Basalt continuous fibers materials production

It is more profitable to remake primary BCF materials into finish BCF products. Organization of based - basalt continuous fiber materials production is very important and key question for improvement of the economic indexes of the BCF production. At the first stage it should be basalt chopped fiber, basalt-plastic rebar, basalt-plastic rods and structural shapes; at the next stage - production of basalt-plastic pipes and composites of various shape, geo grids, meshes and reinforcement nets and various fabrics.

Chopped basalt continuous fiber (BCF chopped fiber)

Chopped basalt continuous fiber (BCF chopped fiber) BCF chopped fiber will be used in great demand at the building and road construction for reinforcing of concrete and asphalt- concrete. Using of basalt chopped fiber is one of the effective and perspective methods for strengthening of characteristics of concrete, which are using in the building of foundation, piles, wall panels, slab floors, finishing cement covering, and for reinforcing of asphalt-concrete road.                       

For volumetric formed reinforcement needs about 1, 5–2 kg of basalt chopped fiber for 1 metric cubic concrete (one cubic cm includes about 100 filament fibers with diameter of 15-18 microns and length of 12mm).

Results of volumetric formed reinforcement is the hardening of concrete, including:

• Compressive resistance to be increased by 20 - 25%;                                       
• Tensile load on bending - by 200 – 230 %;             
• Refinement of freeze resistance by 1.6 – 2 times;
• Gain of crack growth resistance under load and dynamic load.                                   

Good results give reinforcements of the finishing covering of the floor.   BCF can not destroy or damage under the influence of MOISTURE, SALT and SEA WATER.

See article. « Application of BCF-based materials in construction»

There are two types of the equipment for chopping basalt fibres, including: the simplest machines for chopping of rovings and more productive installations for chopping the bundles of primary fibres (filament) in the process of their production (immediate chopping).  Installation for multi-passage drawing and chopping of primary BCF-bundles is used at the big production volume of chopped BCF. 

Production of composite basalt-plastic materials and products. Basalt-plastic rebar. Section materials. Pipes.

There are three types of the process equipment (pultrusion lines) for production of basalt-plastic rebar and section materials.

Bobbin carrier for basalt fiber roving and the section for installing the bobbin carriers for feeding basalt fiber roving to the pultrusion process linePultrusion process line for the production of basalt-plastic section materials and rebar

Process line for manufacturing of basalt-plastic rebar

Basalt-plastic rebar of two types and basalt-plastic rods

Lately, production of composite materials based on basalt fiber has significantly increased, and conventional metallic materials are substituted with light durable composite materials in automobile, municipal service, chemical, power, and construction industries.  Basalt-plastic rebar have strength which is 2 … 2.5 times higher than the strength of steel reinforcement,  are 6 … 8  times lighter than steel rebar, are not subject to corrosion, and have no fatigue cracks in long-term service and under alternating loads. The cost of BPR is lower then the cost of analogous steel materials at 10-20%. Basalt-plastic reinforcing (BPR) have advantages when used in the production of no tensioned concrete products and road slabs. At the present time, the use of basalt-plastic reinforcing materials is sufficiently regulated. The corresponding tests of such materials were performed and normative documents - specifications and standards for the use of BPR have been developed by design institutions in Ukraine, China, and Russia and some other countries. In USA Standard ASTM for Composite reinforcement was developed.  With consideration of these factors, continuous basalt fiber is perspective material, specifically for use in production of basalt-plastic composite materials.

More information see in Article: «Application of basalt fiber -based materials in construction and in anti-seismic building»

Specimens of basalt-plastic tubes, suspension rods, and oil pump jack rods made from Basalt continuous Fiber and Glass fiberBasalt-plastic cores of overhead conductors for high-voltage power transmission lines

Composite pipes, large-diameter pipes, tanks, high pressure cylinders, made from BCF roving.

Process equipment for manufacturing of pipes up to 500 mm in diameter

Оборудование для производства труб диаметром до 500 ммОборудование для производства труб диаметром до 500 мм

Process lines for manufacture of large-diameter pipes, high pressure cylinders, special tanks, produced by spinning techniques

The advantages of composite Basalt-plastic pipes, tanks and reservoirs, high pressure cylinders over steel materials and products are the following: higher chemical resistance to aggressive media and corrosion, longer service life, lower density (the weight of basalt-plastic pipes is about 6 -8 times lower at the same strength), and higher strength properties; no need insulation and carrying out of welding works

Production of the Geo- textile road meshes and construction meshes

Toughening of requirements to the quality of road construction, operation and maintenance of road pavements entails the use of new reinforcing and geo-textile materials.
State Standard for application of Geo- textile road meshes in road construction were developed and introduced in Europe, USA, PR China, Ukraine, Russian Federation and other countries.  Materials made of whinstone-based continuous fibers possess fairly high strength properties, chemical and thermal resistance, and to the fullest extent meet the requirements to road pavements. The use of BCF-materials for motor-road construction and repair works decreases the total cost of their fulfillment and considerably increases operational lifetime, as well as overhaul life of road pavements.   

More information see in Article: «Appliancation of basalt fiber based materials in road building »

Road geo-textile BCF-meshes of different types and density The complex of knitting-punching machines intended for the road mesh manufacturing

Road meshes are manufactured from BCF-roving, warp-wise and weft-wise, and are interknitted with twisted thread using knitting-and-punching machines. Then, they are permeated with bitumen compounds in dipping tanks and are heat-treated (polymerized and dried) in driers.

To manufacture construction meshes (with the cells 4x4 mm and 5x5 mm), the special looms are used for netting meshes from twisted thread.  Then, the interknitted meshes are permeated with latex and silane compositions, polymerized and dried in driers. The reinforcing meshes are used in construction and also for reinforcement of cutting and abrasive wheels

Образцы сеток БНВThe loom for manufacture of construction meshes

Production of duck and fabrics made from BCF

Demand for duck fabrics are growing in compliance with more wide application of composite materials and articles. At the present time fabrics are manufacturing from glass, carbon, aramid and chemical fibres. Fabrics made from BCF are traditionally export products.  There are: BCF structural roving fabrics for producing composite materials and high-strength articles, Basalt fabrics different types of various applications for aviation and ship building Industries, electro insulating fabrics for electronic and electrical Industries and others.

BCF fabrics manufacture. Samples of basalt fabrics:

Production of mats made from chopped BCF

Chopped strand mats designed for manufacturing of composite products and articles of the complex shape (automobile panels, screens, for reinforcing plastic, etc.) Also it’s used for the production of water tanks and chemical products containers, for manufacture of sanitary products. BCF chopped strand mats applies for construction of small ship hulls and additional structures, as an anticorrosive with great dispatch and wears proof coverings of the bottoms of cars.
Process line for producing of chopped strand mats has enough high productivity; it is 1,000-2,000 tones p.a. The technological process is automated. Production of BCF chopped strand mats has good prospects for application in various industries.

BCF chopped strand mats used at the production of compositesProcess line for producing of chopped strand mats

BCF needle-punched mats and Basalt Paper

Non woven materials made from BCF, including: BC thin paper, ВМС felts, ВМС (N) needle-punched mats are used as initial material for the production of filters for gases and liquids, as a reinforcing material for composites,  electro - isolating material, as  heatproof and soundproof materials. Nonwovens are uninflammable and fire-resistant materials and used for fire protection of  nuclear and electric power-stations, refineries, chemical plants, walls of high buildings and other modern industrial projects, which require protection from possible inflammation and flame spreading.

BCF Nonwoven materialsBCF paper is used for filters and composites

Needle-punched mat (felt) from basalt chopped fiberBCF needle-punched mat with foil

Nonwovens from chopped fibers are producing on processing lines with low labor and energy costs.

Process equipment list for manufacturing of BCF-based materials

• Cutting machines
• Installation for lisle threads (yarns) manufacture.
• Pultrusion process lines for reinforcement ( rebar) production.
• Pultrusion process lines for manufacturing of rods, section materials, tubes of small diameters.
• Equipment for road mesh production.
• Equipment for manufacture of reinforcing and construction meshes.
• Process lines for chopped strand mats (felts) production made from chopped fiber.
• Process equipment for manufacturing of needle-punched mats.
• Process lines for production of paper, think mats made from chopped fiber.
• Process lines for prepregs manufacturing.
• Process lines for manufacturing of roll plastics.
• Process lines for production of large and middle diameters pipes.
• Process equipment for producing of high pressure cylinders
• Process equipment for producing of tanks and reservoirs.
• Process equipment for manufacturing of composites with spray up technology application.
• Looms for producing of basalt fabrics of various applications made from twisted thread.
• Knitting-punch machines
• Machine for producing basalt roving fabrics.

Process equipment will be supplied according to requiems of Customers.