A TECHNICAL PAPER ON

BASALT ROCK FIBRE

NEW CONSTRUCTION MATERIAL
PRESENTED BY:
SHINDE MADHUKAR DATTATRAYA
(Email: shindemadhukar45@yahoo.com) (B.E. Civil)
DARADE DHARMA K. (T.E. Civil)
GUDED BY:
Dr. ARUN KUMAR (H.O.D., Civil Department)
Prof. Raj Kamble (Civil Department)
SANJIVANI RURAL EDUCATION SOCIETYS
COLLE!E O" EN!INEERIN!, #O$AR!AON
- 1 -
NDE!
". n#roduc#ion To Basa$# Rock %i&re 'BR%(
). Sco*e +, Basa$# Rock %i&re
-. .d/an#a0es o, Basa$# Rock %i&ers
4. %ie$d +, .**$ica#ion +, Basa$# Rock %i&re
4.1 Construction
4.2 Road Construction
4.3 Underground Construction
4.4 Engineering et!or"
4.# $griculture
5. Basa$# Rock %i&re Produc#s
#.1 Basalt Rein%orcement Rods
#.2 Basalt &eote'tile (Rein%orcing (inens and ets)
#.3 Continuous Basalt )i*re
#.4 Basaltic +lastic +i,es
1. Basa$# Rock %i&re 2anu,ac#urin0 Techni3ue
-.1 Basalt Roc" $s Ra! .aterial
-.1.1 Tec/nical +ro,erties
-.1.2 C/emical com,osition *asalt roc"
-.1.3 Region o% Basalt Roc" in 0ndia
-.2 .anu%acturing +rocess o% Continuous Basalt )i*re (CB))
-.2.1 +lant la1out
-.2.2 +rocess 2escri,tion
-.2.3 T/e .ain C/aracteristics o% t/e +lant
4. 5onc$usion
- 2 -
ABSTRACT
Basalt is !ell "no!n as a roc" %ound in virtuall1 ever1 countr1 round t/e !orld. Basalt Roc"
%i*res /ave no to'ic reaction !it/ air or !ater3 are non-com*usti*le and e',losion ,roo%.
4/en in contact !it/ ot/er c/emicals t/e1 ,roduce no c/emical reactions t/at ma1 damage
/ealt/ or t/e environment. Basalt *ase com,osites can re,lace steel and "no!n rein%orced
,lastics (1 kg of basalt reinforces equals 9.6 kg of steel). T/ere seemed to *e somet/ing 5uite
,oetic in using a %i*re made %rom natural roc" to rein%orce a material3 !/ic/ mig/t 5uite
reasona*l1 *e descri*ed as artificial rock.
Ra! material %or ,roducing *asalt %i*re is a roc" o% t/e volcanic origin. )i*res are received
*1 melting *asalt stones do!n at t/e tem,erature o% 14667C. .elted *asalt mass ,asses
t/roug/ t/e ,latinum *us/ing and is e'tended into %i*res. Basalt Roc" %i*re s,ecial
,ro,erties reduce t/e cost o% ,roducts !/ilst im,roving t/eir ,er%ormance.
Sco*e: (o! cost3 /ig/ ,er%ormance *asalt %i*res o%%er t/e ,otential to solve t/e
largest ,ro*lem in t/e cement and concrete industr13 crac"ing and structural %ailure o%
concrete.Basalt %i*re rein%orced concrete could *ecome t/e leading rein%orcement s1stem in
t/e !orld %or minimi8ing crac"ing3 reducing road !ear3 im,roving concrete ,roduct li%e3
lo!ering maintenance and re,lacement costs3 and minimi8ing concrete industr1 la! suits.
0t !as t/ere%ore !it/ considera*le interest t/at use o% *asalt %i*res as a rein%orcing material
%or concrete. 4e ,ro,ose /ere to investigate t/e usage o% Basalt %i*ers in lo! cost
com,osites %or civil in%rastructure a,,lications re5uiring e'cellent mec/anical su,,ort
,ro,erties and long li%etimes.
Because o% t/e /ig/er ,er%ormance (strengt/3 tem,erature range3 and dura*ilit1) and lo!er
,otential cost ,redicted %or *asalt %i*ers3 t/e1 /ave t/e ,otential to cost e%%ectivel1 re,lace
%i*erglass3 steel %i*er3 ,ol1,ro,1lene3 ,ol1et/1lene3 ,ol1ester3 aramid and car*on %i*er
,roducts in man1 a,,lications.
- 3 -
". NTR+DU5T+N T+ B.S.6T R+57 %BRE:
T/e %irst ideas9attem,ts to e'trude continuous %ilaments %rom *asalt roc"s !ere made
in t/e U:$ and date *ac" to 1;23. :ince 4orld 4ar 00 (44 00)3 )renc/3 &erman3 Britis/3
0talian and mainl1 $merican researc/ers develo,ed some activities in t/e %ield o% Basalt
e'trusion. 2uring t/e 1;-6<s t/roug/ t/e =6<s t/e tec/nolog1 !as o*>ect o% secret3 militar1
and aeros,ace a,,lications. 0n 1;;# it !as declassi%ied and released %or civilian use. )rom
t/en on3 onl1 ver1 %e! com,anies /ave - !it/ signi%icant investments in R?2 and ca,ital -
mastered t/e di%%icult ,roduction ,rocess and are ,roducing continuous %ilament (C)) Basalt
%i*res in commercial 5uantities.
Ra! material %or ,roducing *asalt %i*re is a roc" o% t/e volcanic origin. )i*res are
received *1 melting *asalt stones do!n at t/e tem,erature o% 14667C. .elted *asalt mass
,asses t/roug/ t/e ,latinum *us/ing and is e'tended into %i*res. T/e ,/1sical ,ro,erties
(strengt/3 elasticit1) o% *asalt %i*re are considera*l1 /ig/er t/ose o% mineral and glass %i*re.
Basalt Roc" %i*re s,ecial ,ro,erties reduce t/e cost o% ,roducts !/ilst im,roving t/eir
,er%ormance. .ore t/an /undreds s,eci%ic uni5ue manu%acturing tec/ni5ues using *asalt
%i*er materials and ,roducts /ave *een develo,ed and ,atented in Russia.
[http://www.aketoma.se/basalt.html]
). S5+PE T+ B.S.6T R+57 %BRE:
(o! cost3 /ig/ ,er%ormance *asalt %i*res o%%er t/e ,otential to solve t/e largest
,ro*lem in t/e cement and concrete industr13 crac"ing and structural %ailure o% concrete.
@nce t/e ,rocess /as *een develo,ed3 tested3 demonstrated and acce,ted on a !ide scale
*asis3 *asalt %i*er rein%orced concrete could *ecome t/e leading rein%orcement s1stem in t/e
!orld %or minimi8ing crac"ing3 reducing road !ear3 im,roving concrete ,roduct li%e3
lo!ering maintenance and re,lacement costs3 and minimi8ing concrete industr1 la! suits.
)i*re made %rom *asalt3 a ,lenti%ul3 ine',ensive ra! material3 out,er%orms glass
%ilament3 steel %i*re3 ,ol1,ro,1lene %i*er and ot/er t1,es o% %i*ers %or man1 a,,lications. Aust
!e t/in" o% /o! man1 tons or cu*ic meters o% rein%orced concrete are used to ma"e u, t/e
run!a13 roads3 terminal *uildings3 /otels and con%erence centers. T/e tec/nolog1 and
a,,lications o% rein%orced concrete ma1 not *e as glamorous as t/ose o% sa13 *oron-gra,/ite
%lame cans and t/rust reversers *ut t/e1 are ever1 *it as demanding and ,er/a,s o% more
relevance in da1 to da1 li%e. 0t !as t/ere%ore !it/ considera*le interest t/at use o% *asalt
%i*res as a rein%orcing material %or concrete.
- 4 -
4e ,ro,ose /ere to investigate t/e usage o% Basalt %i*ers in lo! cost com,osites %or
civil in%rastructure a,,lications re5uiring e'cellent mec/anical su,,ort ,ro,erties and long
li%etimes. [http://www.globalcomposites.com/news/newsfiche.asp!i"#$1$%]
-. .D8.NT.GES +% B.S.6T R+57 %BERS:
T/e advantages o% Basalt Roc" )i*re are as %ollo!s3
1. T/e1 /ave no to'ic action !it/ air ? !ater. 4/en in contact !it/ ot/er c/emicals t/e1
,roduce no c/emical reactions t/at ma1 damage /ealt/ or t/e environment.:,ecial ,ro,erties
o% *asalt %i*re reduce t/e cost o% ,roducts !/ilst im,roving t/eir ,er%ormance.
2. Basalt %i*res are non-%lamma*le and resistant to t/e attac" o% aggressive media suc/ as acids
and al"alis and steam i.e. ver1 /ig/ c/emical resistance.
3. Basalt is t/e *est rein%orcement %or concrete due to its tensile strengt/ and natural resistance
to deterioration %rom al"ali.
4. Basalt %i*re ,roducts /ave e'cellent noise a*sor,tion 5ualities
#. E'treme /ardness3 =-; on t/e .o/Bs scale (2iamondC16).
-. Basalt *ased com,osites can e%%icientl1 re,lace steel and all "no!n rein%orced ,lastics.
D. 4ater a*sor,tion o% *asalt %i*re ,roducts is 16 times less t/an t/at o% %i*re glass. T/us in
/ig/ /umid environment !/ere %i*reglass looses its tensile strengt/3 *asalt %i*re ,roducts
retain t/eir ,ro,erties.
=. .elting tem,eratures a*ove 13667C ? 4or"ing tem,eratures u, to -667C.
[http://www.albarrie.com]
4. %E6D +% .PP65.T+N +% B.S.6T R+57 %BRE:
4." 5ons#ruc#ion:
1. Rein%orcement o% *ridges3 tunnels.
2. +roduction o% sand!ic/-,anels *ased on *asalt and car*on-*asalt %i*res.
1. 2irectional and de,ressive rein%orcement o% concrete.
2. :o%t roo%ing made o% non-com*usti*le *araltoinsol and *aslalto,lastic
3. Reusa*le s/utters3 0nternal !aste ,i,es3 Eeat-su,,l1 s1stems3 ca*le conduits.
4. oise ,rotection elements o% road screens3 la1ing t/e so%t roo%s3 E1draulic construction.
#. 0n t/e %ield o% de%ense: ma"ing incom*usti*le containers %or militar1 ammunition and to'ic
su*stances (incom*usti*le)
4.) Road 5ons#ruc#ion:
1. Rein%orcement o% concrete and as,/alt ,avements and run!a1s.
2. Construction o% sound-a*sor*ing *arriers %or /ig/!a1s3 rail!a1s3 and underground metro
lines.
- # -
4.- Under0round 5ons#ruc#ion:
1. $nc/ors3 ,illars3 ceilings vaults.
2. )oundations %or *uilding and constructions.
4.4 En0ineerin0 Ne#9ork:
1. +i,elines %or /eating and /ot3 !ater su,,l1.
2. Canalisation3 @il and &as *ig si8e *asalt and ,lastic ,i,elines.
3. Ca*le-conduit3 tele,/one s1stems ,rotected against electromagnetic %ields and in%ormation
lea"age t/roug/ electronic surveillance.
4. +i,es %or c/emical ,roducts and trans,ortation o% aggressive media.
4.5 .0ricu$#ure:
1. (and drainage ,i,es.
2. +i,es and gutters %or irrigation3 %ilter *odies and %ilter elements.
2. $gricultural construction. [http://www.laseroptroni&.com/things/basalt.p"f]
5. B.S.6T R+57 %BRE PR+DU5TS:
Basalt Roc" %i*er is a uni5ue ,roduct derived %rom volcanic Basalt Roc" in a single-
melt ,rocess and com,rised o% single-ingredient ra! material melts. 0n t/ermal conductivit13
articles made o% Basalt Roc" )i*ers are 3 times as e%%icient as t/ose made o% as*estos and
su,erior to glass and mineral %i*ers. T/e a,,lication tem,erature o% articles made o% Basalt
Roc" )i*ers is mar"edl1 /ig/er (%rom F2-6
6
C to ;66
6
C). 2ue t/e elasticit1 o% micro and
macro structure3 Basalt %i*ers are vi*ration-resistant com,ared to similar ,roducts. T/is
,ro,ert1 is o% ,articular im,ortance in mec/anical construction and civil engineering. )or
e'am,le3 !/en *uildings are erected near /ig/!a1s3 rail!a1s and underground3 !/ereas
under vi*ration cus/ions o% mineral and glass %i*ers e',erience damage and %inall1
disintegrate3 *asalt sla*s are vi*ration-resistant and3 /ence3 more dura*le.
)ollo!ing are t/e ,roducts o% Basalt Roc" )i*re
1. Basalt Rein%orcement Rod 3. Basalt &eote'tile
2. Continuous Basalt )i*re 4. Basaltic +lastic +i,es
5." Basa$# Rein,orcemen# Rods:
Rods o% unidirectional *asalt com,osite success%ull1 re,lace metal rein%orcement. $t
/ig/er s,eci%ic strengt/ and resistance to aggressive media3 1 kg of the basalt reinforcement
replaces 9.6 kg of metallic. T/e *asalt %i*res /o!ever /ave t/e advantage o% *eing around
one t/ird t/e !eig/t o% steel3 are ver1 resistant to corrosion in an al"aline environment and
/ave a similar co-e%%icient o% t/ermal e',ansivit1 to concrete. T/e %i*res ma1 *e used eit/er
as is3 or c/o,,ed into needles3 >ust as steel and n1lon %i*res can *e em,lo1ed to rein%orce
concrete. 0n vie! o% t/e %act t/at due to its c/emical inertness t/e *asalt rein%orcement is
- - -
com,ati*le !it/ concretes /aving di%%erent G,EH3 /aving actuall1 t/e same coe%%icient o%
t/ermal e',ansion and no residual de%ormation under *ending.
)ig. 1.1 Basalt Rein%orcement Rods [http://www.composites.org.uk]
5."." Technica$ Pro*er#ies o, Basa$# Rein,orcemen# Rod:
Ta*le o. 1.1
[http://www.su"aglass.com/ro"s.html]
5.".) .d/an#a0es Basa$# rod o/er S#ee$ re&ar:
1. Eig/er s,eci%ic strengt/ t/an steel re*ar =;I lig/ter in !eig/tJ one ton o% *asalt
rein%orcement rods ,rovides t/e rein%orcement o% ;.- tons o% steel re*ar.
2. Resistant to corrosion3 al"ali and acid and deterioration o% natural elements.
3. :ame coe%%icient o% t/ermal e',ansion as concrete.
4. o ,ermanent de%ormation !/en *ent.
#. C/emicall1 inert3 *asalt rods are com,ati*le !it/ concrete /aving di%%erent ,E values.
5.".- .**$ica#ion o, Basa$# Rein,orcemen# Rod:
1. T/e1 are used in ,roduction o% *uilding com,onents3 ,anelsB *arriers side!al"3 ,avement3
concrete *arriers and %acing sla*s3 and man1 ot/er structural com,onents.
$. 0n vie! o% t/eir /ig/ electro insulation ,ro,erties3 *asalt *ars are used %or ma"ing insulators
%or /ig/ voltage ,o!er lines.
'. $n es,eciall1 success%ul a,,lication o% *ars is %or rein%orcement o% concrete sla*s in
/1draulic engineering and3 /ig/!a1 rein%orcement.
- D -
2ensit13 g9cm
3
1.;#
T/ermal conductivit13 "cal9m ' / ' deg 6.3
Ultimate strengt/3 .,a
Tensile 1266
Com,ressive 426
Bending =66
.ass %raction o% ,ol1mer *inder 26 to 2#
(. Basalt rein%orcement rods are also an alternative *uilding and construction solution in
regions ,rone to eart/5ua"e and seismic /a8ards. [http://www.aketoma.se/ro"s.htm]
5.) Basa$# Geo#e:#i$e 'Rein,orcin0 6inens and Ne#s(:
&eote'tiles are !idel1 used in !a1 construction. $,,lied geote'tiles %or
rein%orcing !a1 coverings are /ig/l1 dura*le. &eote'tiles are !idel1 used in rein%orcing o%
slo,es3 !a1s3 em*an"ments3 dams3 in revegetation (o% ravines3 o,en ,its3 etc)3 erosive
,rotection o% lands3 antilandslides etc. &eote'tiles made *1 con5uers are made o% c/emical
and glass %i*ers using s,ecial im,regnation solutions. (:ee %ig. 1.2) [http://niis).ukrbi*.net/]
)ig. 1.2 Basalt &eote'tile [http://www.laseroptroni&.com/things/basalt.p"f]
5.)." .d/an#a0es o, Basa$# Geo#e:#i$e:
1. T/e1 are made o% natural ra! material (natural c/emical com,osition ,rovides c/emical
sta*ilit1 and resistance).
2. T/e1 are non-in%lamma*le and t/e1 can carr1 out distri*uted load.
3. T/e cost is 4-# lo!er t/an ot/er geote'tile material. [http://niis).ukrbi*.net/]
5.).) .**$ica#ion o, Basa$# Geo#e:#i$e:
1. )or rein%orcing o% road coverings3 em*an"ments3 slo,es3 !aste *an"s3 antilandslides3 erosive
,rotection3 recultivation etc.
U"r Road :cience Researc/ 0nstitute o,erated t/e tests. T/e materials !ere used in
section o% /ig/!a1 Kiev- @dessa. T/e test con%irmed t/e e%%ectiveness o% t/e a,,l1ing.
+reliminar1 calculations and gained e',erience s/o!s t/at t/e geote'tiles reduce t/e
,ro*a*ilit1 o% crac"ing3 slum,ing3 /oles3 ,its on road coatJ t/e dura*ilit1 is 1.#-2 times
/ig/er. [http://niis).ukrbi*.net/]
5.- 5on#inuous Basa$# %i&re:
Continuous Basalt %i*re is a uni5u6e ,roduct derived %rom volcanic mineral de,osits.
)i*er is manu%actured %rom *asalt roc" in a single-melt ,rocess and com,rised o% single-
ingredient ra! material melts. Basalt %i*ers are su,erior to ot/er %i*ers in terms o% t/ermal
sta*ilit13 /eat and sound insulation ,ro,erties3 vi*ration resistance and dura*ilit1.
- = -
5.-." Technica$ Pro*er#ies o, 5on#inuous Basa$# %i&re:
1. T/ermal limit o% a,,lication3
6
C -266 to L-66
2. 2ensit13 "g9m
3
2=66
3. Elasticit1 modulus3 "g9mm
2
;166 to 1166
4. :ta*ilit1 at tension (a%ter 1 /our t/ermal treatment)3 I
26
6
C 166
266
6
C ;4
466
6
C -#
#. I !eig/t lose a%ter *oiling during 3 /ours in
E2@ 6.1-
2 a@E #.6
2 ECl 2.1
-. :,eci%ic volume electrical resistance3 @/m.m 1M16
13
D. ormal coe%%icient o% sound a*sor,tion 6.; to 6.;;
[http://niis).ukrbi*.net/]
5.-.) .**$ica#ion o, 5on#inuous Basa$# %i&re:
1. Used in geo-te'tiles %or rein%orcing o% ,avements3 landing stri,s3 %or
strengt/ening o% land slo,es (o,en mines) and em*an"ments.
2. Rein%orcing materials %or concrete constructions (*asalt ,lastic rein%orcement3
c/o,,ed *asalt %i*ers3 *asalt-rein%orcing nets).
3. (inens3 canvases !it/ longitudinal rein%orcement %or so%t roo%ing.
4. .aterials %or underground ,i,eline re,air and C/emicall1 resistant ,i,es.
#. T/ermal3 $coustic *arriers and3 Com,osite rein%orcements.
-. Electro- insulating linens %or manu%acturing o% electronics com,onents F *oards3
%or electrical industr1. [http://niis).ukrbi*.net/]
5.4 Basa$#ic P$as#ic Pi*es:
T/e strengt/ o% a ,lastic-,lastic ,i,e is several times stronger t/an t/at o% glass-%i*re
,i,es and steel-,i,es. T/is 5ualit1 o% *asalt-,lastic ma"es it ,ossi*le to create /ig/ ,ressure
s1stems o% /ig/er relia*ilit13 i.e. over 1666 atm3 !/ic/ is not ,racticall1 !it/ metal ,i,es.
Basalt %i*re com,osite ,i,es are o*tained *1 !inding *asalt t/reads3 %a*rics3 ,re,egs
im,regnated !it/ a *inder. T/e ,i,es ma1 *e use%ul as com,onents %or s/a%ts linings3
*uilding com,onents3 %or trans,orting corrosive li5uids and gases in t/e construction3
industrial3 agricultural and ,u*lic services sectors.
- ; -
T/ere%ore ,i,es made o% *asalt %i*ers ma1 *e used in t/e c/emical ,roduction %or
trans,orting /ot acids3 in t/e construction o% se!erage s1stems3 trans,ortation o% aggressive
li5uids and gases3 loose materials3 etc.
5.4." .d/an#a0es o, Basa$# P$as#ic Pi*es:
1. T/e !eig/t o% one meter o% *asalt-,lastic ,i,es is 3 to 4 times less t/an t/e one o%
steel ,i,e.
2. T/e li%e o% *asalt ,i,es3 designed %or variet1 o% a,,lications is at least #6 1ears
!it/out maintenance or electric or tec/nical ,rotection.
3. T/e strengt/ o% a ,lastic-,lastic ,i,e is several times stronger t/an t/at o% glass-
%i*re ,i,es and o% t/e ma>orit1 o% steel-,i,es.
4. Eig/ c/emical resistance to aggressive media ma"es it ,ossi*le to manu%acture
,i,elines %or trans,orting /1drogen sul,/ide3 acid al"alises etc.
#. Basalt ,i,es are resistant to t/e action o% %ungi and microorganisms.
-. Basalt-,lastic /as lo! t/ermal conductivit13 t/ere*1 ,reventing t/e de,osition o%
salts and ,ara%%inBs in ,i,elines and re5uiring no additional /eat insulation.
D. Being insulators3 *asalt-,lastic ,i,es are resistant to electroc/emical corrosion.
$ll t/is ma"es it ,ossi*le to increase t/e guaranteed service li%e o% *asalt-,lastic ,i,es to -6
F =6 1ears3 i.e. 2 to 3 times as t/at o% metallic ones.
=. $nd as a result o% t/e a*ove3 t/ere is no need %or insulation and anti corrosion
measures.
[http://www.aketoma.se/+asaltpipes.htm]
5.4.) 5om*arison o, Basa$# Rock %i&re Porduc# ;i#h +#her 2a#eria$:
Com,arative c/aracteristics o% steel3 glass-,lastic and *asalt ,i,es: Ta*le o. 1.2
5harac#eris#ic S#ee$ G$ass<*$as#ic Basa$#<*$as#ic
Ultimate tensile strengt/3 .,a 266 146 (366)M
Tensile modulus3 &,a 216 #- D6 (1-6)M
2ensit13 "g9m
3
D=66 1;66 1D66
T/ermal3 conductivit13 4D 6.# 6.3
Nolume resistivit13 o/m9m Conductor 1 '16
16
4 '16
12
Mote: 0n t/e *rac"ets are values %or ,i,e !inding %rom /1*rid *asalt-car*on %i*res. T/ese
,ro,erties indicates ma1 *e muc/ /ig/er.
1. Basa$# Rock %i&re 2anu,ac#urin0 Techni3ue:
1." Basa$# Rock .s Ra9 2a#eria$:
- 16 -
Basicall1 *asalt is an e'trusive igneous roc" !it/ a melting ,oint o% a*out 1466 OC3
!/ic/ can *e %ound all over t/e !orld !it/ di%%ering c/emical com,ositions. Basalt roc" is
dense %ine-grained roc" t/at is o% ver1 dar" color- green or *lac" and o%ten /aving a glass1
a,,earance. 4/en molten lava %rom dee, in t/e eart/<s crust rises u, and solidi%ies. 0nitiall1
*asalt roc" !ere mainl1 used in com,osite construction materials suc/ as cement3 roo%ing
s/ingles3 ,aving materials3 railroad cross ties and ot/er /ig/ volume a,,lications !/ere ver1
little c/emical alteration o% t/e *asic material is needed. :ome *asalt %lo!s are ten to
/undreds o% /undreds o% million 1ears old and t/roug/ all t/ose ages it /as not !eat/ered
a!a1. 0t is a ver1 ine',ensive material.
1."." Technica$ Pro*er#ies:
1. Eig/ tensile strengt/3 5uite dura*le3 $l"ali ? acids resistant3 Eig/ t/ermal conductivit1.
2. Com,letel1 inert !it/ no environmental ris"s.
3. Eig/ E modulus resulting in e'cellent s,eci%ic tenacit13 t/ree times t/at o% steel %i*er.
[http://www.rea"e.com/,pplications.htm]
1.".) 5hemica$ com*osi#ion &asa$# rock:
5hemica$ Name: Basic volcanic igneous roc" %rom calc-al"ali series.
5hemica$ s#ruc#ure: Ta*le o. 1.3
P/tt,:99!!!.*asalt%i*re.com9eng9catalog9"ros/"a9*as"/ar9Q
1.".- Re0ion o, Basa$# Rock in ndia:
Basalt roc" (2ecan Tra,) an area o% a*out #663666 s5uare K. cover large ,art o% t/e
.a/aras/tra3 Kutc/3 :auras/tra3 &u>arat3 2ecan3 Central 0ndia3 .ad/1a +rades/3 E1dera*ad
region etc. (-eolog. of /n"ia0 +. 1. 2. 3,1/, 0 4age 2o. $56)
1.) 2anu,ac#urin0 Process o, 5on#inuous Basa$# %i&re '5B%(:
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5hemica$
com*ound
= 9ei0h# o,
&asa$#
:i@
2
4;3#=
Ti@
2
236=
$l
2
@
3
1434=
)e
2
@
3
4342
)e@ ;343
K2@ 13=;
a2@ 2316
.g@ #316
Ca@ =3#6
.n@ 631D
T/e e'trusion o% vitreous %i*er t/roug/ a mec/anical roller ,rocess !as claimed to
/ave *een invented several 1ears ago. Basalt Continuous %i*ers are made %rom *asalt roc"s
using a single com,onent ra! material in a single stage ,rocess. Basalt %i*res are currentl1
,roduced *1 /eating Basalt and dra!ing t/e melt t/roug/ a die to create a %i*re3 not unli"e
t/e ,rocess used to manu%acture glass %i*res. 4or" is also under!a1 on develo,ing a means
o% dra!ing out a %i*re *et!een rollers3 t/is giving sco,e %or modi%1ing t/e cross section and
sur%ace %inis/ o% t/e %i*re in order to tailor its ,ro,erties %or s,eci%ic a,,lications. @nce t/e
*asalt %i*ers /ave *een ,roduced3 t/e1 are converted into a suita*le %orm %or t/eir intended
a,,lication. [http://www.eurotechlt".com]
1.)." P$an# $ayou#:
$ sc/ematic re,resentation o% t/e manu%acturing o% CB) %i*ers3 %rom care%ull1
selected and ,re,ared Basalt roc"s to t/e continuousl1 e'truded %ilaments3 is given in
%ollo!ing sc/eme
)ig 1.3 +lant la1out o% Continuous Basalt )i*re
[http://www.basalte&.com/+asalte&0-roep 7asureel 28.htm]
5on,i0ura#ion:
1. Batc/ silos: ra! material su,,l13 2. 4eig/ing3 dosing and mi'ing3 3. Trans,ort3
4. Batc/ c/arging3 #. .elting )urnace3 -. )ore/eart/s3 D. Bus/ings3 (continuous
%ilament %ormation)3 =. :i8ing a,,lication3 ;. :trand %ormation3 16. Traversing3
11. $utomated !inder.
1.).) Process Descri*#ion: (:ee )ig. 1.3)
Crus/ed Basalt roc" %rom Batc/ silos (1) is trans,orted t/roug/ trans,ort (3) to Batc/
c/arging (4).T/e Batc/ C/arging unit disc/arge ra! material into t/e melting %urnace (#).
T/e molten *asalt is ,re,ared to %orming %i*ers in t/e section o% t/e %urnace called a
R%eederR. T/e melt %lo!s t/roug/ t/e *us/ing (D) (4/ic/ is made o% ,latinum grou, metals)
!it/ a large num*er o% /oles (ori%ices). T/e *us/ing is /eated electricall13 and t/e /eat is
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controlled ver1 ,recisel1. T/e %i*ers are dra!n do!n %rom t/e melt and cooled ra,idl1 as
t/e1 e'it t/e *us/ing. $ si8ing is t/en a,,lied to t/e sur%ace o% t/e %i*ers *1 t/e device called
a Rsi8ing a,,licatorR (=). T/e com,onents o% t/e si8ing im,art strand integrit13 lu*ricit13 and
resin com,ati*ilit1. $%ter t/e si8ing is a,,lied3 t/e %ilaments are gat/ered into a *undle called
a RstrandR (;) means o% a gat/ering s/oe *e%ore a,,roac/ing t/e ta"e-u, device. T/e
attenuation rate3 and t/ere%ore t/e %inal diameter3 is controlled *1 t/e ta"e-u, device
(%orming !inder). T/e strand ,asses %rom t/e gat/ering s/oe to a automated !inder (11)
!/ere it is !ound onto a %orming tu*e (%orming ,ac"age is o%ten re%erred to as R%orming
ca"eR). T/e dried ca"es are read1 %or %urt/er ,rocessing.
1.).- The 2ain 5harac#eris#ics o, #he P$an#:
Ca,acit13 (tons ,er 1ear) : 2-6
um*er o% manu%acturing units : =
atural gas consum,tion3 (n.m
3
9"g) : #.3
Crus/ed *asalt consum,tion3 ("g9"g) : 1.1
Com,ressed air consum,tion3 (n.m
3
9"g) : 2
Electric ,o!er consum,tion (3=69226 N3 #6 E8)3 ("49/) : #.=
)urnace %lame s,ace tem,erature3 (
o
C) $,,ro'. : 1#66
Eeated air tem,erature3 (OC) : 366 to 466
:ervice !ater consum,tion3 (m
3
9da1) .a'. : 11.=
Cooling !ater ,ressure3 (.,a) : 6.2 to 6.3
[http://www.basaltfibre.com/eng/equip/nb)/]
4. 5onc$usion:
Basalt Roc" %i*res /ave no to'ic reaction !it/ air or !ater3 are non-com*usti*le and
e',losion ,roo%. 4/en in contact !it/ ot/er c/emicals t/e1 ,roduce no c/emical reactions
t/at ma1 damage /ealt/ or t/e environment. Basalt *ase com,osites can re,lace steel and
"no!n rein%orced ,lastics (1 kg of basalt reinforces equals 9.6 kg of steel). Basalt can
re,lace almost all a,,lications o% as*estos and /as t/ree times its /eat insulating ,ro,erties.
Basalt is !ell "no!n as a roc" %ound in virtuall1 ever1 countr1 round t/e !orld.
Basalt roc" is more in 0ndia (s,eciall1 in .a/aras/tra). T/e cost o% *asalt is 16 times lo!er
t/an t/at o% ra! materials %or %i*reglass. Basalt is more availa*le t/an an1 ot/er ra!
material. $lso t/e melting tem,erature is lo!er3 t/us energ1 consum,tion lo!er. T/us3 t/e
cost o% *asalt %i*re is considera*le lo!er t/an t/at o% similar materials. .ore !or"ers are not
re5uired to o,erate t/e manu%acturing ,lant.
Thus> conc$ude #ha# 9e can ins#a$$ #he %irs# *ro?ec# in ndia '2aharash#ra(.
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BB6+GR.P@Y
1. 0ntroduction To Basalt Roc" )i*re: P/tt,:99!!!.a"etoma.se9*asalt./tmlQ
2. :co,e To Basalt Roc" %i*re:
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4. )ield @% $,,lication @% Basalt Roc" )i*re:
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#. Basalt Roc" )i*re +roducts
#.1 Basalt Rein%orcement Rods
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#.1.1 Tec/nical +ro,erties o% Basalt Rein%orcement Rod
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#.1.3 $,,lication o% Basalt Rein%orcement Rod
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#.2 Basalt &eote'tile (Rein%orcing (inens and ets)
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#.4 Basaltic +lastic +i,es:
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-. Basalt Roc" )i*re .anu%acturing Tec/ni5ue
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-.1.2 C/emical com,osition *asalt roc":
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-.1.3 Region o% Basalt Roc" in 0ndia:
P&eolog1 o% 0ndia- B1 2. . 4$20$ - +age o. 2D#Q
-.2 .anu%acturing +rocess o% Continuous Basalt )i*re (CB))
-.2.1 +lant la1out: P/tt,:99!!!.*asalte'.com9Basalte'-&roe, .asureel N./tmQ
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-.2.3 T/e .ain C/aracteristics o% t/e +lant:
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