BASALT AS A CONSTRUCTION MATERIAL

ABSTRACT:

This paper focuses on enhancing the importance of basalt as a construction material. Basalt being
one of the most widely available rocks on the earth’s crust has a great potential in context with the
construction scenario. One of the latest technologies that has emerged, aims at drawing thin wires out
of basalt rock, which can be, weaved into the formation of fibers and basalt reinforcement bars. Using
basalt for reinforcement is one of the most important applications of naturally available basalt. Basalt
base composites can replace steel and known reinforced plastics (1 kg of basalt reinforce equals 9.6
kg of steel). Even the tensile, compressive and flexural tests on basalt fibers and rebars pose better
result in comparison with other material. Thus, understanding basalt as a construction material and its
various technical and general applications demarcates the purpose of this paper.

KEYWORDS: Basalt, volcanic rock, reinforcement, roving, weaving, wires, fibers, cables, rebars,
toughness index, impact strength, flexural strength, bond strength, plain rebars, corrugated rebars,
basalt composite reinforced concrete.

INTRODUCTION:

Use of naturally available materials is the need of the hour for man on this planet due to the
continuous and rapid dearth of conventional sources. Many different naturally available materials are
used for different purposes after subjecting them to certain modifications and changes. This dearth of
materials has led to a profound and new search is the use of BASALT-“a naturally occurring rock
as a construction material.”

1.0) BASALT-A NATURALLY OCCURING ROCK TYPE:

Basalt is the type of a volcanic rock, which is widely

available in and around the earth’s crust. It is found in
virtually every country round the world. Basalt
is composed almost entirely of dark, fine-
grained silicate minerals, chiefly plagioclase
feldspar and pyroxene, and magnetite. It
forms by the outpouring of lava all along the
world's mid-ocean ridges, where sea-floor
spreading continually adds new crust to
counterbalance that lost by subduction. Usually
dark-gray in color, basalt often has a vesicular
texture. Other characteristic textures are pillow-
shaped masses caused by rapid cooling of lava
erupted on the sea floor. In addition to lava flows, basalt is also found in the
form of dikes and sills. Columnar jointing, as exhibited by Devils Tower in
Wyoming and the Giant's Causeway in Ireland, is a common feature of
these shallow intrusive bodies.

Basalt material is made from basalt rock and is a chemically very stable and an inert material.
Slightly coarser old sheets of basalt, now partially altered but still dark in color,
are extensively quarried and crushed. This material is mainly used as a crushed rock
in construction, industrial and high way engineering. Some possible applications of
basalt material are - thermal and sound insulation/protection (e.g. basalt wool, engine insulation),
pipes, bars, fittings, fabrics, structural plastics, automotive parts, concrete reinforcement
(constructions), insulating plastics and frictional materials.

2.0) GENERAL CHARACTERISTICS:

 It has a sound density.

 It has considerable strength value.
 It is non-toxic material.
 It is non-corrosive in nature.
 It has considerable resistance against alkali matter.
 High tensile strength.
 High thermal conductivity.
 No carcinogenic risk or other health hazards.
 Completely inert with no environment risks.
 Resistant to acid and aggressive chemicals.
 High E modulus resulting in excellent specific tenacity, three times that of steel.
 Electro-magnetic resistance.
 Good fatigue resistance.

3.0) APPLICATIONS:

 Crushed stone, concrete aggregate,

railroad ballast, production of high quality
textile fibers, floor tiles, acid-resistant equipment
for heavy industrial use, rock wool, basalt plastic
pipers, basalt plastic reinforcement bars, basalt fiber
roofing felt (ruberoid), basalt laminate used as
protective coating, heat-insulating basalt fiber
materials, glass wool (fiber glass), etc.
 Basalt is the best reinforcement for concrete due to
its tensile strength and natural resistance to Basalt as a naturally available rock,
deterioration from alkali. fiber and synthetic
 Reinforcement for composites, polyester/epoxy resins and plastics as used in automotive body
panels, boat hulls and pultruded products, etc.
 Friction materials such as brake pads and linings.
 Manufacture of basalt mat/felt.
 High-temperature insulation applications.
 Passive fire protection materials
 Filler for gypsum and sheetrock board requiring increased ‘burn-thru’ capability, to meet
building regulations.
 High-performance automotive muffler filler.
 Replacement for glass fibers in composite industry.

 Production of textiles and cloths resistant to fires

 Special textiles for public areas like curtains in cinemas and large scenic areas

 Textiles resistant to UV and sun radiation

 Production of ropes and hoses needing to resist fires (fire brigades)

 Reinforcement carpets for concrete designs and cement structures.

  The life of basalt pipes, designed for variety of applications is at least 50 years without
maintenance or electric or technical protection

4.0) REINFORCED BASALT FIBRE CONCRETE COMPOSITES:

With respect to the different characteristics and applications of basalt, it can be easily analyzed that
basalt has a wide range of advantages. But it is not known commonly that basalt can be used in
manufacturing and made into fine, superfine and ultra fine fibers. Comprised of single-ingredient raw
materials melt, basalt fibers are superior to the other fibers in terms of thermal stability, heat and
sound insulation properties, vibration resistance and durability. Basalt continuous fibers offer
prospect of a completely new range of composite materials and products.

4.1) BASALT AS A FIBRE:

Practically fibers are added to the cementing and concreting mix to allow a random pattern of fiber
reinforcing. The resulting concrete will have an improved ultimate
strength and this process is used in fabricating precast beams and
columns. Basalt fibers are manufactured in a single stage process by
melting naturally occurring pure basalt rock. The tensile strength of
continuous basalt fibers is about twice that of E-glass fibers and
modulus of elasticity is about 15-30% higher. Basalt fibers in an
amorphous state exhibit higher chemical stability than glass fibers.
When exposed to water at 70 degree centigrade, basalt fibers
maintain their strength for 1200 hours whereas the glass fibers do Basalt fibers
so only for 200 hours.

4.1.1) ADVANTAGES OF BASALT FIBRES:

 Melting temperatures above 1300ºC

 Working temperatures up to 600ºC
 Extreme hardness, 8-9 on the Moh’s scale (Diamond=10)
 Low thermal conductivity (very good insulating properties)
 Very high chemical resistance.
 Excellent economic alternative to other high temperature resistant fibers

4.2) BASALT AS REBARS:

Utilizing basalt fibers and a resin epoxy binder makes basalt

composite rebars. They are non-corrosive and consist of 80%
fibers. They have a tensile strength 3 times that of steel rebars
normally used in building construction. Wherever the corrosion
problem exists, basalt fibers composite rebars have the potential
to replace steel in reinforced concrete. In comparison, the E-glass
fiber and thermosetting resin bars lack sufficient durability under
extreme environments. These bars are costly and also non
resistant to alkalis.
Basalt reinforcement bars
4.2.1) ADVANTAGES OF REINFORCEMENT RODS:
 Rods of unidirectional basalt composite successfully replace metal reinforcement.
They are used in production of building components, panels’ barriers sidewalk,
pavement and facing slabs, and many other structural components.
  In view of their high electro insulation properties, basalt bars are used for making
insulators for high voltage power lines.
 An especially successful application of bars is for reinforcement of concrete slabs in
hydraulic engineering and construction in seismically hazardous regions, in view of
the fact that due to its chemical inertness the basalt reinforcement is compatible with
concretes having different “pH”, having actually the same coefficient of thermal
expansion and no residual deformation under bending.

The above-mentioned advantages alone could warrant a sufficient argument for substitution of the
basalt rebars in place of steel on a large scale. Other advantages of basalt rebars are:

 At higher specific strength and resistance to aggressive media 1 kg of the basalt

reinforcement replaces 9.6 kg of metallic; i.e. 89% lighter in weight.
 The weight of basalt rebars is 1/3rd of the weight of steel.
 The thermal expansion coefficient is very close to that of concrete.
 No permanent deformation when bent.

4.3) TECHNIQUE OF PREPARATION:

Basalt continuous fibers are made from basalt rocks using a single
component raw material in a single stage process. Once the
continuous basalt fibers have been produced, they are converted
into a suitable form for their intended application. Assembling a
bundle of strands into a single large strand, which is then
wound into a stable, cylindrical package produces basalt
roving. These basalt fiber strands of yarns are covered with a Roving
special sizing agent to provide sufficient integrity required for further processing. Basalt twisted yarn
is produced by twisting the basalt roving. Twist provides additional
integrity to the yarn before it is subjected to weaving. The main
advantages of basalt continuous fiber, roving and yarn, are higher
operating temperature, Young's modulus and chemical resistance
compared to fiberglass. They are suitable to replace fiberglass
roving and yarn as reinforcement elements for various composite
materials. Due to its good high temperature resistance and excellent
mechanical properties basalt fiber may also be considered as a
replacement for asbestos and expensive carbon fibers.

Weaving

5.0) EXPERIMENTAL ANALYSIS:

In order to analyze the performance characteristics of 3D and 2D basalt fiber reinforcement in

concrete, several tests were conducted and results were being compared with that of plain concrete.
All the tests were done in accordance with the ACI-318 Building Code through the medium of ASTM
method. These test clearly brought out the behavior of concrete subjected to basalt reinforcement and
clearly depicted the upper hand of basalt in comparison with steel.

5.1) 3-DIMENSIONALLY REINFORCED BASALT FIBRE

CONCRETE:

The following properties of Basalt fiber concrete were being

investigated:
  Properties of fresh concrete with and without fibers.
 Properties of hardened concrete such as compressive strength, static modulus, flexure
strength, unit weight and impact strength.
 The toughness indices by the ASTM method with help of load deflection curves
 The flexural toughness factor and equivalent flexural strength by the Japanese standard
method.

5.1.1) TEST RESULTS FOR FRESH CONCRETE:

A total five mixes along with one plain mix were done and the dosage of basalt fibers added to the
concrete were 0.1, 0.25,0.4 and 0.5% by volume. The water cement ratio was kept constant at 0.5 for
all the mixes. The freshly mixed concrete was tested for slump (ASTM C143), air content (ASTM
C231), fresh concrete unit weight (ASTM C138), concrete temperature (ASTM C 1064) and Vebe
time. The room temperature and humidity varied in range of 18.3 degree C to 26.67 degree C.

The test results indicated that satisfactory workability could be maintained even with addition of
fibers, whereas the Vebe time increased with the addition of the fibers. Overall, there was no
bridging, balling, bleeding or segregation. Even though the slump values decreased with the addition
of the fibers, no difficulty was encountered in placing and consolidating the concrete with the use of
the table vibrator.

5.1.2) TEST RESULTS FOR HARDENED CONCRETE:

 Static modulus and compressive strength:

Solid cylinders were tested for static modulus (ASTM C469) and compressive strength (ASTM C39)
at 7 days and 28 days. Plain concrete cylinder failed fully shattering into pieces while fiber reinforced
concrete continued to sustain load with the change in mode of failure from a brittle type to ductile
type.
 Static Flexure Test:

Beams were tested at 7 and 28 days for flexural strength for a deflection controlled test. Load-
deflection curves were drawn from which the toughness indices and residual strength factors bogy
ASTM method and equivalent flexural strength by Japanese Standard method were calculated. The
plotting indicated ductile behavior and large energy absorption. Also, significant addition of fibers
increases the flexural strength.

 Load Deflection Behavior:

Toughness indices and residua strength indices were calculate d by using the load-deflection curves.
Indices have been defined on the basis of three service levels, identified as the multiples of the first
crack deflection. E.g. a toughness index I5 is calculated at three times the first crack deflection.
Similarly I10, I20 and I30 are the other indices. Toughness indices and residual strength indices are
shown in the following figure:

 Japanese Standard Method of Calculating the Flexural Toughness Factor and

Equivalent Flexural Strength:

This test takes into account the absorbed energy up to the deflection of L/150 th of the span and
equivalent flexural strength was calculated using the following equation:
 Fe = Tb*L/δtb*b*h2
Where; Fe = equivalent flexural strength
tb = flexural toughness(nm)
L = span in meters
δtb = deflection of L/150th of the span
b = width of failed cross section in meters
h = depth of failed cross section in meters

 Impact test:

Specimens were tested for impact strength at 28 days by the drop weight test method (ACI 544) for
both plain and fiber reinforced concrete specimens. The impact strength increased with the increase
in the fiber content. Age of the specimen also affected the impact strength.

5.2) CONCRETE REINFORCED WITH BASALT FIBER COMPOSITE REBARS:

5.2.1) TENSION TEST ON BASALT BARS:

Tensile test were done on 14.25 mm and 6mm diameter basalt bars and also
on a 6mm diameter cable. Ultimate tensile strengths were found to be 1458
Mpa, 707.5 Mpa and 308 Mpa respectively. The bars experienced a brittle
type of failure. The cable broke into two pieces without any splintering of the Basalt reinforced in
fibers, unlike both the bars. concrete

After the basalt bars were being tested, the further analysis was being carried out on the beams
reinforced with such bars. This analysis was being divided into 5 phases to carry out the step-by-step
analysis to understand the behavior of such basalt-reinforced beams. These phases are as follows:

 PHASE I – FLEXURE TEST ON PLAIN BASALT BAR REINFORCED CONCRETE

BEAMS:

A total of six beams reinforced with basalt rebar were tested. These beams, which were designed by
ACI – 318 Building Code recommended design procedures, were tested in flexure after a 14-day
curing period. Beams failed with a single crack instead of multiple cracking, which indicated slip of
the reinforcing bars. All the actual ultimate moments were much less than the calculated ultimate
moments due to bar pullout failure. Finally, the beam edges were being cut and the slippage was
clearly visible.

 PHASE II - FLEXURE TEST OF PLAIN BASALT BAR REINFORCED CONCRETE

BEAMS, CONCRETE 3-DIMENSIONALLY REINFORCED WITH BASALT FIBERS:

In this test, along with the plain bar reinforcement, basalt fibers were being used to reinforce the
beams 3-dimensionally. A total of eight beams were being tested in bending. These beams having
small amount of fiber had a ductile failure and fibreless beams had a brittle failure instantly at the
appearance of the first crack. All the beams reinforced with the basalt rebars had a gradual falure after
considerable amount of deflection, thus converting the brittle failure into ductile failure. The actual
ultimate moments was very less when compared to the calculated ultimate moments of the
beams due to slip of the bars. But the actual cracking moment was more than the calculated
cracking moment due to the addition of basalt fibers.

 PHASE III – BOND TEST ON BASALT REBARS AND CABLES (ASTM C 234):

Due to the bond failure between rebars and concrete, the actual ultimate moments of basalt rebar
reinforced concrete beams were less than the theoretically calculated ultimate moments. To avoid
this, basalt cables with corrugations, rods with slots, barriers and anchors, for improving the bond
strength were being used. Such beams are then subjected to “pull out test” in which concrete is
subjected to compression and the reinforcing bar is subjected to tension, and reinforcing bar is
subjected to tension and both the bar and the surrounding concrete are subjected to the same
stress.

In this phase, 4-slot basalt bar was tested with both the lower and upper horizontal position of the
reinforcement. Such bars did no slip and hence there was no bond failure, but the bar itself failed due
to tension failure in the zone where slots were being provided. Same results were being observed for
the 8-slot bars also. Similarly the cables were also being tested for the bond strength. The cables
failed due to tension under the brittle mode and not due to lack of bond.

 PHASE IV – DETERMINATION OF CRACKING AND ULTIMATE LOADS FOR

EXTREMELY UNDER-REINFORCED BEAMS:

Here, the reinforcement provided for the beams was less than the minimum required according to
ACI code 318. Similarly beams were also provided with minimum value of reinforcement according
to the ACI code. Both such beams were tested in flexure.

The extremely under reinforced beams failed suddenly breaking into pieces without slipping
indicating good bond between concrete and bars. Those beams reinforced with the minimal amount
of rebars had a flexural crack at 85% of calculated ultimate moment but ultimately failed in shear and
took 88% of the calculated ultimate moment. Also it was observed that if the beam had failed in
flexure rather than in shear, the beam would have definitely carried more ultimate moment.

 PHASE V – TO DETRERMINE CRACKING AND ULTIMATE LOADS FOR FIVE

UNDER REINFORCED BEAMS:

Different results were obtained when the beams with under reinforcement and 28 day curing period
were tested for flexure tests. Following are the results of the tests:

NATURE OF THE SPECIMEN BEHAVIOR OF THE SPECIMEN

One basalt rod of 1245 mm length and 8.6 mm First crack at 95% of the calculated cracking
diameter. Basalt rod had a corrugated surface. moment. The beam took 2.7 times more moment
than the cracking moment. Beam failed at 98%
of the calculated ultimate moment. The beam
failed primarily in flexure and secondarily in
shear.
Two basalt strands of 1524mm length and 8 mm First crack at 76% of the calculated cracking
diameter. Each strand was made by twisting 3 moment. The beam took 4.9 times more moment
individual basalt wires of 4.8 mm in diameter. than the cracking moment. Beam failed at 97%
of the calculated ultimate moment. Beam failed
 purely in flexure.
Three basalt cables of 1041mm length and 9.65 First crack at 95% of the calculated cracking
mm in diameter. Two basalt wires were spirally moment. The beam took 2.4 times more moment
wound to form cable. than the cracking moment. Beam failed primarily
in flexure and secondarily in shear.
Two basalt rods of 1219mm length and 9,65 mm Actual cracking moment exceeded the calculate
in diameter. Each rebar was provided with 2 slots moment by 4.5 %. Beam took 5.1 times more
and Fe-Mn-Ni anchors on each end. moment than cracking moment. beam failed
primarily in flexure and secondarily in shear.
Two basalt rods of 1245 mm length and 10.1 mm Actual cracking moment exceeded the calculated
diameter. Each rear was provided with two slots moment by 7.3%. Beam took 5.9 times more
for improving the bond. Rods were also provided moment than the cracking moment. Beam took
with two Ti-Ni anchors on each end of the bar. 21 % more than the calculated ultimate moment.
Beam failed primarily in flexure and secondarily
in shear.

5.3) CONCLUSIONS:

5.3.1) 3-DIMENSIONALLY REINFORCED BASALT FIBER CONCRETE:

 Satisfactorily workability can be maintained, with the addition of basalt fibers up to 0.5% by
volume. Much larger quantities of fibers could be added without causing any bailing or
segregation.
 Compared to plain concrete there was considerable increase in toughness and impact strengths
for basalt fiber reinforced concrete.
 The most notable change was change in mode of failure i.e. from brittle to ductile failure
when subjected to compression, bending and impact.
 Based on earlier research conducted with other fiber reinforced concrete, it is suggested that
the length of the fibers could be increased to 25 to 50 mm for a better performance.

5.3.2) CONCRETE REINFORCED WITH BASALT FIBER COMPOSITE REBARS:

 Phase I-
o The beams reinforced with plain basalt composite bars failed in flexure, due to
inadequate bond between the rod and the concrete. All the actual ultimate moments
were much less than calculated ultimate moments due to the bar pullout failure.

 Phase II –
o Beams supplied by the manufacturer reinforced with 3-D fibers and rebars exhibited a
primary failure in flexure and shear followed by a secondary failure in splitting.
o 3D-fibers caused a ductile failure of the beam and also increased the actual cracking
moment capacity of the beam.
o All the actual ultimate moments were much less than the calculate ultimate moments
due to bar pullout failure.

 Phase III to V –
o Bond strength was good
o Experimental ultimate moments nearly matched the calculate moments.
o Deflections were considerable indicating adequate ductility.
o Beams had primary flexural failure and secondary shear failures.
DISCUSSIONS:

The following experimental analysis depicts the behavior of basalt fiber, cables and rebars under
different loading conditions pertaining to tension, compression and flexure strength. All the results
show better performance of basalt to loading as compared to steel and glass fibers. It is found that
basalt fiber reinforced concrete has better toughness and impact strengths than plain concrete. Also
the first cracking load and ultimate moment resisted by basalt reinforced concrete are more
substantial than that taken by mild steel reinforcement bars.

CONCLUSION:

In context with the details regarding “basalt as a construction material” given above; it can be
concluded that usage of basalt as an engineering material is more advantageous in comparison to the
other materials. Basalt with its exhibit properties like thermal conductivity, non-corrosive nature,
non-toxicity, alkali resistance, etc. are far better option for reinforcement. Also, basalt fibers require
less maintenance, are light in weight and have a longer life span, which adds to its advantage. Thus,
finally, basalt poses a better potential and performance characteristics for usage as an engineering
material.