BASALT ROCK FIBER BRIEF REVIEW

 

 INTRODUCTION:

In the recent days, the various fibers develop and are used in the construction industrial and highway engineering. The steel is mainly used in the various applications. Also fiber glass, polythene fibers, carbon fibers, polyamide fibers are now developed and also used in the construction, industrial and infrastructural development. In that list new one fiber is added called the, basalt rock fiber.

And flood volcanoes, a very hot fluid or sem– fluid material under the earth crust solidified in the open air. Basalt is the name given to  wide variety of volcanic rocks which is gray. Brown are dark in colour are formed by the volcanic lava solidification. Basalt originates from volcanic magma

The heavily thickened lava contains olivine, clino-pyroxene (salite), plagioclase and opaque metal oxides. Plageocene and pyroxene make up 80% of many types of basalt.Because of good hardness and thermal properties, basalt has been used in the construction,  Industrial and highway engineering in the form of the crushed rock . It is used in surfacing  and filled in roads , the floor tiles in the construction and as the lining materials in the pipes

 for transporting of the hot fluids. This can major replacement to the asbestos, which posses  Health hazards by damaging the respiratory systems.

                           However, it is not commonly known that the basalt can be used in the Manufacturing and made in to fine, superfine ultrafine fibres. Basalt is the alternative raw material for fiber forming because of its relatively homogenous chemical structure, it’s large scale availability throughout the world, its freedom from impurities and off course its ability  to form fibers in the molten state.

                         Basalt fiber offers prospect of completely new range of composite materials and product. Low cost high performance fiber offers the potential to solve the largest probable in the cement and concrete industry, cracking and structural failure of concrete. They have potential to high performance and cost effectively replace of fiber glass, steel fibers, Polyamide fiber and carbon fiber product in much application. 1kg basalt replaces 9.6kg  steel reinforcement.

 

 

 

 

 

  Literature Review:  

                                                                                                                  

Basalt Fiber Reinforced Concrete... by Nayan Rathod, Mukund Gonbare, Mallikarjun Pujari. “International Journel of Science and Research”

Basalt is defined by its mineral content and texture, and physical descriptions without mineralogical context may be unreliable in some circumstances. Basalt is usually grey to black in colour, but rapidly weathers to brown or rust-red due to oxidation of its mafic (iron-rich) minerals into rust. Although usually characterized as "dark", basaltic rocks exhibit a wide range of shading due to regional geochemical processes. Due to weathering or high concentrations of plagioclase, some basalt rocks are quite light coloured, superficially resembling rhyolite to untrained eyes.

 Basalt has a fine-grained mineral texture due to the molten rock cooling too quickly for large mineral crystals to grow, although it is often porphyritic , containing the larger crystals formed prior to the extrusion that brought the lava to the surface, embedded in a finer-grained matrix.

 

“A Short Review on Basalt Fiber”. By Kunal Singh .Department of Textile Engineering Panipat   Institute of Engineering and Technology, Haryana, India

 

 A hard, dense, inert rock found worldwide, basalt is an igneous rock, which is solidified volcanic lava. Cast basalt liners for steel tubing shows very high abrasion resistance in various industrial applications. In recent years, continuous basalt fibers extruded from naturally fire-resistant basalt are attracted attention as a replacement for asbestos fibers. In the last decade, basalt has emerged as a contender in the fiber reinforcement of composites. Some manufacturer of basalts claims it offers performance similar to S-2 glass fibers at a price point between S-2 glass and E-glass, and may offer manufacturers a less-expensive alternative to carbon fiber. Basalt fiber (BF) is capable to withstand very high temperature and can act as fire blocking element.

 

The basalt fiber is now being a popular choice for the material scientist for the replacement of steel and carbon fiber due to its high rigidity and low elongation or extension at break. Its supreme tenacity value makes it as a useful reinforcement material in the present and also for the future era to come.

 

“Experimental Study on Mechanical Properties of Basalt Fiber Reinforced Concrete”, by Md Tabaseer Ahmed, Md Abid Alam, Manohar Singh Chaful.

 

 Several experimental investigations have been done in the past to study the behavior &mechanical properties of basalt fiber reinforced concrete. The inclusions of basalt fibers in the concrete have shown better results in relation to tensile, compressive and flexural strength. The results also indicate improved ductility and better resistance to cracking. The performance of basalt fiber concrete was reported by varying the percentages of fibers in the concrete. It shows that the performance of concrete is higher at 0.25% then it gets decreased slowly [3].The addition of basalt fibers in high strength concrete decreases the 7 and 14 days strength but the strength increases more than the design mix after 28 days [1]. About 83 to 92% increase in compressive strength was observed when basalt fibers are introduced in the concrete. Similarly 40 to 50% increase in flexural strength was observed [4]. The split tensile strength of concrete is supposed to increase with increase in the volume fraction of fiber till 0.3% and then it decreases with 0.5% basalt fiber. The slump of concrete decreases with increasing the volume fraction of basalt fiber and the unit weight is not sensitive to it as the fiber content was low in all mixes. The modulus of elasticity shows the trend of the strengths results [5]. In the present study basalt fibers were used throughout the experiments to obtain the concrete specimens. The study comprises of a comparative study of some of the properties of concrete at the age of 7 and 28 days by varying the percentages of fibers.

 

 

 

 

 

METHODOLOGY:

—  Basalt Rock as raw material

—  Technical properties

—  Chemical composition of basalt

—  Plant layout

—  Manufacturing process

 

 

 

 

 

 

                                       

 

 

 

 

TECHNICAL PROPERTIES           :

·         High tensile strength

·         Quite durable

·         Alkali and acid resistance

·         High thermal conductivity

·         Chemically inert with no environmental risk

 

CHEMICAL PROPERTIES OF BASALT

Chemical Composition of Basalt rocks	%
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

 

 

 

 

 

 

PLANT LAYOUT:

 

 

 

 

 

 In one         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 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 12850C 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.

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

 

 

 

 

 

 

 

 

 

 

 

         

 

 

 

 

CHAPTER 4

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.

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.

 

PROPERTIES OF BASALT FIBER COMPARING TO OTHER TYPES OF FIBERS(Kunal Singha. “A Short Review on Basalt Fiber”, (International Journal of Textile Science 2012)

Properties	Continuous basalt fiber	Glass fiber    (E glass)	Glass fiber (S glass)	Carbon fiber
Breaking strength (Mpa)	3000-4840	3100-3800	4020-4650	3500-6000
Modulus of elasticity (Gpa)	79.3-93.1	72.5-75.5	83-86	230-600
Breaking extension %	3.1	4.7	5.3	1.5-2.0
Fiber Diameter (µm)	6-21	6-21	6-21	5-15
Linear Density tcx	60-4200	40-4200	40-4200	60-2400
Temperature withstand	-260 to +700	-50 to +380	-50 to 300	-50 to +700

 

 

 

 

 

 

 

ADVANTAGES OF BASALT ROCK FIBER IN REINFORCED CONCRETE:

·        The impact strength of basalt reinforced fiber concrete increases in about 20 times.

·        Basalt fiber is not liable to galvanic corrosion, comparing to usual rebar that it is an electric conductor and have cathode effect.

·        Construction tie reduces due to the needle to install wire mesh.

·        The thickness of the concrete can be reduced to half.

·        The total cost of the construction work reduces.

·        Reduces the width of the crack.

·        The cost of repairs and maintenance gently reduces due to the fiber reinforced concrete for a longer period.

·        In reservoirs and underground water channels thickness of concrete cover significantly reduces, and construction tie becomes shorter.

·          

·         CHA

 

 

 

 

 

 

 

 

tha REFERENCES:

 

·         Kunal Singha. “A Short Review on Basalt Fiber”, (International Journal of Textile Science 2012)

·         Nayan Rathod 1- “Basalt Fiber Reinforced Concrete,” International Journal of Science and Research (IJSR) ISSN(2013)

·         Jean Marie Nolf (2003). “Basalt Fibers - Fire Blocking Textiles.” Technical Usage Textile, no 49(3^rd tqr) pp   38-42

·         K. Vladimir & L. Vladimir (2003). ‘Fibers from Stone,’ International Textile Bulletin, no Bulletin, no 5, pp  48-52

·         Basaltex. 2008 The thread of stone, Wevelgem, Beldium. Available from internet:, http://www.basalttex.com

·        Sim , J., Park C., D.Y. Characteristics of basalt fibers as a strengthening material for concrete structure

·        Basalt Fiber Reinforced Concrete... by Nayan Rathod, Mukund Gonbare, Mallikarjun Pujari. “International Journel of Science and Research”.

·         Gajanan Deshmukh; Basalt - The Technical Fibre; Man-made Textiles in India; July 2007; 258-261.

·          http://www.seminarprojects.com/Thread-basalt-rock-fibre-brf; dt 14/10/2010.

·          D Saravanan; Spinning the Rocks - Basalt Fibres; Journal of the Institution of Engineers (India): Textile Engineering Di-vision, Feb2006, Vol. 86, p39-45.

·          S. E. Artemenko, Y.. A. Kadykova; Polymer composite materials based on carbon, basalt, and glass fibres; Fibre Chemistry, Vol. 40, No. 1, 2008

·         V. V. Pakharenko, I. Yanchar, V. A. Pakharenko, V. V. Efanova; Polymer composite materials with fibrous and dis-perse basalt fillers; Fibre Chemistry, Vol. 40, No. 3, 2008.