“Basalt fiber is 100% natural lava rock
& significantly reduces the carbon footprint
—because during the formation of the lava,
all the harmful emissions have
already been released”
—Gordon Forrester, PMSA-South Africa, Johannesburg Area
Alkali-resistant basalt fiber is a fine-grained volcanic rock (silicate/mineral feldspar) reinforcement for construction and roads, and an effective way to achieve excellent results due to high mechanical properties and good chemical resistance of basalt fiber. Basalt reinforcement can be used in:
- Mesh and Scrim
- Fiber-reinforced Concrete
- Geogrid Mesh for Roads
- Rebars and Pultruded Profiles
Alkali-resistant sizings KV-13, KV-42 and KV-41 for basalt fibers were developed specifically for construction applications. These sizings provide excellent alkali resistance and good compatibility with concrete and different resins used for production of rebar and other composite products in construction industry. Besides high alkali resistance, these products have much higher mechanical properties than glass fiber and much lower price compared to all other alkali resistant fibers. The high-performance, alkali-resistant basalt mesh will not rot, rust or corrode, and it provides increased strength in different cementitious applications. It is lightweight, easy install, and use, basalt mesh will be superior alternatives to steel.
Pan Mixers South Africa (PMSA) has launched a ground-breaking, basalt-fiber technology and superior concrete-reinforcing product, made from crushed and melted basalt rock. Gordon Forrester, Basalt Technology Director-PMSA-Johannesburg Area, said that basalt fiber technology has been known in Europe since the 1920s, however, it was deemed too complicated and expensive to invest in at the time. It was not until the 1990s that it moved into commercial production internationally.
Forrester explained that the basalt rock is transformed into fibers by taking the rock in its purest form, melting it, then drawing it through dyes. The material can then be spun to produce a twisted yarn, or can be wound as a single filament material. “Once the basalt fibers are formed, they are processed to create different products. Basalt fiber has similar chemical properties to glass fiber and basalt materials can be used in all of the applications where glass fiber is traditionally used. He stresses the fact that Basalt Technology is committed to highlighting the numerous benefits of basalt fiber to industries by hosting various presentations and providing product samples, where possible. He said, “The product’s resistance to rusting means that the concrete does not become distressed as is common with steel reinforcement.”
In South Africa, basalt fiber rebar is currently being tested at the Civil Engineering Department-Wits University and the basalt fibers are being tested at the Civil Engineering Department-University of Johannesburg. The test program has been put in place in order to provide future customers with additional assurances regarding the products’ quality and authenticity.”
Forrester pointed out that basalt rebar is being used increasingly internationally in road construction; is corrosion-proof; is 87% lighter than steel; has a tensile strength of 1 200MPa; can be used in various building and civil engineering applications in concrete rebar, concrete floor reinforcement, fence droppers, Shotcrete, and to reinforce pothole patching materials. Nowadays, composite materials successfully replace steel and glass in the construction industry—basalt fiber is a product of choice, due to its unique combination of properties:
COMPARISON to STEEL:
- High strength-to-weight ratio: Basalt fiber is 87% lighter and up to 2.5 times stronger in tensile strength
- Chemical resistance: Doesn’t rust
- Corrosion proof: Resistant to the action of salt ions, chemicals, and the alkalinity inherent in concrete
- Low thermal conductivity: Basalt fiber has extremely low coefficient of heat conductivity—helps to reduce heat transfer from building interiors to exteriors and significantly improves energy efficiency
- Zero electrical conduction—much higher electrical resistance
- Zero magnetic conduction—doesn’t interfere in the operation of sensitive electronic devices
COMPARISON to GLASS FIBER:
- Almost 50% stronger
- Impervious to water and heat, which negatively impacts E-glass
- 25% higher tensile strength
- 15% higher tensile modulus
- More resistive to chemical aggressive environment: Basalt fiber shows much better chemical resistance
- Heat and fire resistance: Melting point of basalt fiber is 150°C higher
- Decelerates the process of cracks and rutting formation
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BASALT REINFORCING MESHES and SCRIMS-APPLICATION IN SOIL and PAVEMENT: Concrete roads are longer lasting than asphaltic roads and concrete wearing surfaces are now less expensive to place in comparison with asphaltic layers. Basalt-reinforcing mesh with alkali resistant coating was developed to prevent cracks forming in different applications in construction industry as well as for reinforcement of mortars and non-load-bearing concrete. The higher tensile strength of this product—compared to glass fiber or steel—increases impact resistance and prevents appearance of cracks. This mesh can meet the expectations and strict requirements of most demanding companies from construction market. Increasing numbers of construction companies around the world are using different types of basalt mesh and geogrid in their projects, and more mesh manufacturers began production of basalt geogrid and mesh instead of traditional fiber products.
This increased use of basalt fibers in construction is due to increased quality of the road pavement and construction structures—increases service life by an additional 3-5 years and time between overhauls by 15%, decelerates the process of cracks and rutting formation compared to meshes produced with glass. Nowadays up to 50% of the total production of basalt fiber goes to the geogrids and construction mesh manufacturing. The use of basalt fiber mesh as the reinforcement has enabled a 50mm-thick overlay to withstand 1625 axles per day, transporting in excess of more than 110,000 metric tons/month.
The higher tensile strength of this product compared to glass or steel increases impact resistance and prevents from cracks appearance. This mesh can meet the expectations and strict requirements of most demanding companies from construction market.
High-performance, alkali-resistant basalt mesh
will not rot, rust, or corrode;
it provides increased strength in different cementitious applications; it is lightweight, easy to install, & easy to use;
& basalt mesh will be superior alternatives to steel
Sewing-knitting Production Technology used for mesh production allows the achievement of the best attainment of physical and mechanical properties of basalt fiber in the finished product. 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. Typical paving temperatures will not cause any loss of strength or distortion which may occur with synthetic material. It significantly outperforms synthetic materials by its ability to withstand low temperatures that is extremely important for roads and highways in the north regions. Pavement life between maintenance can be prolonged significantly.
BASALT MESH ADVANTAGES:
- Environment friendly
- Based on naturally occurring material that is found worldwide
- Lower elongation before brake than for synthetic material
- Easily milled using typical milling equipment
- Does not stretch and pull (like polymer meshes)
- No special equipment is required to install the reinforcement
- Specially developed coating provides good adhesion with concrete to improve tensile strength and increase impact resistance
- High mechanical strength and modulus
- High resistance to chemical aggressive environment
- High alkali resistance won’t allow appearance of rust or corrode
- Minimizes crack width and spread
- Easy to install and use
- No special equipment is required
- Extremely low coefficient of heat conductivity significantly reduces heat transfer from building exteriors to interiors—significantly improves energy efficiency
- The melting point of basalt fibers is 1450°C
- Typical paving temperatures will not cause any loss of strength or distortion (may occur with synthetic material)
- Lower application temperature than for synthetic material that is especially important for north region
- Transport costs are substantially lower
- Lifespan of the product is significantly longer
- More cost-effective in the long-term
- Prolonged pavement life between maintenances
____________________
REBAR:
Reinforced concrete is a traditional building material for construction. By far steel is the most common reinforcement in this application, but basalt fiber is more and more used for that purpose. Basalt-fiber-reinforced rebar/StoneRod fibers significantly improve the durability of civil engineering structures, especially under corrosion environment. Basalt rebar technology is produced by combining pultrusion and winding processes from high quality basalt fibers along with polyester, vinylester or epoxy resin. The lifespan of concrete can be extended significantly, particularly in coastal areas.
Basalt fibers can be manufactured into concrete rebar using a pultrusion process, and Forrester notes that basalt rebar is corrosion proof, in addition to being 87% lighter than steel, and has a tensile strength of 1 200 MPa. “The lifespan of the concrete can be significantly prolonged using basalt fiber rebar, particularly in coastal areas. The resistance to rusting means that concrete does not become distressed, as is common with steel reinforcement.”
According to Forrester, basalt fiber is also more environmentally-friendly than steel or glass. “During glass or steel production, the products are compounded using a blend of materials, many of which have a negative impact on the environment. Basalt fiber is 100% natural lava rock and significantly reduces the carbon footprint, due to the fact that during the formation of the lava, all the harmful emissions had already been released,” he concluded.
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CHOPPED BASALT STRAND: This application is an effective way to increase chemical, impact, and cracking resistance of cement panels or concrete. Chopped basalt concrete grade is produced with a special sizing agent to provide good compatibility with different types of concretes, high alkali resistance and easy mixing.
______________________
Forrester points out that basalt fiber can be used by the building, construction and civil engineering industries for numerous applications, including; concrete rebar, concrete floor reinforcement, fence droppers, Shotcrete, and asphalt reinforcing for roads. The fiber can also be used to reinforce pothole patching materials, and is finding increasing use in international road construction.
For more information, please contact:
Gordon Forrester | E-mail: rgforrester@gmail.com
Website: https://basfiber.com/application/construction
For more information about basalt fiber (Basfiber®), please see these links:
https://basfiber.com/application/construction
https://basfiber.com/products/reinforcing-mesh
https://www.basaltft.com/products/rm.htm
Advantages and benefits PDF:
https://www.basaltft.com/pdf/MSH_Technical_Data_Sheet.pdf
https://www.specifile.co.za/news/building-systems-and-materials/pmsa-basalt-technology-introduces-stonerod/
Pan Mixers South Africa (PMSA): (StoneRod is a Basalt Technology (Pty) Ltd trademark)
https://pmsa.com
http://media.ngage.co.za/new-product-offering-from-pmsa-is-rock-solid