2013/2014 edition 1. revised version | www.bafanet.

com

BASALT
the Magazine of the german Basalt fibre industry

cover story:
turning stone into fibre
the process
applications
NETwork

Forum Technologie & Wirtschaft e.V.

MeixstraSSe 5
01326 Dresden
germany
mail@forum-tuw.net
www.BAFANET.COM

www.sternkopf.biz

is a business network for the research and development of basalt fibre

and its applications in textile manufacture, in lightweight structures, in
the construction sector and in various other industries. Responsibility for
managing the network falls to Forum Technologie & Wirtschaft e.V. This
association coordinates research and development in the textile sector
and identifies areas of potential collaboration between different fields.
By establishing and supporting networks and research collaborations, the
Forum is playing a key role in consolidating the regional economic structure in Central Germany.

Funded by:

(German Federal Ministry of Economics and Technology)

following a resolution passed by the

German Federal Parliament

COMPETENCE MATRIX

EDITORIAL

Competence matrix
An industry on the move
BASALT The Magazine of the German Basalt Fibre Industry.

Yarn and fabric production

Filament, chopped strands, equipment
DBF

UD tapes, scrim
CETEX

Sewing and
embroidery yarn

Alterfil

3D fibre structures
Fiber Engineering

Non-woven fabric
Norafin
Fibtex

Spinning, core yarn

Hoftex
Yarn finishing, thread
Alterfil

Knitted fabric
STS

Knitted/ crocheted
fabric

Woven fabric
STFI

Netting
STFI, Karl Mayer

Karl Mayer

Tapes, rope
Barthels-Feldhoff

finishing, coating
Finishing,
functionalisation
Thorey

Coating,
lamination
VIS

Additives and auxiliary

products for fabrics
Lefatex Chemie GmbH

Surface
functionalisation
Innovent

Bonding
AB-Tec

service
Research,
testing,
certification,
surface formation,
equipment
STFI

Research,
technology,
engineering

CETEX

Analysis

Project management
with Forum TuW
e.V.

Research,
analysis,
surface treatment,
functionalisation

Research,
development,
lightweight structures

Development,
construction,
engineering services

Research,
analysis,
ceramic
materials

Innovent

TU Chemnitz

EBF Dresden

KI Keramikinstitut

This is the ambitious title we have given to this publication, now

into its second edition. The German basalt fibre industry is there
really such a thing? And what should we include under this heading? When you Google for the term, the references you find are
generally academic articles on the quarrying of basalt. But thats
not what our magazine is about. Because basalt is much more
than rock; it is more like spun gold. Melted basalt produces fibres
that open up completely new technical possibilities. The nature
of these possibilities is the theme of our magazine published on
behalf of the German basalt fibre industry.
Basalt fibre is a truly innovative material. Although the underlying science has been the subject of research since the 1960s, it
is only now that basalt fibre is on the threshold of an industrial
breakthrough. We are certain that a huge new sector of the economy is about to mushroom from the first pioneering projects.
The basalt fibre industry is an industry on the move. These fibres
spun from stone have tremendous potential for a variety of applications, ranging from the automotive industry to mechanical
engineering and from construction to textile manufacturing.
Forward-looking enterprises and research institutions that have
recognised the potential of basalt fibre and wish to exploit its
economic benefits have joined forces to form BASALTFASERNETZWERK (Basalt Fibre Network). Together, they intend to
explore the possibilities for the technical application of basalt
fibre, to resolve the issue of reliability in quality and to develop
new applications.
We hope that the visionary projects we report on in this edition
will excite and inspire you. We are already looking forward to
the next issue in which we will update you on the latest developments surrounding basalt fibre.

From left to right:

Torsten Kunz (Project Coordinator)
Mirko Jacob (Project Coordinator)
Torsten Bz (Project Leader)
Peggy Wunderlich (Project Administration)
In 2013, the two established networks COMBAFI
and TEXSALT banded together to form BASALTFASERNETZWERK. TEXSALT focuses on textiles made
of basalt, while COMBAFI specialises in basaltfibre-reinforced composites. By joining forces, the
members of this new association aim to benefit
from synergies and to develop new approaches to
the exploitation of basalt fibre.

Torsten Bz
Project Leader BASALTFASERNETZWERK
baez@forum-tuw.net

TEXTILe applicatons
Geotextiles, textiles for
the construction industry
IGG

Filtration
IGG, Norafin

Textile Architecture

Abrasion-resistant
conveyor belts
VIS

Geomats, filters,
non-woven liners

Norafin

Textile products
for marine
applications
Beka Mare
Solutions

High-temperature
applications

Automotive
BMW

Norafin,
Fibtex

Soundproofing
IGG,
Fibtex

Application field: composite materials

Woven prepregs
Barthels-Feldhoff
Automotive
BMW

Facade elements
FIBER TECH

Ceramic composite
components
KI KERAMIKINSTITUT

Profiles, plates,
rods, prepregs
CG Tec

Asphalt reinforcement,
geotextiles
Tensar

Tubes,
pressure tanks,
power systems,
plant engineering
Roth Industries

Fibre composite
products for marine applications
Beka Mare
Solutions

Prefabricated buildings,
building, construction
materials

CONTENTS
4 / 5

6 / 7

8 /9

10 / 11

TURNING STONE INTO

FIBRE
The process

FEELING EuphoriC
Interview with Christoph
Osterroth, CEO of Deutsche Basalt Faser GmbH

revolutionary fIBRE
Applications and
benefits

NETWORK PARTNERS

Zapf

Plant technology, fibre

injection technology
Fiber Engineering

Competence matrix of the networK: The diagramme illustrates how companies and research institutions have pooled their diverse

skills and resources by collaborating in the network. The entire multi-faceted value chain from filament production to recycling is represented here,
facilitating a variety of applications and solutions.

COMPETENce MATRIX | EDITORIAL

2/3
process 4/5
Interview 6/7
applications

8/9
Network

10/11

PROCESS

PROCESS

TURNING STONE INTO FIBRE

THE PROCESS
HOW DO YOU SPIN STONE INTO THREAD? A LOOK INTO THE FURNACE:

FACTS & FIGURES

10%

1,450C
2,000 m/min

THE proCess

The diameter of a basalt thread is 10%

of a human hair.

1,450C is the temperature at which basalt rock

starts to melt.

2,000 metres per minute: the speed at which the thread is spun.

THE PRODUCTS
Rovings:
A basic thread consists of 250 filaments. Several threads are bundled as yarn and bundled
up into a roving which in turn serves as the
starting material for textile production. Rovings
are the raw material for twisting, spinning or
weaving.

Lumps of basalt rock, 5cm

to 10cm in diameter, are fed
through a funnel into the
furnace. The precisely controlled temperature inside the
furnace ranges from 1,300C
to 1,450C. The basalt is
plasticised , i.e. smelted and
liquefied.

The yellowish-red molten basalt is then extruded through

the flow feeder (a heated
tube) into the bushing. The
flow feeder builds up a precisely regulated melting pressure.
The molten basalt is drawn
off through the nozzles in the
bushing, forming hair-thin basalt fibres.

In order to ensure optimum

processability, the filaments
are coated with sizing which
allows them to be treated
like a textile and serves as a
bond-ing agent between fibre and matrix. The sizing has
been specially developed for
this process and is adapted for
specific applications.

Next, the fibres are drawn by a

winder and wrapped around a
The
so-called spinning cake.
fibre is now ready for delivery
to the customer.

COMPLEX SYSTEMS

CAUTION, HOT!

It may sound straightforward, but in fact it is a highly

complicated technical process. Pressure, temperature
and extrusion speed at the nozzle plates are precisely
regulated, with extremely low tolerances. Within these
parameters, the viscosity of the melt is controlled, thereby enabling the thickness of the drawn thread to be regulated. Consistent filament thickness is a crucial factor
for later applications and an essential quality feature.

The temperatures at which the furnace is

run are exceptionally high. This requires
appropriate technical adjustments. Consequently, the nozzle plates are made from
special noble metal, as temperatures of this
magnitude would melt steel.

CHOPPED STRANDS:
50 continuous fibres running in parallel are
drawn into a coating machine. After coating,
they are dried, which causes the coating to be
polymerised. This ensures high strand integrity.
The fibres are then chopped into 1cm lengths
which are characterised by their high strength
and satisfy the most stringent quality requirements. Their high frictional properties, low wear
and high temperature stability make them ideal
for a number of uses, such as the manufacture
of brake linings.

This intermediate product will

be further processed in various applications, and Deutsche Basalt Faser GmbH supplies it in two versions: rovings
and chopped strands.

THE BIRTH OF THE FIBRE:

The molten mass is ready for extrusion through the nozzles and
forms a funnel-shaped head. The fibre is created by extracting it
at such a high speed that the molten material has no time to crystallise; it solidifies in an amorphous state. In this way, basalt rock is
turned into flexible fibres with fascinating properties.

INTERVIEW

INTERVIEW

FEELING EuphoriC
Interview with Christoph Osterroth,
CEO of Deutsche Basalt Faser GmbH

christoph Osterroth

WHAT DOES INVESTMENT IN SUCH INNOVATIVE PROJECTS MEAN FOR YOU PERSONALLY?
The personal appeal for me is the element of challenge.
As an engineer and businessman, I see these innovative
development projects as having immense potential.

HAVE YOU REACHED ALL YOUR GOALS WITH

THE DEVELOPMENT YET?

HOW WOULD YOU ASSES THE FUTURE OF THE

GERMAN BASALT FIBRE INDUSTRY?
What you see here today is just the beginning. The basalt fibre industry is in the initial phase of a completely
new technology that opens up undreamed-of possibilities. We have pursued a high-risk strategy and overcome
many legal and regulatory hurdles along the way. I see a
huge potential. Various well-defined projects are about
to show concrete results. A commercial breakthrough for
basalt fibre is within our grasp.

hOW WELL EQUIPPED ARE YOU TO COPE WITH

THE PRODUCTION ASPECTS OF THE IMMINENT
BOOM?
We have approval for ten furnaces and are about to expand our production in line with demand. Our first furnace designed and built in-house is more than just a pilot.
It is already a fully functional production unit which is

capable of operating at a profit. We now intend to build

several more.

HOW DID YOU GO ABOUT DEVELOPING THE

TECHNOLOGY FOR THE PRODUCTION OF BASALT FIBRES?
The furnace in which we smelt the basalt was built completely by ourselves. With the support of the experienced
professionals at our affiliated company in Georgia, we have
fine-tuned the process to ensure optimum and consistent
quality of the basalt fibre. Thanks to our in-house development, we have acquired an in-depth technical understanding of the entire process. As simple as it looks, the
technology is actually highly sophisticated. But we have
this technology fully under control. It fills us with a sense
of pride that we have managed to get the technology up
and running, producing basalt fibres of consistent quality
and functioning at a high level of reliability.

No, but thats the exciting thing about it. For example,
if you were researching sheet metal at this point in history, you might be able to achieve an improvement of
a few percentage points. But you see, basalt is a very
young material. With just a moderate amount of R&D,
you can achieve significant improvements. Each time we
come up with a new product, we can still expect farreaching improvements in its technical characteristics.
There is enormous potential here that we are constantly
aware of. So my assessment of the current situation is
that weve already achieved some magnificent results
but that there are many more to come.

BASALT IS ACTUALLY A CRYSTALLINE PROdUCT, SO WHY DOES IT LEND ITSELF TO PROCESSING AS A FIBRE FOR TEXTILES?
In its natural state, basalt rock is indeed crystalline, just
like sugar. During the natural process of formation, basalt takes a certain time to acquire its crystalline structure. We cant afford to give it this amount of time in our
production process. We solidify the amorphous structure
of the basalt. This is what makes it susceptible to processing for textile purposes.

BASALT IS A NATURAL PRODUCT, SO HOW DO

YOU ENSURE CONSISTENCY IN THE QUALITY
OF THE FIBRES?

The two factors that are crucial in ensuring consistently

high quality are reliability of process and raw materials
that do not vary in their properties. We have our own
quarry in Georgia, and the rock there is characterised by
a particularly favourable chemical composition. The quarry
has sufficient reserves to assure uninterrupted supplies
over many decades to come, even when production
really takes off.

WHAT IS THE SPECIAL FASCINATION OF BASALT

FIBRE FOR YOU PERSONALLY?
Basalt is a revolutionary fibre. In terms of cost-efficiency
and performance, it builds a bridge between carbon fibre
and glass fibre. Basalt opens the door to numerous projects for which glass fibre cannot be used and for which
carbon fibre would be too expensive. And the most exciting thing is that countless totally new areas of use are
opening up, some of which might seem like a distant
dream today, for example constructing motorway bridges
without steel reinforcement and metals which develop
completely new property profiles by the addition of basalt fibres. And why must cars be made of sheet metal
anyway? Almost every day, I have new ideas about what
can be done with this fibre.

WHAT VOLUME OF SERIOUS ENQUIRIES ARE

YOU RECEIVING FOR FURTHER PROJECTS?
We are seeing an industry on the move. At the moment,
a lot of enquiries and concrete projects are coming in,
and that gives me a feeling of euphoria.

APPLICATIONS

APPLICATIONS

A REVOLUTIONARY FIBRE
Applications and benefits

Euphoria. Visions. Optimism.

This is the impression left by every conversation with companies
and engineers who are busy developing applications for basalt
fibre. Lets take a look at some of these opportunities below.

APPLICATION-SPECIFIC BENEFIT PROFILES

It is significant for the industrial use of basalt fibre that different applications derive benefit from
different characteristics. For example, high temperature resistance, which generally ranks high on
the list of benefits, is of minor importance during the lifetime of products made from composite
materials, because the melting point of the plastic is well below that of the basalt fibre content. But
when the time comes to recycle the product, this factor works in its favour, as the plastic can easily
be separated from the basalt by melting. By contrast, for applications involving insulation, fire protection or concrete reinforcement, this high temperature resistance is essential.
For each potential application, a specific benefit profile can be identified which exploits the special
characteristics of basalt fibre to the maximum.

REINFORCEMENT OF TEXTILE SURFACES USING BASALT FIBRES

Woven fabrics, non-wovens, knitted and crocheted fabrics, scrims, ribbons, tapes and ropes
all of these applications are examples of textiles that can be reinforced with basalt fibres. In
the following technical applications, current research has shown that the use of basalt fibres
would be appropriate, and this has already been partially confirmed in practice:
for filters used in high-temperature environments, e.g. incinerators, cement factories
for stabilisation of road embankments or hillsides in ski resorts
as a scrim in textile-reinforced concrete instead of steel grid
for eye-catching designs
for fire protection applications
for renaturalisation of surfaces
for non-woven materials used for technical insulation, drainage material, soundproofing
and agriculture

Potential benefits of Basalt fibre

Current research has identified a number of specific advantages that are characteristic of basalt fibre.
These initial findings will be explored in depth by means of targeted research and development projects
within the BASALTFASERNETZWERK network.

High temperature resistance

2 Excellent mechanical properties,

such as tensile strength

COMPOSITES
Basalt fibres can be incorporated into a fibre matrix structure as constituents of compounds.
Wind turbine blades, aircraft fuselages and yacht hulls are already being manufactured from
epoxy resin in combination with carbon or glass fibre. Basalt fibre is also conceivable for all
of these applications; in a number of parameters, it would be more cost-efficient and
deliver better performance.
One groundbreaking development associated with basalt fibre is the
organic sheet, which is a combination of natural basalt fibre with polyamide plastic
film to produce a freely malleable lightweight material for industrial manufacturers.
In combination with mineral substances, basalt fibre is used to reinforce concrete.

fire protection

composites

3 Chemical resistance

filter textiles

4 Corrosion resistance

concrete applications

5 Excellent vibration damping

6 Natural product
7 Antifouling properties

8 UV resistance

acoustic insulation

good recyclability
eliminating growth of
algae and/or moss
geotextiles

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NETworK

Network

one networkmany options

Visionary companies and research institutions that have recognised
the potential of basalt fibre and wish to exploit its economic benefits have joined forces to form BASALTFASERNETZWERK (Basalt
Fibre Network). Together, they intend to explore the possibilities for
the technical application of basalt fibre, to ensure reliable qualities
and to develop new applications.

Zapf GmbH

Roth Industries GmbH & Co. KG

Manufacture of prefabricated buildings,

prefabricated garages and elements for
major building projects, production of
construction materials

Development and production of energy

systems, plumbing systems, pipe technologies and pressure reservoirs, as well as
composites and plants for the manufacture thereof

www.zapf-gmbh.de

www.roth-industries.com

Schsisches Textilforschungsinstitut e.V.

www.deutsche-basalt-faser.de

Fiber Engineering GmbH

Barthels-Feldhoff GmbH & Co. KG
Development and manufacture of
technical textiles, braiding, tape weaving,
plus the manufacture of yarn, coating and
finishing, assembling

Development and manufacture of equipment for the production of fibre-reinforced

components with a 3D contour based on
the Fibre Injection Moulding (FIM)
technology developed in-house.

www.barthels-feldhoff.de

www.fiber-engineering.de

Fibre processing and recycling plus

production of chopped strands and
development of non-woven fabrics used
in fire protection, acoustic insulation and
composite material

Research and development of technical

textiles and non-wovens, accredited test
centre for textiles and for the certification
of personal protective equipment
(Notified Body 0516)

KI Keramikinstitut GmbH

Production of basalt fibre in the form

of rovings and chopped strands,
development of basalt fibre for specific
applications

FIBTEX GmbH

(SAXON TEXTILE RESEARCH INSTITUTE)

www.stfi.de

DBF
Deutsche Basalt Faser GmbH

Basalt-fibre-reinforced profiled rebars

www.fibtex.eu

BEKA Mare SOLUTIONS GmbH

Development and marketing of corrosion
protection systems for marine applications
and composite materials in the marine
engineering sector

www.bekamaresolutions.de

INNOVENT e.V.

www.tensar.de

www.norafin.com

Chemnitz university of
technology, department of
lightweight structures and
polymer technology

hoftex coretech gmbh

Research and development of composites,

technologies and equipment for lightweight structures in the fields of plastics
and building materials

Development and production of classic

yarns, threads and fabrics, as well as
specialised technical textiles; partner for
cutting-edge production and technology
skills

www.leichtbau.tu-chemnitz.de

www.hoftex.de

ALTERFIL Nhfaden GmbH

Thorey Gera Textilveredlung

GmbH

Development, manufacture and distribution of innovative sewing and embroidery

yarns and technical yarns; operating its
own dyeing plant

Textile finishing of woven, knitted, crocheted or non-woven fabrics to the highest

quality standards

www.alterfil-shop.de

www.thotex.de

EBF Dresden GmbH

Engineering services and consulting for the
development and design of machinery and
equipment; wear materials and construction materials

www.innovent-jena.de

www.cg-tec.de

www.ebf-dresden.de

AB-Tec GmbH & Co.KG

VIS GmbH

LEFATEX CHEMIE GMBH

Trading in geotextiles made from natural

fibres and synthetics, gabion and embankment support systems

Production of thermoplastic, heat-activated adhesive non-wovens in Germany,

and Europe-wide marketing of these
products under the name TecWeb

Manufacture of conveyor belts and drive

belts, e.g. for the textile, food, machine
tool, logistics, tobacco, paper and printing
industries

www.igg.de

www.ab-tec.com

www.visbelting.eu

IGG
Internationale Geotextil GmbH

Manufacture of high-grade material structures, composites and special non-wovens

for filtration, work clothing, the medical
sector, automotive manufacturing and the
construction industry

CetexInstitut fr Textil- und Verarbeitungsmaschinen gGmbH

Research, development and transfer for

surface engineering, biomaterials, analysis,
as well as testing of materials and organisation of conferences

www.keramikinstitut.com

Norafin Industries GmbH

Development, manufacture and application of geogrids and geosynthetic

materials, e.g. in base layer stabilisation, in
the reinforcement of steep slopes and retaining structures and in the reinforcement
of asphalt surfaces

CG TEC GmbH
Development and production of profiles
and plates made from CFRP carbon fibre,
glass-fibre reinforced plastic (GRP) and
fibreglass and basalt-fibre reinforced
plastic (BRP), prepreg winding technology,
prepreg moulding technology, pultrusion

Development of ceramic materials, products and technologies, special and highperformance ceramics, quality assessment
and certification of ceramic raw and basic
materials

TeNSAR INTERNATIONAL

Manufacturer of dispersions and emulsions

www.lefatex.de
www.zschimmer-schwarz.com

German research institute for new technologies and machinery for the production of
textile-based semi-finished products, functional components and high-performance
structures
Basalt-reinforced spacer fabric

STS Textiles GmbH & Co.KG

Development and production of fabrics
for home textiles and for automotive and
technical applications

www.sts-textiles.com

www.cetex.de

BMW Group
Automobile manufacturer

www.bmwgroup.com

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