures made of high performance threads for constructional reinforcement could open up completely new possibilities in construction was the starting point for today s large research network Textile reinforcements in concrete construction basic research and applications As a novelty parallel applications to the research with the required approvals in individual cases such as the world s first textile reinforced concrete bridges and the upgrading of shell structures with the thinnest layers of textile concrete are reported University of Applied Sciences Regensburg Department of Mechanical Engineering Mechanical characterization of basalt fibre reinforced plastic with different fabric reinforcements Tensile tests and FE calculations with representative volume elements RVEs Marco Romano Ingo Ehrlich UsesHeat protection Friction materials Windmill blades Lamp posts Ship hulls Car bodies Sports equipment Speaker cones Cavity wall ties Rebar Load bearing profiles CNG cylinders and pipes Absorbent for oil spills Chopped strand for concrete reinforcement High pressure vessels e g tanks and gas cylinders Pultruded rebar for concrete reinforcement e g for bridges and buildings Design codesRussia Since October 18 2017 JV 297 1325800 2017 Fibreconcrete constructions with nonmetallic fiber has been put into operation Design rules which eliminated the legal vacuum in the design of basalt reinforced fiber reinforced concrete According to paragraph 1 1 the standard extends to all types of non metallic fibers polymers polypropylene glass basalt and carbon When comparing different fibers it can be noted that polymer fibers are inferior to mineral strengths but their use makes it possible to improve the characteristics of building composites See alsoPele s hair Mineral wool Glass wool Beta clothReferences Research surveys for basalt rock quarries Basalt Projects Inc Engineering continuous basalt fiber and CBF based composites Basalt Projects Inc Retrieved 2017 12 10 De Fazio Piero 2011 Basalt fibra from earth an ancient material for innovative and modern application PDF Energia Ambiente e Innovazione 3 89 96 Archived from the original PDF on 2021 09 18 Retrieved 2021 09 08 Schut Jan H August 2008 Composites Higher Properties Lower Cost www ptonline com Retrieved 2017 12 10 Ross Anne August 2006 Basalt Fibers Alternative To Glass www compositesworld com Retrieved 2017 12 10 Basalt Fibers from continuous filament basalt rock basalt fiber com Soares B Preto R Sousa L Reis L 2016 Mechanical behavior of basalt fibers in a basalt UP composite Procedia Structural Integrity 1 82 89 doi 10 1016 j prostr 2016 02 012 Choi Jeong Il Lee Bang 30 September 2015 Bonding Properties of Basalt Fiber and Strength Reduction According to Fiber Orientation Materials 8 10 6719 6727 Bibcode 2015Mate 8 6719C doi 10 3390 ma8105335 PMC 5455386 PMID 28793595 Some aspects of the technological process of continuous basalt fiber novitsky1 narod ru Retrieved 2018 06 21 Basalt Continuous Fiber Archived from the original on 2009 11 03 Retrieved 2009 12 29 Ibrahim Arafa M A Fahmy Mohamed F M Wu Zhishen 2016 3D finite element modeling of bond controlled behavior of steel and basalt FRP reinforced concrete square bridge columns under lateral loading Composite Structures 143 33 52 doi 10 1016 j compstruct 2016 01 014 Basalt fiber basfiber com in Russian English German Korean and Japanese Retrieved 2018 06 21 the main work is the book Konstruieren mit Faser Kunststoff Verbunden of Helmut Schurmann B Jungbauer M Romano I Ehrlich Bachelorthesis University of Applied Sciences Regensburg Laboratory of Composite Technology Regensburg 2012 Albarrie BASALT FIBER Neuvokas Henderson Tom December 10 2016 Neuvokas raises the bar on manufacture of rebar Crain s Detroit Business Retrieved 17 December 2018 BibliographyE Lauterborn Dokumentation Ultraschalluntersuchung Eingangsprufung Internal Report wiweb Erding Erding bOctober 2011 K Moser Faser Kunststoff Verbund Entwurfs und Berechnungsgrundlagen VDI Verlag Dusseldorf 1992 N K Naik Woven Fabric Composites Technomic Publishing Co Lancaster PA 1994 Bericht 2004 1535 Prufung eines Sitzes nach BS 5852 1990 section 5 ignition source crib 7 fur die Fa Franz Kiel gmbh amp Co KG Siemens AG A amp D SP Frankfurt am Main 2004 DIN EN 2559 Luft und Raumfahrt Kohlenstoffaser Prepregs Bestimmung des Harz und Fasermasseanteils und der flachenbezogenen Fasermasse Normenstelle Luftfahrt NL im DIN Deutsches Institut fur Normung e V Beuth Verlag Berlin 1997 Epoxidharz L Harter L Technische Daten Technical Data Sheet by R amp G 2011 Quality Certificates for Fabrics and Rovings Incotelogy Ltd Bonn January 2012 Nolf Jean Marie 2003 Basalt Fibres Fire Blocking Textiles Technical Usage Textile 49 3 38 42 Ozgen Banu Gong Hugh May 2011 Yarn geometry in woven fabrics Textile Research Journal 81 7 738 745 doi 10 1177 0040517510388550 S2CID 138546738 L Papula Mathematische Formelsammlung fur Naturwissenschaftler und Ingenieure 10 Auflage Vieweg Teubner Wiesbaden 2009 Saravanan D 2006 Spinning the rocks basalt fibres IE I Journal TX 86 39 45 Schmid Vinzent Jungbauer Bastian Romano Marco Ehrlich Ingo Gebbeken Norbert June 2012 The influence of different types of fabrics on the fibre volume content and porosity in basalt fibre reinforced plastics Applied Research Conference pp 162 165 Osnos S Osnos M BCF developing industrial production for reinforcement materials and composites JEC Composites magazine N 139 March April 2021 p 19 24 Osnos S Rozhkov I Application of basalt rock based materials in the automotive industry JEC Composites magazine N 147 2022 p 33 36 External linksThe production of basalt fibers Information from the Uzbekistan state scientific committee Basalt Continuous Fiber Information and Characteristics Basalt Roving Dome Video demonstration of concrete construction reinforced with basalt fiber Generation 2 0 of Continuous Basalt Fiber Comparing the technologies used in CBF production Compressive behavior of Basalt Fiber Reinforced Composite Product range of Basfiber products offered by Kamenny Vek Extruded Acrylic Sheet Excellent Thermoforming Capabilities Some aspects of the technological process of continuous basalt fiber CBF Video demonstration of production of continuous basalt fiber at Kamenny Vek
