Basalt fiber and products on its basis

JSC “Polotsk-Steklovolokno” has started to manufacture a new product - basalt fiber and items on its basis (roving, chopped fiber, fabrics, thermal insulation materials). As a raw material serve rocks of basalt group. Basalt is a natural substance having high strength, resistance to application in corrosive medium and the products that are made from basalt have long operation life. In comparison with other composite materials, basalt fiber is a more ecological product.

Operating temperature of basalt materials ranges from - 260°С to + 700°С, during a single temperature exposure it reaches up to 1000°С.

At present basalt fiber catches greater interest of the market of composites and it’s viewed by specialists as one of the most perspective composite material with a unique combination of properties. Due to its mechanical characteristics basalt fiber occupies intermediate position between glass fiber and carboxylic fiber with relatively inexpensive price. This product is highly attractive for customers who have limitations on the incoming price but at the same time they put special emphasis on high mechanical properties. From all the fibers presented on the market of composites carboxylic fiber possesses the highest mechanical characteristics while E-glass has the cheapest price. 10% increase in mechanical properties is known to lead to price growth that is unlikely be equal to 10%.When we talk about different special types of fibers, such as glass with higher mechanical properties, high modular glass (S-2) or aramid glass, one can trace the following tendency: 10% of changes in strength lead to nearly 200% price boost. At the same time basalt fiber shows 25% strength increase and 15% elastic modulus improvement in comparison with E-glass whilst it has lower cost against the prescription of the line trend.

Serious research of production area of continuous basalt fiber started simultaneously in the USA and in the USSR in the 60’s. The target of the work lied in finding high-performance basalt fiber for rocket engineering. But in the 70’s specialists rejected this idea and concentrated on the development of a special high modular glass and, as a result, S2-glass was created. In the USSR works with basalt fiber continued up to the end of the 90’s, they took place mainly in Ukraine. Feeders were constructed in Russia, Georgia and Kazakhstan. Following the disintegration of the USSR, centralized financing of work was ceased. With knowledge, technology and investment level, fiber capable of combining reasonable price, as compared to glass fiber, and quite high mechanical characteristics was not developed. Moreover, it was obvious that a huge part of the prime cost of basalt fiber was occupied by energy resources and labor force expenses that, apart from technological problems, made the production of this fiber inefficient in the regions with costly natural gas, electricity and high remuneration of labor, i.e. in Europe, the USA and Japan.

As a result, in the end of the 90’s several factories in Ukraine and Russia used to produce low-grade continuous fiber for application chiefly to thermal and fire insulation, to be more precise, when customers didn’t require high mechanical properties. Only at the beginning of the 21st century after the establishment of a number of enterprises (in Russia, Austria, China, Ukraine), after achievement of technological perfection, the development of modern impregnation and construction of big furnaces with 400-800 tip bushing, the situation was improved and the enterprises started a regular production of continuous fiber of high performance with great mechanical properties, perfect adhesion to resins, low level of difference in length and quite an appealing price. Currently this brand new product appeared on the Belarusian market and its manufacture was mastered by JSC “Polotsk-Steklovolokno”, it caters both for the domestic market and for export supplies.

Properties and Advantages of Basalt Fiber

Basalt fiber has a universal set of heightened characteristics that mark it out among other fibers applied in the industry of composites. If each single benefit is taken separately it’s possible, without a doubt, to find some materials that are more efficient than basalt. But if a customer demands a scope of characteristics, basalt becomes a perfect solution due to quality-price ratio. Properties of basalt fiber significantly excel qualities of E-glass and put it closer to the features of special fibers such as S-glass, chemical-resistant glass, quartz fiber. Basalt fiber and products on its base have higher natural strength, resistance to corrosive environment, long life time, as well as perfect electric and thermal insulation properties.

The key advantages:

Wider range of temperature application (working temperature up to 700o C). This attribute helps to use the material for thermal insulation of different equipment in areas where high temperature insulation is required and also for fire barriers as a fireproof material.
Higher chemical resistance in acid and alkaline medium, sea water, as compared to E-glass. This property of basalt fiber opens wide horizon for the application in constructions that work under the influence of moisture, saline, chemical and alkaline medium. This will enable consumers to replace metal structures and parts that under the influence of chemically active medium are subject to corrosion, with light, solid and corrosion resistant products made from basalt fiber. Thus, different forms of basalt fibers can be used for reinforcement of concrete. Being made from geological materials, basalt fiber does not react with salts or colorant, that’s why concrete solutions with fiber addition can be employed in the construction of marine structures, in architectural and decorative concrete. In covering of roadways fiber protects concrete and fittings from the penetration of deicing salts and aggressive substances; it also enlarges retained strength and resistance to freezing-defrosting, increases roughness of the surface. Chemical resistance of basalt fiber is also one of the competitive advantages for its usage while making filters for chemical and metallurgy industry as well as for the production of different containers for chemical industry and utility.
25% higher strength in comparison with E-glass.
15% higher Young’s modulus of elasticity in comparison with E-glass.
Ecological friendliness of the material. Full compliance with REACH. The finished product does not contain any hazardous substances and totally corresponds to REACH protocol as well as to other sanitary standards.
Long operating life. Life time of materials is 50 years. Usage of such materials helps to be economical due to long operating life, and it also strengthens safety of industrial objects maintenance.
The material is resistant to vibration. This quality stimulates its usage for turbine insulation.
The material is not exposed to the impact of mould and other microorganisms.
Low price as opposed to high cost of special purpose glass.

Basalt products manufactured at JSC “Polotsk-Steklovolokno” and field of their application

BASALT ROVING

Application:

Production of basalt fabrics;
Manufacture of geotextile meshes and webs that serve for reinforcement of asphalt covering;
Fabrication of automotive composite materials;
Making of pipes for oil and gas industry as well as for flue-pipe chemical industry.
Manufacture of basalt plastics and basalt plastic fittings;
Production of needle felts for thermal and sound insulation, etc.

	Type
	BS16 1200Н-76(200)	BS16 2400Н-76(200)
Filament nominal diameter, mkm	16±1
Nominal linear density, tex	1200	2400
Tolerance in linear density, %	±5	±5
Tensile strength, not less than, mN/tex (gf/tex)	396(40)	396(40)
Loss on ignition, %, not less than	0,6	0,6

CHOPPED BASALT FIBER

Application:

as a reinforcing additive for fibrous concrete,
production of brake blocks;
manufacture of needle felts,
production of composite materials.

	Type
	BS16 6 76	BS16 12 76	BS16 24 76
Filament nominal diameter, mkm	16±1
Chopping length, mm	6±1	12±2	24±2
Loss on ignition, %, not less than	0,6
Moisture, %, not more than	0,1

BASALT YARN

Application:

Production of various woven and non-woven materials (fabrics, tapes, cords, etc.)
Manufacture of composite materials on the basis of epoxy, phenol, polyester and other bindings.

Basalt Yarn BS12 110 Z20 76
Nominal linear density, tex	110
Tolerance in linear density, %	+5 -7
Number of twists per 1 m	20
Tensile strength, mN/tex (gf/tex)	460(47)
Loss on ignition, %	Not less than 0,6

BASALT FABRIC

Basalt fabrics replace asbestos, silica and other fabrics in many spheres of usage. Basalt fabric is a superb insulation, reinforcing and filtering material. In comparison with glass fabrics, those made of basalt have better sound insulation, dielectric and mechanical properties. At the same time chemical resistance of basalt fabrics gives an opportunity to use them in corrosive medium.

Application:

as thermal insulation for welding, production of fireproof shutters and flameproof clothing.
as thermal insulation for industrial equipment, furnaces, recuperators, pipelines, turbines as well as for protection of other hot surfaces (fire protection of walls close to stoves and fireplaces, protection of covers from hot tubes, etc.)
as a covering material for thermal insulation mats.
as a filter to refine end gases from dust at metallurgical works.
in the production of composite materials.

Basalt fabric TBK-100(100)
Fabric density, yarns/cm		Surface density of the fabric g/m²	Width, cm	Loss on ignition, %	Thickness, mm	Tensile strength, N/2,5 сm
Warp	Weft					Warp	Weft
10±1	9±1	210±20	100±1	Not less than 0,6	0,19±0,025	Not less than 784	Not less than 784

Address:

JSC “Polotsk-Steklovolokno”

The Republic of Belarus

211400, 30 Stroitelnaya str., Polotsk

Contact data:

Tel. +375-214-415561, 415673, 415767,

Fax: +375-214-415420

e-mail: sale@psv.by