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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

BASALT ROCK FIBRE

SEMINAR REPORT 2011-2012

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

SEMINAR REPORT 2011-2012

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.

SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

CONTENTS
1. INTRODUCTION5 2. BASALT ROCK FIBRE-SCOPE...6 3. ADVANTAGES OF BASALT ROCK FIBERS7 4. FIELD APPLICATIONS OF BASALT ROCK FIBRE...8 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 5.1. 5.2. 5.3. 5.4. 6.1. 6.2. 6.3. 6.4. 6.5. 6.6. 6.7. 6.8. CONSTRUCTION.......9 ROAD CONSTRUCTION.10 ENGINEERING NET WORK...11 AGRICULTURE12 UNDERGROUND CONSTRUCTION.13 MACHINE CONSTRUCTION.14 BASALT REINFORCEMENT ROD16 CONTINUOUS BASALT FIBRE 17 BASALT GEOTEXTILE ..18 BASALT REINFORCING MESH19 HISTORY...22 BASALT ROCK AS RAW MATERIAL..23 TECHNICAL PROPERTIES.........24 CHEMICAL COMPOSITION BASALT ROCK..25 REGION OF BASALT ROCK IN INDIA.26 MANUFACTURING PROCESS .27 PLANT LAYOUT..28 PLANT CONFIGURATION.....29

5. BASALT ROCK FIBRE PRODUCTS.15

6. MANUFACTURING TECHNIQUE21

7. CONCLUSION..30 8. REFERENCE.31

SEMINAR REPORT 2011-2012

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 com posite 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. Whe n 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 m ade 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.

SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

2. 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

SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

3. 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 concr ete 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 600 C.

SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

4. FIELD APPLICATIONS OF BASALT ROCK FIBRE

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

SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

4.1. 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 building, 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


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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

4.2. 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


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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

4.3. 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

4.4. 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

4.5. 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

4.6. 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

5. BASALT ROCK FIBRE PRODUCTS


1. BASALT REINFORCEMENT ROD 2. CONTINUOUS BASALT FIBRE 3. BASALT GEOTEXTILE 4. BASALT REINFORCING MESH

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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

5.1. 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

5.2. BASALT GEOTEXTILE


ADVAVTAGES OF BASALT GEOTETILE:

1.

They are made of natural raw material (natural chemical composition provides chemical stability and resistance). They are non-inflammable and they can carry out distributed load. The cost is 4-5 lower than other geotextile material

2.

3.

Fig 7: Basalt Geotextiles


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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

5.3. 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


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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

5.4. 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 1450 C. 5. Lower elongation before brake than for synthetic material. 6. Easily milled using typical milling equipmen t. 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.
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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

Fig 9: Basalt reinforcing mesh


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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6. 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6.1. 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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BASALT ROCK FIBRE

6.2. BASALT ROCK AS RAW MATERIAL

Fig 10: Basalt Quarries And Quarry spalls

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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6.3. 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 Elastic modulus Elongation at break Density

4.84 GPa 89 GPa 3.15 % 2.7 g/cm

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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6.4. CHEMICAL COMPOSITION BASALT ROCK


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

CHEMICAL COMPOUND SiO2 TiO2 Al2O3 Fe2O3 Feo K2O Na2O Mgo Cao

% WEIGHT OF BASALT 49.58 2.08 14.48 4.42 9.43 1.89 2.10 5.10 8.50

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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6.5. REGION OF BASALT ROCK IN INDIA


Basalt 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6.6. 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 basal t 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 m which is far enough above the respiratory limit of 5 m to make basalt fiber a suitable replacement for asbestos. They also have a high elastic modulus, resulting in excellent specific tenacitythree times that of steel.

Fig 11: Manufacturing Process

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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6.7. PLANT LAYOUT

Fig 12: Plant Layout

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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

6.8. 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 (continuous filament formation) 8. Sizing application 9. Strand formation 10. Traversing 11. Automated winder

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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

7. CONCLUSION
Basalt Rock fibres have no toxic reaction with air or water, are noncombustible 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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SEMINAR REPORT 2011-2012

BASALT ROCK FIBRE

8. REFERENCE
1. http://www.seminarprojects.com/Thread-basalt-rock-fibrebrf#ixzz1PG4ofX2i 2. http://www.scribd.com/doc/49566986/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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