Basalt fiber explained

Basalt fibers are produced from basalt rocks by melting them and converting the melt into fibers.Basalts are rocks of igneous origin. The main energy consumption for the preparation of basalt raw materials to produce of fibers is made in natural conditions.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.[1] Basalt of high acidity (over 46% silica content[2]) and low iron content is considered desirable for fiber production.[3] Unlike with other composites, such as glass fiber, essentially no materials are added during its production. The basalt is simply washed and then melted.[4]

The manufacture of basalt fiber requires the melting of the crushed and washed basalt rock at about 1500°C. 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.[5] They also have a high elastic modulus, resulting in high specific strength—three times that of steel.[6] [7] 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.[8]

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[9]
Tensile strength
Elastic modulus
Elongation at break 3.15%
Density

Comparison:

MaterialDensity
(g/cm3)		Tensile strength
(GPa)		Specific strength
Elastic modulus
(GPa)		Specific
modulus
Steel rebar 7.85 0.5 0.0637 210 26.8
A-glass2.46 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
S-2 glass2.49 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
0.91 0.27-0.65 0.297-0.714 38 41.8
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
Material type[10] Elastic modulus (E)Yield stress (fy)Tensile strength (fu)
13-mm-diameter steel bars
10-mm-diameter steel bars
6-mm-diameter steel bars
10-mm-diameter BFRP bars -
6-mm-diameter BFRP bars -
BFRP sheet -

History

The first attempts to produce basalt fiber were made in the United States in 1923 by Paul Dhe who was granted . 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.[11]

Schools

  1. 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.
  2. The Institute for Lightweight Design at the TU Berlin[12]
  3. The Institute for Lightweight Design Materials Science at the University of Hannover
  4. The German Plastics Institute (DKI) in Darmstadt[13]
  5. 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.
  6. 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.[14]

Uses

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

Bibliography

• 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

Notes and References

  1. News: Research surveys for basalt rock quarries Basalt Projects Inc. Engineering continuous basalt fiber and CBF-based composites. Basalt Projects Inc.. 2017-12-10.
  2. De Fazio . Piero . Basalt fibra: from earth an ancient material for innovative and modern application . Energia, Ambiente e Innovazione . 3 . 2011 . 89–96 . 2021-09-08 . 2021-09-18 . https://web.archive.org/web/20210918161624/https://www.enea.it/it/seguici/pubblicazioni/pdf-eai/maggio-giugno-2011/sr-basaltfibra.pdf . dead .
  3. Web site: Composites: Higher Properties, Lower Cost. Schut. Jan H.. www.ptonline.com. August 2008 . 2017-12-10.
  4. Web site: Basalt Fibers: Alternative To Glass?. Ross. Anne. www.compositesworld.com. August 2006 . 2017-12-10.
  5. Web site: Basalt Fibers from continuous-filament basalt rock. basalt-fiber.com.
  6. Soares . B. . Preto . R. . Sousa . L. . Reis . L. . Mechanical behavior of basalt fibers in a basalt-UP composite . Procedia Structural Integrity . 2016 . 1 . 82–89 . 10.1016/j.prostr.2016.02.012 . free .
  7. Choi . Jeong-Il . Lee . Bang . Bonding Properties of Basalt Fiber and Strength Reduction According to Fiber Orientation . Materials . 30 September 2015 . 8 . 10 . 6719–6727 . 10.3390/ma8105335 . 28793595 . 5455386 . 2015Mate....8.6719C . free .
  8. Web site: Some aspects of the technological process of continuous basalt fiber. novitsky1.narod.ru. en-US. 2018-06-21.
  9. Web site: Basalt Continuous Fiber . 2009-12-29 . dead . https://web.archive.org/web/20091103234348/http://www.albarrie.com/techfabrics/continuousfiber.aspx . 2009-11-03 .
  10. 10.1016/j.compstruct.2016.01.014. 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. 2016. Ibrahim. Arafa M.A. Fahmy. Mohamed F.M. Wu. Zhishen.
  11. Web site: Basalt fiber. basfiber.com. ru, en, de, ko, ja. 2018-06-21.
  12. L. Fahrmeir, R. Künstler, I. Pigeot, G. Tutz, Statistik – Der Weg zur Datenanalyse. 5. Auflage, Springer-Verlag, Berlin/Heidelberg, (2005).
  13. (the main work is the book "Konstruieren mit Faser-Kunststoff-Verbunden" of Helmut Schürmann)
  14. B. Jungbauer, M. Romano, I. Ehrlich, Bachelorthesis, University of Applied Sciences Regensburg, Laboratory of Composite Technology, Regensburg, (2012).
  15. http://www.albarrie.com/techfabricscontinuousfiber.aspx Albarrie - BASALT FIBER
  16. https://www.neuvokascorp.com Neuvokas
  17. News: Henderson . Tom . Neuvokas raises the bar on manufacture of rebar . 17 December 2018 . Crain's Detroit Business . December 10, 2016.

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