basalt fiber

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.{{Cite news|url=http://basalt.pro/activities/materials/|title=Research surveys for basalt rock quarries {{!}} Basalt Projects Inc. {{!}} Engineering continuous basalt fiber and CBF-based composites|work=Basalt Projects Inc.|access-date=2017-12-10}} Basalt of high acidity (over 46% silica content{{cite journal |last1=De Fazio |first1=Piero |title=Basalt fibra: from earth an ancient material for innovative and modern application |journal=Energia, Ambiente e Innovazione |volume=3 |year=2011 |pages=89–96 |url=https://www.enea.it/it/seguici/pubblicazioni/pdf-eai/maggio-giugno-2011/sr-basaltfibra.pdf |access-date=2021-09-08 |archive-date=2021-09-18 |archive-url=https://web.archive.org/web/20210918161624/https://www.enea.it/it/seguici/pubblicazioni/pdf-eai/maggio-giugno-2011/sr-basaltfibra.pdf |url-status=dead }}) and low iron content is considered desirable for fiber production.{{Cite web|url=http://www.ptonline.com/articles/composites-higher-properties-lower-cost|title=Composites: Higher Properties, Lower Cost|last=Schut|first=Jan H.|website=www.ptonline.com|date=August 2008 |access-date=2017-12-10}} Unlike with other composites, such as glass fiber, essentially no materials are added during its production. The basalt is simply washed and then melted.{{Cite web|url=http://www.compositesworld.com/articles/basalt-fibers-alternative-to-glass|title=Basalt Fibers: Alternative To Glass?|last=Ross|first=Anne|website=www.compositesworld.com|date=August 2006 |access-date=2017-12-10}}

The manufacture of basalt fiber requires the melting of the crushed and washed basalt rock at about {{convert|1500|°C|°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.{{Cite web|url=https://basalt-fiber.com/|title=Basalt Fibers from continuous-filament basalt rock|website=basalt-fiber.com}} They also have a high elastic modulus, resulting in high specific strength—three times that of steel.{{cite journal |last1=Soares |first1=B. |last2=Preto |first2=R. |last3=Sousa |first3=L. |last4=Reis |first4=L. |title=Mechanical behavior of basalt fibers in a basalt-UP composite |journal=Procedia Structural Integrity |date=2016 |volume=1 |pages=82–89 |doi=10.1016/j.prostr.2016.02.012 |doi-access=free }}{{cite journal |last1=Choi |first1=Jeong-Il |last2=Lee |first2=Bang |title=Bonding Properties of Basalt Fiber and Strength Reduction According to Fiber Orientation |journal=Materials |date=30 September 2015 |volume=8 |issue=10 |pages=6719–6727 |doi=10.3390/ma8105335 |pmid=28793595 |pmc=5455386 |bibcode=2015Mate....8.6719C |doi-access=free }} 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. As of 2018, one of the most promising applications for continuous basalt fiber is making rebar that could substitute for traditional steel rebar in construction.{{Cite web|url=http://novitsky1.narod.ru/basalt_fiber.technology.html|title=Some aspects of the technological process of continuous basalt fiber|website=novitsky1.narod.ru|language=en-US|access-date=2018-06-21}}

The table refers to the continuous basalt fiber specific producer. Data from all the manufacturers are different, the difference is sometimes very large values.

Comparison:

{{Citation needed|date=May 2012}}

The first attempts to produce basalt fiber were made in the United States in 1923 by Paul Dhe who was granted {{US 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.{{Cite web|url=http://basfiber.com|title=Basalt fiber|website=basfiber.com|language=ru, en, de, ko, ja|access-date=2018-06-21}}

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 Materials Science at the University of Hannover
3. The German Plastics Institute (DKI) in Darmstadt(the main work is the book "Konstruieren mit Faser-Kunststoff-Verbunden" of Helmut Schürmann)
4. 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.
5. 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.B. Jungbauer, M. Romano, I. Ehrlich, Bachelorthesis, University of Applied Sciences Regensburg, Laboratory of Composite Technology, Regensburg, (2012).

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• Heat protection[http://www.albarrie.com/techfabricscontinuousfiber.aspx Albarrie - BASALT FIBER]
• Friction materials
• Windmill blades
• Lamp posts
• Ship hulls
• Car bodies
• Sports equipment
• Speaker cones
• Cavity wall ties
• Rebar[https://www.neuvokascorp.com Neuvokas]{{cite news |last1=Henderson |first1=Tom |title=Neuvokas raises the bar on manufacture of rebar |url=https://www.crainsdetroit.com/article/20161210/NEWS/161219992/neuvokas-raises-the-bar-on-manufacture-of-rebar |access-date=17 December 2018 |work=Crain's Detroit Business |date=December 10, 2016}}
• 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)

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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.

• Pele's hair
• Mineral wool
• Glass wool
• Beta cloth

{{reflist}}

• 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).
• {{cite journal |last1=Nolf |first1=Jean Marie |title=Basalt Fibres-Fire Blocking Textiles |journal=Technical Usage Textile |volume=49 |issue=3 |year=2003 |pages=38–42 }}
• {{cite journal |last1=Ozgen |first1=Banu |last2=Gong |first2=Hugh |title=Yarn geometry in woven fabrics |journal=Textile Research Journal |date=May 2011 |volume=81 |issue=7 |pages=738–745 |doi=10.1177/0040517510388550 |s2cid=138546738 }}
• L. Papula, Mathematische Formelsammlung für Naturwissenschaftler und Ingenieure. 10. Auflage, Vieweg+Teubner, Wiesbaden, (2009).
• {{cite journal |last1=Saravanan |first1=D. |title=Spinning the rocks-basalt fibres |journal=IE (I) Journal-TX |volume=86 |year=2006 |pages=39–45 }}
• {{cite conference |last1=Schmid |first1=Vinzent |last2=Jungbauer |first2=Bastian |last3=Romano |first3=Marco |last4=Ehrlich |first4=Ingo |last5=Gebbeken |first5=Norbert |title=The influence of different types of fabrics on the fibre volume content and porosity in basalt fibre reinforced plastics |pages=162–165 |conference=Applied Research Conference |date=June 2012 }}

• 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.

• [https://web.archive.org/web/20040719170403/http://www.sfsti.uzsci.net/basalt.htm The production of basalt fibers] Information from the Uzbekistan state scientific committee
• [http://www.basaltfm.com/eng/fiber/info.html Basalt Continuous Fiber - Information and Characteristics]
• [https://www.youtube.com/watch?v=N18HcPfKv1E Basalt Roving Dome] Video demonstration of concrete construction reinforced with basalt fiber
• [https://web.archive.org/web/20160506195156/http://basalt.pro/activities/constraction-basalt-plant/cbf-production-technologies-compared/ Generation 2.0 of Continuous Basalt Fiber] Comparing the technologies used in CBF production
• [https://web.archive.org/web/20160223165630/http://en.basalt.today/2016/02/2460/ Compressive behavior of Basalt Fiber Reinforced Composite]
• [http://basfiber.com/products/all-products Product range of Basfiber products offered by Kamenny Vek]
• [https://web.archive.org/web/20160418203147/http://www.isikplastik.com/acrylic-sheets Extruded Acrylic Sheet - Excellent Thermoforming Capabilities]
• [http://novitsky1.narod.ru/baz141.htm Some aspects of the technological process of continuous basalt fiber CBF]
• [http://basfiber.com/production Video demonstration of production of continuous basalt fiber at Kamenny Vek]

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