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BBaassaalltt FFiibbrreess

Basalt is well known as rock found in virtually everycountry around the world. Its main use is as a crushed rockused in construction, industrial and highway engineering.However it is not commonly known that basalt can be usedin manufacturing and made into fine, superfine and ultrafine fibers. Comprised of single-ingredient raw material

melt, basalt fibers are superior to other fibers in terms of thermal stability, heat andsound insulation properties, vibration resistance and durability.

Basalt continuous fibers offer the prospect of a completely new range of compositematerials and products.Basalt products have no toxic re-action with air or water, are non-combustible andexplosion proof. When in contact with other chemicals they produce no chemicalreactions that may damage health or the environment. Basalt replace almost allapplications of asbestos and has three times its heat insulation properties. Basaltbased composites can replace steel and all known reinforced plastics (1 kg of basaltreinforcement equals 9.6 kg of steel). The life of basalt fiber pipes, designed for avariety of applications, is at least 50 years without maintenance or electrical ortechnical protection.

Basalt fibers together with carbon or ceramic fibers as well as various metals is themost advanced and exciting area of application, as they can develop new hybridcomposite materials and technologies.

Basalt's special properties reduces the cost of products whilst improving theirperformance. More than hundred specific unique manufacturing techniques usingbasalt fiber materials and products have been developed and patented in Ukraine.

Basalt fibers are new unique and economic products with superior properties tosimilar one in present use like as glass fibers.In thermal conductivity, articles made of basalt fibers are 3 times as efficient asthose made of asbestos, and superior to glass and mineral fibers. The applicationtemperature of articles made of basalt fibers markedly higher (from -260 to 900°C).

In their physical properties (strength, elasticity) basalt fibersconsiderably exceed mineral and glass fibers.Due the elasticity of micro- and macrostructure, basalt fibers arevibration-resistant compared to similar products. This property is ofparticular importance in mechanical construction and civil engineering.For example, when buildings are erected near highways, railways andunderground, whereas under vibration cushions of mineral and glassfibers experience damage and finally disintegrate, basalt slabs arevibration-resistant and, hence, more durable.

In chemical properties basalt fibers are more resistant to aggressive media i. e. acidsand alkalis. Therefore pipes made of basalt fibers may be used in the chemicalproduction for transporting hot acids, in the construction of sewerage systems,transportation of aggressive liquids and gases, loose materials, etc.

Dielectric properties of basalt-plastics, in particular volume resistance of basalt fibersare 1 to 2 orders of magnitude higher than those of fiberglass.

Basalt fibers can be used in various branches of industry fully replacing cancerousasbestos and to a considerable degree glass fibers and metals.The processing technologies of basalt fiber conforms to traditional technologies ofglass fiber processing (fabrics, roving, chopped strands, GFRP). Thanks to theirexcellent properties basalt fiber may be used for manufacturing of thermo and alkaliresistant articles (tanks, pipes, GFRP, warm insulating materials) and as ecologicalharmless substitute for asbestos.

THERMAL BEHAVIOUR

Good resistances against low and high temperatures characterize Basalt. Basalt isnon-combustible and explosion proof. In pure form it does not release toxiccombustion products.

In applications with stress on the fibers, (continuous filament) Basalt fibres performrelatively better than E-glass fibres in the temperature range +300 to 500 °C.We have learnt however that the true comparative performances at hightemperatures of E-glass fibers vs. continuous filament Basalt fibers is best obtainedby considering the key functional parameters of the final product - made from thetwo fibers - in its specific end-use application.

In application with very low stress on the fibers, temperatures around +1250 °C -the flame temperature - can be sustained continuously without loss of fabricintegrity. The melting temperature of Basalt is about 1400 °C. The material hencehaving excellent resistance to fire, Basalt fabrics are ideally suited for fire protectiveapplications. Flame barrier fabrics as e.g. a stand-alone fire curtain or a componentin an end product (such as a fire blocking interliner in a train seat construction) granthours of protection against fire.

MECHANICAL PROPERTIES

The specific tenacity (ratio: rupture stress divided by density) of basalt fibresexceeds that of steel fibres, many times. Basalt is roughly 5 % denser than glass.The tensile modulus (E modulus, Young modulus) of basalt fibers is higher than theone of E-glass fibers. This makes Basalt fibers & fabrics attractive for thereinforcement of composites.

The low elongation - perfectly elastical up till rupture - results in dimensionally verystable fabrics. Basalt textiles show sufficient suppleness and drapeability. Theyexhibit good fatigue resistance. The yarn shows low friction coefficients vs. mostmaterials.

The basalt fabrics, as they come from the weaving loom, present however severalshortcomings which actually prevent readily further applications.

These are:

high instability - due to the low friction coefficient of the material - resultingin: unravelling of the fabric at the edges, and it being easily damaged bypointed objects or during transportation and handlingvery low stichability and seam strengthskin irritation - the high rigidity and low elongation of basalt filaments(somewhat like carbon fibers) result in the continuous filaments showingrupture points. These stiff filament ends penetrate the skin, when rubbed overthe fabric breaks when folded over and pressured at the foldthe solution to the issues above may not be detrimental to the intrinsic hightemperature and fire blocking properties of the Basalt fabric. When subjectedto flames, fire may not propagate on the fabrics' surface, no corrosive or toxicgasses may emanate, and a minimal level of smoke may be generated.

Technical Data „stone“ Fibre Basalt

Properties Unit ValueThickness Mikrons 9 – 23Density g/cm³ 2,7Thermal Conductivity W/mk 0,031- 0,038E-Modulus GPa 90 – 100Moisture absorption < 0,1TensileElongation

MPa%

3800 – 41004

Temperature resistance:

min. operating temp.max. operating temp under pressuremax. operating temp without presuremax. operating temp at flammablepointMelting point

°C

-260+450+650+1200

+1450-1650

dielektric Constant Compared toE-Glass

1-2 x >

chemical resistance, retention of weigthin % after 3 hrs: H2O

0,5N NaOH2N NaOH2N H2SO4

99,693,4

65,4 – 77,366,4 – 98,5

CHEMICAL BEHAVIOUR

Basalt fibers have good acid and solvent resistances, surpassing those of E-glassfibers and many mineral and synthetic fibres. Basalt fibers have better resistance toalkalines than E-glass fibers.

The inert basic material possesses, in addition to its corrosion resistance, also goodresistances to UV-light and biologic contamination. It does not become radio-activeafter irradiation. In pure form, it is free of odour and has low soiling sensitivity.Absorption of humidity comes to less than 0.1 % at 65 % relative air humidity androom temperature.

Basalt fibres show excellent "wet ability" of - or a natural adhesion to - a broad rangeof binders, coating compounds and matrix materials in composite applications. Thisproperty can be further enhanced through optimized surface treatment.

BASALT FIBRES AS REINFORCEMENT FOR COMPOSITES

Basalt is mainly used (as crushed rock) in construction, industrial and high wayengineering. One can also melt basalt (1300-1700°C) and spin it into fine fibres.

When used as (continuous) fibres, basalt can reinforce a new range of (plastic andconcrete matrix) composites. It can also be used in combination with otherreinforcements.

Some possible applications of basalt fibres and basalt-based composites are: thermaland 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.

This wide range of possible applications results from its wide range of goodproperties. Basalt has good thermal, electrical and sound insulating properties. It canreplace asbestos in almost all its possible applications (insulation) since the formerhas three times the latter’s heat insulating properties. Furthermore, the fibrediameter (comparable with E-glass fibres, can be controlled in order to preventuptake of harmful ultra-fine fibres. Because of its good electrical insulating properties(10 times better than E-glass), basalt fibres are also incorporated into printed circuitboards, resulting in superior overall properties compared to conventional componentsmade of fibreglass. It is also used in other electro technical applications such as extrafine resistant insulation for electrical cables and underground ducts. Because of itsthermal insulating properties it is already used as fire protection in the form offabrics or tapes. Automotive, aircraft, ship and household appliances are also made.These are made with thermosetting resins, such as epoxy and (phenolic) polyesters.Possible techniques involve prepregs, laying out, winding, direct pressureautoclaving, and vacuum moulding. Other, structural basalt composite components(such as pipes and rods) are made from unidirectional basalt reinforcement. Incombination with its high specific strength (9.6 times as high as steel), highresistance to aggressive media, and high electrical insulting properties, this results inspecialty products such as insulators for high voltage power lines.Basalt composite pipes can transport corrosive liquids and gases. The sameequipment as for fibreglass pipes can be used for this. These pipes are reported tobe several times stronger than glass-fibre ipes. Next table illustrates this:

Property Glass-plastic Basalt-plastic

Tensile (MPa)Tensile E (GPa)Density (kg/m³)

Therm. Cond. (kcal/m h °C)Volume resistivety ( /m)

14056

19000.510

10 (300)70 (160)

17000.3

4x1012

Values in brackets are for basalt/carbon pipes.Due to basalt’s low thermal conductivity, deposition of salts and paraffin’s inside thepipes is also reduced.Basalt fibres can also be used in machine building because of their good frictional,heat and chemical resistance.

Comparison between glass- and basalt fibresWith regard to their chemical composition glass and basalt fibres are somewhat alike,but for some components there are differences:

Compound w% in E-glass

w% inbasalt

SiO2

Al2O3

CaOMgOB2O3

Na2OK2OFe2O3

52-5612-1616-250-55-100.80.2-0.8

0.3

51.6-57.516.9-18.25.2-7.81.3-3.7-2.5-6.40.8-4.54.0-9.5

Several basalt compounds may vary, but especially the SiO2 content may varylargely. Only SiO2 percentages above 46% (‘acid basalt’) are suitable or fibreproduction.

Mechanical properties

Typical tensile strengths varies greatly:E-glass: 3.4±0.7 GPa for fibres and 0.86-1.27 GPa for rovings (density: 2.52-2.63g/cm³)Basalt: 1.43±0.59 GPa for fibres and 0.69–0.92 GPa for rovings (density: 2.6-2.8g/cm³)Basalt also has a higher modulus (82-110 GPa) than E-glass (68-73 GPa). [5-6]Several basalt (‘B’) and E-glass (‘G’) were tested (‘f’ for fibre tests and ‘r’ for rovingtests); the results are given in the next table.

Sample Tensile(MPa)

Tensile E(GPa)

B1 (r)B2 (r)B3 (r)B3 (f)

860 ± 63835 ± 83650 ± 68

1662 ± 599

76.6 ± 3.373.5 ± 2.570.4 ± 7.474.8 ± 3.6

G1 (r)G2 (r)G2 (f)

1630 ± 1361115 ± 511362 ± 412

63.1 ± 3.275.9 ± 1.567.6 ± 2.1

As expected, basalt has a lower strength and a higher modulus than E-glass. In non-standard conditions, however, basalt could prove to be stronger than E-glass.

FIELDS and APPLICATIONSwhere Basalt Fiber Products are known to - or can - be applied with benefit

1. Surface & Air Transportation

* Fire protected seats in planes, trains, ships, subways, … * Fire proof floorings & ceilings * Airplane life jacket pouches * ...

2. Specialty furniture

* Fire proof mattresses (for hospitals, hotels, etc) * Fire proof seating * ...

3. Electricity and Electronics

* Power: fire resistant cable construction components as fillers, braidings, tapes * Transformer stations: screens, protection, insulation * Motor insulation: tapes * ...

4. Construction

* Fire protective wall, floor & ceiling panels. Fire proof curtains and partitions forindoors and outdoors * Heat insulation in heating systems, power generation, incinerators * Roofing: rigid and flexible roof covers with raised fire resistance * Fire protective clothing * Fire resistant floor coverings: backing, reinforcement * Fire resistant interior decoration

...

Safety Data SheetAccording to 91 / 155 / EWG and 93 / 112 / EG

Print Date: 31 March 2005 Page 1/41. Identification of the substance / Preparation and the Company / Undertaking

1.1 Product name: Basalt Continuous Fiber (BCF) Roving: BCF 13.100/200/300/…/2600.KV2, BC9-150-P8 BCF 13.100/200/300/…/1200…/2600.KV., BC12-800-P8 Chopped Fibers: BCF 13.3/6/9/…/87.KV1, BCF 13.3/6/9/…87.KV5 Basalt Twisted Yarn BC9-330x1x2-P8

1.2 Manufacturer / Supplier: Filter Fabric Consulting Gmundnerstraße 9/3 A-4861 Schörfling Austria1.3 Telephone number: Office Tel/Fax: +43 (0) 7662 57905 e-mail: m.schobesberger@aon.at

2. Composition / Information on Ingredients

2.1 Chemical description: SiO2 50-58%; Al2O3 14-18%; CaO 5-10%; MgO 4-9%;Fe2O 5-10%; Na2O 2-5%; K2O 0,8-3%; other <2

2.2 Hazardous ingredients: No hazardous components

3. Hazards Identification

3.1 Description of potential hazards: none

3.2 Specific hazards for persons and the environment: none

3.3 Classification System: none

4. First Aid Measures

4.1 Inhalation: not applicable

4.2 Ingestion: not applicable

4.3 Skin contact: not applicable

4.4 Eye contact: not applicable

5. Fire-Fighting Measures fire class A

5.1 Appropriate extinguishing agent(s): the product is none flammable

5.2 For safety inappropriate extinguishing agent(s): none

5.3 Particular hazards caused by the material, combustion products or resulting gas: none

5.4 Special safety equipment needed for fire-fighting: none

Safety Data SheetAccording to 91 / 155 / EWG and 93 / 112 / EG

Print Date: 31 March 2005 Page 2/4 6. Accidental Release Measures

6.1 Personal precautions: no special measures are necessary

6.2 Environmental measures: no special measures are necessary

6.3 Methods for cleaning up: sweep, vacuum or wash away

7. Handling and Storage

7.1 Handling: no special measures are necessary

7.2 Handling during a fire and/or explosion: the product is none flammable

7.3 Storage: store product in a dry environment

7.4 Storage class: not applicable

8. Explosion Controls / Personal Protection

8.1 Personal protection equipment:

8.1.1 General protection and hygienic measures: no special measures are necessary

8.1.2 Respiratory protection: not applicable

8.1.3 Hand protection: not applicable

8.1.4 Eye protection: not applicable

8.1.5 Body and skin protection: not applicable

9a. Physical and Chemical Properties

9a.1 Appearance: Form: volcanic rock Color: gray to black Odor: odorless

9a.2 Change of state: Melting point / area of melting temperatures: 1450°C

Boiling point / flash point: not applicable

Flammability / Auto flammability: not flammable

Igniting temperature: not applicable

Explosive properties: not applicable

Safety Data SheetAccording to 91 / 155 / EWG and 93 / 112 / EG

Print Date: 31 March 2005 Page 3/4 9b. Physical and Chemical Properties

9b.1 Vapor pressure: not applicable

9b.2 Density: 2,7 g/cm³

9b.3 Solubility in water: not permeable

9b.4 Viscosity: not applicable

10. Stability and Reactivity

10.1 Materials to avoid: none

10.2 Thermal decomposition: not applicable

10.3 Hazardous reactions: not applicable

10.4 Hazardous decomposition products: not applicable

10.5 Stability: stable

11. Toxicological Information

11.1 Acute toxicity: not applicable

11.2 Irritable impact: eventual dust exposure

11.3 Skin: not applicable

11.4 Eyes: just like any foreign matter possible irritation may occur, do not rub your eyes, rinse withwater

12. Ecological Information

12.1 General Information: basalt is ecologically safe, ecologically recognized and specially suited formultiple applications (reuse)

13. Disposal Considerations

13.1 Waste from residues / Unused products: disposable in accordance with local and national regulations

13.2 Contaminated packaging: disposal (i.e. ARA-Sammelsystem)

Safety Data SheetAccording to 91 / 155 / EWG and 93 / 112 / EG

Print Date: 31 March 2005 Page 4/4

14. Transport Information

not described as a dangerous good by transportation regulations, if possible transport the product in adry environment

15. Regulatory Information

15.1 Labeling according to European eGefStoffV / EG: not necessary to label the product

15.2 National regulations: not applicable

15.3 Labeling according to VbF: not applicable

15.4 Water hazard classification: WGK 0 (self estimation): in general no water damage

16. Additional Information

The above information is based on laboratory testing and literary research and support all factsenclosed in this safety data sheet from the last print of date.The information explains safety relevance of the properties and requirements of the products.With new issues of this safety data sheet, the out dated safety sheets lose their credibility.