Seminar Basalt

SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

BASALT ROCK FIBRE

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BASALT ROCK FIBRE

ACKNOWLEDGEMENT

I express my sincere gratitude to Smt. RAMANY.V.D, Lecture of Civil Engineering Department, who is my seminar guide for their inspiring assistance, encouragement and useful guidance. I am also indebted to all the teaching and non teaching staffs and my friends for their co-operation and suggestions, which is spirit behind this report.

SHEFEEK.M.S

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BASALT ROCK FIBRE

ACKNOWLEDGEMENT

I express my sincere gratitude to Smt. RAMANY.V.D, Lecture of Civil Engineering Department, who is my seminar guide for their inspiring assistance, encouragement and useful guidance. I am also indebted to all the teaching and non teaching staffs and my friends for their co-operation and suggestions, which is spirit behind this report.

SHEFEEK.M.S

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BASALT ROCK FIBRE

ABSTRACT Basalt

fibre which made from fibres of basalt rock is very much similar to

the carbon and the fibre glass and have better physicomechanical properties and cheaper. One Kg of basalt reinforces is equal 9.6 Kg of the steel. They have many field applications and can replace many costly and rare materials. Its manufacturing process is very simple and raw materials are found virtually every country. Basalt fibres offer the potential to solve the largest problem in the cement and concrete industry.

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BASALT ROCK FIBRE

CONTENTS 1. INTRODUCTION««««««««««««««««««««««««««5 2.

BASALT ROCK FIBRE-SCOPE «««««««««««««««««...««6

3.

ADVANTAGES OF BASALT ROCK FIBERS ««««««««««««««7

4.

FIELD APPLICATIONS OF BASALT ROCK FIBRE «««««««««...«8

4.1.

CONSTRUCTION«««««««««««««««««««««««.......9

4.2.

ROAD CONSTRUCTION«««««««««««««««««««««.10

4.3.

ENGINEERING NET WORK «««««««««««««««««««...11

4.4.

AGRICULTURE«««««««««««««««««««««««««12

4.5.

UNDERGROUND CONSTRUCTION««««««««««««««««.13

4.6.

MACHINE CONSTRUCTION«««««««««««««««««.««14

5.

BASALT ROCK FIBRE PRODUCTS «««««««««««««««.««15

5.1.

BASALT

5.2.

CONTINUOUS BASALT FIBRE ««««««««««««««««««17

5.3.

BASALT GEOTEXTILE ««««««««««««««««««««..«18

5.4.

BASALT

6.

REINFORCEMENT ROD «««««««««««««««««16

REINFORCING MESH ««««««««««««««««««19

MANUFACTURING TECHNIQUE««««««««««««««««««21

6.1.

HISTORY««««««««««««««««««««««««««...«22

6.2.

BASALT

6.3.

TECHNICAL PROPERTIES ««««««««««««««««««.........24

6.4.

CHEMICAL COMPOSITION BASALT ROCK «««««««««««..«25

6.5.

REGION OF BASALT ROCK IN INDIA«««««««««««««.««26

6.6.

MANUFACTURING PROCESS «««««««««««««««««.«27

6.7.

PLANT LAYOUT«««««««««««««««««««««««..«28

6.8.

PLANT CONFIGURATION«««««««««««««««««««.....29

7.

ROCK AS RAW MATERIAL «««««««««««««..««23

CONCLUSION«««««««««««««««««««««««««..« 30

8. REFERENCE««««««««««««««««««««««««««.« 31

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BASALT ROCK FIBRE

1. INTRODUCTION Basalt

Fibre which is also known as Basalt Fiber is a material which is

made from the extremely fine fibres of the

Basalt,

which composed of

Pyroxene, minerals plagioclase and Olivine. This is very much similar to the Carbon Fibre and the Fibre Glass, which is having better Physicomechanical properties than the fibre glass, but which is being significantly cheaper that the Carbon Fiber. It is also used as the fiber proof textile in the automotive industries and in the Aerospace and also can be used as a composite to produce the products such as the tripods. Basalt

is well known as the rock found in the virtually every country all

around the world. Basalt Rock fibres has no toxic reaction with the air or water, are non combustible and the explosion proof. When in contact with the other chemicals they will produce no chemical reactions that may damage health or environment. The Basalt base composites can be replacing steel and known reinforced plastics. One Kg of basalt reinforces is equals to 9.6 Kg of the steel. There seems to be something quite poetic in using a fibre made from the natural rock to reinforce a material, which may quite reasonably being described as the artificial rock. Raw material for producing basalt fiber is the rock of a volcanic origin.

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2.

BASALT ROCK FIBRE

BASALT ROCK FIBRE - SCOPE Low cost, high performance fibres offer the potential to solve the largest

problem in the cement and concrete industry, cracking and structural failure of concrete.

Because

of the higher performance (strength, temperature range, and

durability) and lower potential cost predicted for basalt fibers, they have the potential to cost effectively replace fiber glass, steel, Fiber, poly propylene, poly ethylene, polyester, aramid and carbon fiber products in many applications.

Fig 1: Basalt rock and its some products

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3.

BASALT ROCK FIBRE

ADVANTAGES OF BASALT ROCK FIBRES

1. They have no toxic action with air & water. 2. Very high chemical resistance. 3. Basalt is the best reinforcement for concrete due to its tensile strength. 4. Noise absorption qualities. 5. Basalt based composites can efficiently replace steel and all known reinforced plastics. 7.

Water absorption.

8.

Melting temperatures & Working temperatures up to 600ÃÃÂºC.

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4.

BASALT ROCK FIBRE

FIELD APPLICATIONS OF BASALT ROCK FIBRE

1. CONSTRUCTION 2. ROAD CONSTUCTION 3. ENGINEERING NET WORK 4. AGRICULTURE 5. UNDERGROUND CONSTRUCTION 6. MECHINE CONSTRUCTION

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4.1.

BASALT ROCK FIBRE

CONSTRUCTION

Reinforcement of bridges, Tunnels, Production of sandwich-panels based on basalt and carbon-basalt fibres, External and internal heat and sound insulation, Insulation of panel butt joints, Directional and depressive reinforcement of concrete, Repair (healing) of cracks, local damage to buil ding, bridges, building construction, Soft roofing made of non- combustible baraltoinson and basalaltoplastic, Rigid roofing (of slate and tile type), Reusable shutter, Internal waste pipes, Reinforced structures, Heat-supply systems, Cable conduits, Hydraulic construction.

Fig 2: Basalt reinforced bridge 9


4.2.

BASALT ROCK FIBRE

ROAD CONSTRUCTION

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.

Fig 3: Underground road 10


4.3.

BASALT ROCK FIBRE

ENGINEERING NETWORKS

Pipelines for heating and hot water supply, Pipelines for heat supply, Canalization, 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 4: Pipe lines for various purposes

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4.4.

BASALT ROCK FIBRE

AGRICULTURE

Land drainage pipes, Pipes for irrigation and hosting, Raising vegetable and seeding (hydroponics), Basalt

super thin fibre,

Agricultural construction, Agricultural machine construction.

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4.5.

BASALT ROCK FIBRE

UNDERGROUND CONSTRUCTION

Anchors, pillars, ceilings, vaults, Pipelines for various purposes, Foundations for buildings and constructions, Less laying of pipelines.

Fig 5: Basalt rock for underground construction

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4.6.

BASALT ROCK FIBRE

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,

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5. BASALT

1.

BASALT

BASALT ROCK FIBRE

ROCK FIBRE PRODUCTS

REINFORCEMENT ROD

2. CONTINUOUS BASALT FIBRE 3. BASALT GEOTEXTILE 4. BASALT REINFORCING MESH

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5.1.

BASALT ROCK FIBRE

BASALT REINFORCEMENT RODS ADVANTAGES BASALT ROD OVER STEEL REBAR:

Higher specific strength, Resistant to corrosion, Coefficient of thermal expansion, No permanent deformation when bent, Chemically inert.

Fig 6: Basalt reinforcement rods

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5.2.

BASALT ROCK FIBRE

BASALT GEOTEXTILE ADVAVTAGES OF BASALT GEOTETILE:

1.

They are made of natural raw material (natural chemical composition provides chemical stability and resistance).

2.

They are non-inflammable and they can carry out distributed load.

3.

The cost is 4-5 lower than other geotextile material

Fig 7: Basalt Geotextiles 17


5.3.

BASALT ROCK FIBRE

CONTINUOUS BASALT FIBRE ADVANTAGED OF CBF TECHNOLOGIES:

1. Only one component of basalt, which is an environmentally safe natural material is used for CBF production; 2. Cost of basalt raw material is very low; the share of raw material, cost in the final cost of production is less than 5%; 3. CBF production technology consists of only one phase of melting. There is no need for primary enrichment, fusion and Homogenization, as all of those was made for free by nature; 4. To make CBF basalt should be heated up only one time; 5. Further processing of CBF into materials does not require energy; It is made with application of cold technologies.

Fig 8: Continuous Basalt Fibres 18


5.4.

BASALT ROCK FIBRE

BASALT REINFORCING MESH

Basalt

reinforcing mesh is designed for reinforcing road and highway

overlays to prolong the pavement 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. Basalt

reinforcing mesh makes it possible to reduce th ickness of asphalt

concrete pavement up to 20%. ADVANTAGES AND BENEFITS:

1. Higher mechanical strength and modulus. 2. More resistive to chemical aggressive environment than E -glass mesh. 3. Lower cost and better mechanical properties than for mesh made of special glass fiber. 4. The melting point of basalt fibers is 1450ÃÃÂ°C. 5. Lower elongation before brake than for synthetic material. 6. Easily milled using typical milling equipment. Does not stretch and pull as polymer meshes. 7.

No special equipment is required to install the reinforcement.

8. Basalt

mesh is environment friendly and based on naturally occurring

material that is found worldwide. TECHNICAL PROPERTIES:

High tensile strength, quite durable, Alkali & acids resistant, High thermal conductivity. Completely inert with no environmental risks. 19


BASALT ROCK FIBRE

Fig 9: Basalt reinforcing mesh 20


6.

BASALT ROCK FIBRE

MANUFACTURING TECHNIQUE

1. HISTORY 2. BASALT ROCK AS RAW MATERIAL: 3. TECHNICAL PROPERTIES: 4. CHEMICAL COMPOSITION BASALT ROCK: 5. REGION OF BASALT ROCK IN INDIA: 6. MANUFACTURING PROCESS OF CONTINUOUS BASALT FIBRE (CBF): 7.

PLANT LAYOUT

8.

THE MAIN CHARACTERISTICS OF THE PLANT

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6.1.

BASALT ROCK FIBRE

HISTORY

The first attempts to produce basalt fiber were made in the United States in 1923. These were further developed after World War II by researchers in the USA, 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.

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6.2.

BASALT ROCK FIBRE

BASALT ROCK AS RAW MATERIAL

Fig 10: Basalt Quarries And Quarry spalls

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6.3.

BASALT ROCK FIBRE

TECHNICAL PROPERTIES

High tensile strength, Quite durable, Alkali & acids resistant, High thermal conductivity, Completely inert with no environmental risks, High chemical resistance, including to concentrated acids based, High thermal resistance (thermo stability) and low flammability, Low degradation of strength at temperatures as high as +700-900 deg. C. as low as ±250 deg. C, and high humidity, High thermal and acoustic insulation propert ies, Excellent adhesion to polymer resins and rubbers, Relatively high mechanical strength, abrasi on resistance and elasticity, High dielectric properties, Low water absorption, Ecologically clean and non-toxic, Property

Value

Tensile strength

4.84 GPa

Elastic modulus

89

Elongation at break

3.15 %

Density

GPa

2.7 g/cm³

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6.4.

BASALT ROCK FIBRE

CHEMICAL COMPOSITION BASALT ROCK

Chemical Name: Basic volcanic igneous rock from calc -alkali series. Chemical structure: Table No.

CHEMICAL COMPOUND

% WEIGHT OF BASALT

SiO2

49.58

TiO2

2.08

Al2O3

14.48

Fe2O3

4.42

Feo

9.43

K 2O

1.89

Na2O

2.10

Mgo

5.10

Cao

8.50

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6.5. Basalt

BASALT ROCK FIBRE

REGION OF BASALT ROCK IN INDIA

rock (Deccan Trap) an area of about 500,000 square KM cover

large part of the Maharashtra, Kutch, Deccan, Gujarat, Saurashtra, Central India, Madhya Pradesh, Hyderabad region etc.

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6.6.

BASALT ROCK FIBRE

MANUFACTURE

Basalt

fiber is made from a single material, crushed basalt, from a

carefully chosen quarry source and unlike other materials such as glass fiber, essentially no materials are added. The basalt is simply washed and then sent to be melted down. The manufacture of basalt fiber requires the melting of the quarried basalt rock at about 1,400 °C (2,550 °F). The molten rock is then extruded through small nozzles to produce continuous filaments of basalt fiber. There are three main manufacturing techniques, which are centrifugal -blowing, centrifugalmulti roll and die-blowing. The fibers typically have a filament diameter of between 9 and 13 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 excellent specific tenacity²three times that of steel.

Fig 11: Manufacturing Process

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6.7.

BASALT ROCK FIBRE

PLANT LAYOUT

Fig 12: Plant Layout

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6.8.

BASALT ROCK FIBRE

PLANT CONFIGURATION

1. Batch silos: raw material supply 2. Weighing, dosing and mixing 3. Transport 4. Batch charging 5. Melting furnace 6. Fore hearths 7. Bushing 8.

(continuous filament formation)

Sizing application

9. Strand formation 10. Traversing 11. Automated winder

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7.

BASALT ROCK FIBRE

CONCLUSION Basalt

Rock fibres have no toxic reaction with air or water, are non-

combustible and explosion proof. When in contact with other chemicals they produce no chemical reactions that may damage health or the environment. Basalt

base composites can replace steel and known reinforced plastics (1 kg

of basalt reinforces equals 9.6 kg of steel). Basalt can replace almost all applications of asbestos and has three times its heat insulating properties. Basalt

is well known as a rock found in virtually every country round the

world. Basalt rock is more in India (specially in 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. Also the melting temperature is lower, thus energy consumption lower. Thus, the cost of basalt f ibre is considerable lower than that of similar materials. More workers are not required

to

operate

the

manufacturing

plant.

Thus, I conclude that we can install the First project in India (Maharashtra).

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BASALT ROCK FIBRE

8. REFERENCE 1. http://www.seminarprojects.com/Thread-basalt-rock-fibre brf#ixzz1PG4ofX2i 2. http://www.scribd.com/doc/495669 86/Basalt-Rock-Fibre 3. www.ebasalt .com/basalt-fibre 4. www.basaltfm.com/plakat_cbf.pdf 5. www.ieindia.org/pdf/ 86/ext4f6a3.pdf

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Seminar Basalt

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