New developments. Materials

Basalt-plastic rebar. Basalt-plastic cores of cables for power lines

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

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

Manufacturing and usage of basalt reinforcement (rebar) has a great future. Strength characteristics of basalt-plastic rebar (BPR) in 2 - 2.5 times higher than the strength of steel reinforcement; BPR is not subject to corrosion.  Development of the production of BCF and basalt-plastic rebar (BPR) is such that the sales cost of BPR by 10 - 20% below than the price of steel reinforcement A3. Basalt-plastic rebar, due to their advantages and lower cost, will gradually replace the traditional steel reinforcement. 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.  In the coming years volumes of BPRebar production will grow exponentially. More information see in Article Appliance of basalt fiber based materials in building and anti-seismic constructing.

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

Inorganic binders of NS -1B series for the production of thermal insulating materials on the basis of basalt and mineral fibres.

Inorganic adhesives and binding substances NS-1 series are used at the production of heat-insulating fibrous materials, such as: slabs, cardboard, semicylinders, lightweight insulating materials.

NS-1 adhesives, binders have density 1.2 - 1.4 kg / dm 3, depending on the modification. They have different temperatures of application; it is 6000C for NS-1B type; 9000С - for NS-1A, and up to 12000С - for NS-1F. 

Binders and adhesives NS-1 series are a one-component system of inorganic elements with additives based on metal oxides, capable to harden in normal conditions without applying high temperatures.

The binder has good penetrating properties and can be used in the production of fibrous insulation materials, heat-insulating slabs, and lightweight refractory materials.

Specimens of slabs, cardboard and material for false ceilings made from basalt fibres and NS-1B binder.

Basalt continuous fiber for higher-temperatures application.

Basalt continuous fibres possessing by higher characteristics on heat resistance for applications at elevated temperatures were obtained. These basalt fibres used for the production of high-temperature filters, materials for automobile mufflers, automotive engine gaskets, heat-resistant materials for filtering of melts. The problem of obtaining BCF on higher temperatures of application is an actual task; and it was solved by the application of special technologies of melting of basalt rocks of specific chemical composition.

This basaltic fiber of long-term usage at temperatures up to 860°C -890°C is used for manufacturing of  filtering meshes of high-temperature filters and meshes for filtering molten iron in the casting production.   

The specimens of filter meshes made on the basis of BCF of higher temperature applications are shown in the photos.

Meshes, made from thermal-resistant BCF, are used for filtering of melt metal in the casting of engine casings cars.

Foamed heat insulating materials

Heat insulation porous materials in characteristics and appearance are similar to the materials made from foamed glass. The working title of the material is "Penoizol".

Materials "Penoizol" are produced by "cold" technologies without the use of high temperatures.  Foaming of liquid mass of the inorganic components takes place at temperatures of 20 - 25 ° C. Then, the material is dried in drying chambers or drying plant. It is possible to produce of the foamed materials at the place of application.

Material is non-flammable, temperature of long term application is up to + 600 °C. It is possible to produce materials for temperature applications up to 900 °C.   Material does not emit any substances when heated or exposed to an open flame. Pores of the material are closed. 

Specimen of 'Penoizol' materialThe density of material is 40 – 120 kg/m3

The thermal conductivity of the material is 0.045 W / m, if the density of the material is equal to 40 kg / m3; if density is 100 kg / m3 the thermal conductivity is 0.064 W / m (at the temperature of 25С). When the density is more than 120 kg / m3, the material possess enough high strength, and can be used as a structural, thermal insulating material.

"Penoizol» material has good insulating properties, strength and water resistance.  Products from the "Penoizol", including: slabs, semicylinders for pipe insulation, and products of complex shape. The insulation of internal cavities that are not available can be made at the place of use.