Basalt Rock Fibre

1.0 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.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.
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 largescale availability throughout
the world, its freedom from impurities and of course, its ability to form
fibers in the molten state. Used 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.

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 Basalt Rock Fibre
Basalt is well known as a rock found in virtually every country
round the world. Basalt is a mafic extrusive igneous rock formed from the
rapid cooling of magnesium rich and iron-rich lava exposed at or very
near the surface of a terrestrial planet or a moon. More than 90% of all
volcanic rock on Earth is basalt. Basalt lava has a low viscosity, due to its
low silica content, resulting in rapid lava flows that can spread over great
areas before cooling and solidification. Flood basalt describes the
formation in a series of lava basalt flows.
Raw material for producing basalt fiber is the rock of a volcanic
origin. It is a basic volcanic-igneous rock; formed from frozen lava.
Basalt originates from volcanic magma and flood volcanoes, a very hot
fluid or semifluid 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.
It occupies 1/3 of earth’s crust. Brown or dark in colour, formed from
volcanic lava after solidification.Material which is made from the
extremely fine fibres of the Basalt, which composed of olivine, clino-
pyroxene, plagioclase and opaque metal oxides. Plagioclase and pyroxene
make up 80% of many types of basalts.

2.0 LITERATURE SURVEY

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1. Inorganic Natural Fibre Grid:Basalt Fibre Reinforced polymer
Grid(2019) T.Rousakis Basalt fibre grids embedded in cement-based
mortar have been used as external confinement of concrete cylinders. The
application required the patching of a layer of cement-based mortar with
a thickness higher than 4 mm. Then the bidirectional basalt fibre grid was
pre impregnated with epoxy resin or latex. Finally, a second layer of
cement-based mortar was applied with a thickness higher than 4 mm. The
experimental results showed a substantial gain in strength and ductility of
columns and a gradual failure of the specimens. The results also revealed
the need for higher mechanical interaction between the cementitious
matrix and the grid.
2. Study on Mechanical Properties of Basalt rock fibre reinforced
polyester composites (2019) B.S. Keerthi Gowda a study on the
mechanical properties of uniformly distributed randomly oriented basalt
rock fiber (BRF) reinforced composites is presented. The basalt fiber of
13 mm ± 1 mm length having 1 mm width and polymer matrix are used
for casting the composite specimen.
3. Basalt Fibre as Reinforcement of concrete (2007) Hannibal
Olafsson This paper is review of state of art of knowledge of basalt fiber,
the production methods and review of tests on basalt fiber as a
strengthening material for concrete structures. There are several types of
basalt fiber strengthening methods used to strengthen concrete. In this
paper three types are mentioned: External strengthening, fiber matrixes,
and rod type material. Basalt composite bars are made by utilizing basalt
fibers and a resin epoxy binder. They are non-corrosive, consist of 80%
fibers and have a tensile strength three times that of the steel bar normally
used in building construction. Wherever corrosion problems exist, basalt
fiber composite bars have the potential to replace steel in reinforced

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concrete. Compared to FRP bar as they are use for small amount in
building industry the basalt bar are cheaper and have better durability
under extreme conditions. It is concluded that basalt bars are of great
interest for the building industry and can be used for example in bridge
decks, offshore structure and in element buildings.
4. Experimental investigation on mechanical properties of Basalt
Fibre Reinforced Concrete (2005) Sruthi Jalasutram This paper
presents an experimental investigation on the effect of varying volume
fractions of chopped basalt fibres on the mechanical properties of fibre-
reinforced concrete (FRC). The fibre content is varied in the range of 0-
2%. The main parameters investigated are workability, compressive
strength, splitting tensile strength, flexural strength, and flexural
toughness. Test results showed that the compression strength of concrete
is marginally decreased with the addition of basalt fibers as compared to
the plain concrete. However, the mode of failure of FRC under
compression is changed from brittle to ductile.

3.0 BASALT ROCK FIBRE PRODUCTS

Continuous basalt filaments have following primary products such as
Continuous basalt fibers, Chopped fibers, CBF roving, CBF yarns.

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By using these primary products the secondary products are
produced such as Basalt Reinforced Rod, Basalt rebar, Basalt geo-textile,
Basalt mesh, Basalt fiber pipes, Basalt laminates and Basalt fibre fabric.
Primary products are
1. Basalt Chopped Fibre:
The Basalt or Rock fibre is manufactured by crushing a rock of a
special chemical structure followed by its melting in furnaces at high
temperatures, i.e., more than 1500 °С. This complex fibre consists of 200
elementary filaments that are binded with special oiling liquid (sizing)
and is out stretched through a special device, named feeder, at the bottom
of the furnace.
Types of sizing process are selected depending on further contact
environment of Rock fibre fibres in order to ensure maximum adhesion.
Ultimately, after the polymerization phase, it results in subsequent
formation of rock chopped fibre or assembled continuous roving (which
is used for Rock rebar manufacturing).

Fig.No.1 Basalt Chopped Fibre

2. Basalt Plastic Pipes

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Basalt fibre composite pipes are obtained by winding basalt
threads, fabrics, prepegs impregnated with a binder. These pipes are
useful as components for shafts linings, building components, for
transportation corrosive liquids and gases in the construction,
industrial, agricultural and public services sectors. Basalt pipes are
resistant to the action of fungi and micro-organisms.

Fig. No. 2 Basalt Plastic Pipes

3. Basalt Super Thin Fibers:

It has good heat-insulation qualities. The material is absolutely
nonflammable, it has high thermo-durability. High chemical
durability towards water, salt solutions, alkali and acids.

Applications :

1. Fireproof materials of fire protection systems

2. Heat and sound insulation material for the manufacture of
automobile mufflers, gaskets, insulation screens, plastics,
composites.

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Fig. No.3 Basalt Super Thin Fibres

4. Basalt Roving:

Basalt roving is bundle of continuous mono-directional complex

basalt fibres.

Roving possesses high natural strength, resistance to aggressive

environments, long service life and excellent electric insulating
properties.

The Secondary Products are

1. Basalt Reinforced Rod:

Higher specific strength and resistant to corrosion, which is
chemically inert. No permanent deformation when bent.

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Fig. No. 4 Basalt Reinforced Rod

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 carryout distributed loads . The cost is 4-5
lower than other geo textile material.

Fig. No. 5 Basalt GeoTextile

3. Continuous Basalt Fibre:

Basalt Continuous Fibre (BCF) is a raw material for the production
of various types of materials & products.

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Applications:

1. Basalt continuous fibres have been widely used in fibre reinforced

composites, friction materials, shipbuilding materials, thermal
insulation materials, automotive industry, high temperature filter
fabrics and protection fields.
2. Reinforcing material for concrete & asphalt, concrete covering for
roads, airport runways & taxiways.
3. Filters for industrial & residential waste waters, filters for smoke &
dust emissions of industrial enterprises. Reinforcing nets for
construction.

Advantages of Continuous Basalt Fibre:

1. Only one component – basalt, which is an environmently safe

natural material – is used for CBF production; Cost of basalt raw
material is very low; the share of raw material’s cost in the final
cost of production is less than 5%.
2. CBF production technology consists of only one phase – melting.
There is no need for primary enrichment, fusion and
homogenization, as all of those were made for free by nature
3. To make CBF basalt should be heated up only one time.
4. Further processing of CBF into materials does not require energy;
it’s made with application of “cold technologies".

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Fig. No. 6 Continuous Basalt fibre

4. Basalt Reinforcing Mesh:

It is designed for reinforcing road and highway overlays to prolong

the payment 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

This makes it possible to reduce thickness of asphalt concrete pavement
up to 20%.

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Fig. No. 7 Basalt Reinforcing Mesh

4.0 BASALT ROCK FIBRE PROPERTIES

1. Thermal resistance:

Basalt fibre has excellent thermal properties to that of glass fibres. It

can easily withstand the temperature of 1200℃ to 1300℃for hours
continuously without any physical change which is similar to S2 glass
fibres and carbon fibres.

2. Mechanical strength:

Basalt fibre as tensile strength 3000-4840MPa , 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.

3. 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

4. Corrosion and fungi resistance

Basalt fibre 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 fibres exist in the range of less than 1%.
Basalt materials have strong resistance against the action of fungi and
micro-organisms.

5. Abrasion Property

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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 fibre woven fabrics over the
propeller type abraders do not result in the splitting of fibre by fracture
and results nearly in breaking of individual fibres

6. Technical Properties
 High tensile strength, quite durable
 Alkali and acids resistant
 High thermal conductivity
 Completely inert with no environmental risks
 High chemical resistance, high thermal resistance
 Excellent adhesion to polymer resins and rubbers
5.0APPLICATIONS OF BASALT ROCK FIBRE
5.1 CONSTRUCTION
5.2 ROAD CONSTRUCTION
5.3 ENGNEERING NETWORK
5.4 AGRICULTURE
5.5 UNDERGROUND CONSTRUCTION
5.6 MACHINE CONSTRUCTION
5.1CONSTRUCTION:

Reinforcement of bridges, tunnels, external and internal heat and

sound insulation. Insulation of panel butt joints, Directional and
depressive reinforcement of concrete, repair of cracks. Local damage
to building, bridges, building construction, soft roofing made of non-
combustible, rigid roofing.

5.2 ROAD CONSTRUCTION:

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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.

5.3 ENGINEERING NETWORKS:

Pipelines for heating and hot water suppl, pipelines for heat supply,
canalisation, 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. No. 8 Pipelines

5.4 AGRICULTURE:

Land drainage pipes, pipes for irrigation and housing. Raising

vegetable and seeding(hydroponics), Basalt super thin fiber,
Agricultural construction, Agricultural machine construction.

5.5 UNDERGROUND CONSTRUCTION:

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Anchors, Pillars, Ceilings, Vaults, Pipelines for various purposes,
Foundations for Buildings and Construction, less laying of pipelines.

5.6 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.

6.0 ADVANTAGES

1. Higher mechanical strength and modulus.

2. More resistive to chemical aggresive environment
3. Lower cost and better mechanical properties than for mesh made of
special glass fibre
4. Lower elongation before break than for synthetic material
5. Easily milled using typical milling equipment. Does not stretch and
pull as polymer meshes
6. No special equipment is required to install the reinforcement. They
have no toxic action with air and water.
7. Very high chemical resistance

8. Basalt is the best reinforcement for concrete due to its tensile

strength

9. Noise absorption qualities

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10.Basalt based composites can efficiently replace steel and all known
reinforced plastics

11.Water absorption

7.0 DISADVANTAGE
Breakable and low in withstanding bending force

8.0 CONCLUSION
1. Basalt can be used in manufacturing and made into fin , 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 coarse, its ability to form fibres in the molten
state. Basalt rock fibres have no toxic reaction with air or water,
are non-combustible.

2. When in contact with contact with other chemicals they produce no

chemical reaction that may damage health or the environment.

3. So it is ecological friendly material. Basalt rock fibres have new

range of material in building construction, road construction,
concrete industry and agriculture field.

4. Basalt is well known as a rock found in virtually every country

round the world. Basalt rock is more in India(especially in

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maharashtra). The cost of basalt is 10 times lower than that of raw
materials for fibreglass. Basalt is more available than any other raw
material.

9.0 REFERENCES

1. Dr. Patnaik Anil (2009), “Applications of Basalt Fibers Reinforced

Polymer (BFRP) Reinforcement for Transportation Infrastructure”,
Developing a Research Agenda for Transportation Infrastructure – TRB.

2. Dr. Sergey Osnos(2011), “Basalt continuous fiber: development of

technologies and equipment from the past to the present”, Basalt Fiber &
Composite Materials Technology Development Company, China.

3. Dr. Murray Allan(2015), “Basalt Fibers for high-performance

composites”, Allied composite Technologies LLC

4. Dr. D. Saravanan(2016), “Spinning of rocks – Basalt fibers”, Institute

of Engineers (India) Journal, volume 82

5. Sheldon G. L. (2020). “Forming fibers from basalt rock”, platinum

metal review.

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