Basalt Chopped Fiber

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Basalt Chopped Fiber
New brand TURBOBUILD-24-300 in concrete
reinforcement segment

• Basalt Fibers LTD.

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About the companysHistory

• The world's first experimental steady basalt
  continuous fiber was obtained in the laboratory
  of the Institute of Building Materials, in
  Georgia, in the 60-th of the last century, and in
  1985, In Belich (Ukraine) the first production
  was lunched.
• Basalt Fibers LTD. Produces textile basalt
  fiber with its own technology since 1998. In the
  world exist three types of textile basalt fiber
  production technologies (one of them is Georgian)
  and are functioning only 7 manufactures.
  Currently the whole capacity of the textile
  basalt fiber manufacturers doesnt exceed three
  thousand tones per year.

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Process Textile basalt fiber is derived from
Basalt stone melting and melted mass stretching.
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• Basalt Fibers LTD presents Textile basalt fiber
  for the following applications in Construction
  sector.
• Basalt Mat for thermal and noise insulation,
  which company produces by high-technological
  German equipment (www.truetzschler.eu) without
  any binders, is ecologically clean product.
• Basalt Chopped Fiber
• Accelerates the timeline for the concrete
  strengthening
• Suppresses the formation of cracks on the
  concrete surface
• Allows to reduce amount of fittings in concrete
• Company with the leading research institute in
  Germany (www.ibu-trier.de) has accomplished tests
  on the produced products in different type of
  concrete reinforcement and has accordingly
  created recommendations for its optimal usage.

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Why is it desirable and necessary to use the
chopped fiber in concrete reinforcement process?

• Plain concrete
• Traditional construction using plain concrete is
  of course the cheapest, but slow process. This
  Type of constructions have high compressive
  strength, but they lack proper bending and
  elasticity parameters and cant resist to impact.
  They tend to plastic shrinkage, Therefore causing
  surface cracks as well as some deep ones, That is
  prerequisite for quick collapse of the
  construction, especially in severe climate
  conditions.
• Steel fittings reinforced concrete
• To improve drawbacks of the plain concrete steel
  fittings were used, but it eliminated only part
  of the problems, at the same time adding some
  negative characteristics to construction, because
  of incompatibility of particular physical and
  chemical parameters. For example thermal
  conductivity in steel is higher (27 63 w/mK),
  than in concrete (0,17 2,33 w/mK).

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Properties of the plain concrete

• Positive
• Cheap construction material
  
• High compressive strength.

• Negative
• Slow strengthening process
• Lack of bending and elasticity parameters
• Cant endure impact.
• Inclined to plastic shrinkage while strengthening
  process, that causes formation of cracks. That is
  prerequisite for the future damage of the
  construction, especially in severe climate
  conditions.

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Properties of steel reinforced concrete

• Negative
• Expensive construction material
• Slow strengthening process
• Generally, Surface cracks are formed, their
  deepening process is enhanced by intensive
  changes of environmental temperature, as thermal
  expansion coefficient in concrete and steel are
  different
•  1m3 construction is becoming heavier
• To reduce hardness parameters, amount of
  intersections is raised, therefore element is
  becoming more heavy
• To reduce the negative effect of temperature
  fluctuations, it is prohibited to use fittings
  near the surface of the element, therefore it
  becomes more heavy.

• Positive
• High compressive strength
• Improved bending and elasticity parameters
• Improved impact resistance in compare to plain
  concrete.

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Chopped fibers reinforced concrete
(Fiber-concrete)

• Main determinant of economic efficiency of
  modern construction projects is time of their
  accomplishment. In this case, the traditional
  steel - concrete construction system is quite
  slow process and does not allow to create light,
  spatial elements. So the weight of steel-concrete
  elements and slow and time consuming process of
  their creation has negative effect on economic
  characteristics of the construction process.
• Chopped fiber concrete reinforcement is the most
  effective way to improve negative characteristics
  of plain concrete elements in modern
  construction, that was actively accomplished in
  the world, especially during the last decade.
  Chopper fiber reinforced concretes have sharply
  improving parameters of strength, stability,
  impact resistance, freeze resistance and
  waterproofing.

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Chopped fiber reinforced concrete parameters

• Negative
• Dont have

• Positive
• Because of better strength parameters amount of
  intersections is reduced, therefore construction
  materials are becoming cheaper
• High compressive strength
• High, steel concerted, bending and elasticity
  parameters
• Impact resistance
• Surface crack resistance
• Enhanced concrete strengthening process, not less
  than 2 times
• As doesnt have surface cracks is stable to
  temperature fluctuations
• Improved product hardness parameter
• Improved stretching parameters of concrete
• Concrete plastic shrinkage effect disappears,
  while strengthening process
• Freeze resistance is raised
• Increased working life time of the element
• Improved parameter of waterproofing.

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Preferential areas for fiber-concrete (Chopped
fiber reinforced concrete) usage
4.1. On the floors, ground plates and thin self
straightening concretes for crack prevention.
Also for the reduction of amount of fittings and
the thickness of the concrete.
4.2.For improvement of strength parameters in
steel-concrete constructions and other structural
elements, also may be used in steel-concrete
sills and in supportive elements, instead of
traditional steel frame.
4.3. On warehouse floors and road construction
for increasing surface viability.
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4.4. In tunnels and relief constructions, while
shotcreting process, to reduce the effect of
concrete fall out.
4.5. In hydroelectric power station dikes for
speeding up massive concrete pouring process.
4.6. For creation of relief, thin and wide
surface concrete elements, where usage of steel
for reinforcement is unavailable.
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4.7. In bank protection elements for increasing
viability against aggressive sea waters.
4.8. In breeding complexes in the floor tiles, to
create protection against exceptionally
aggressive environmental conditions.
4.9.For speeding up steaming process and for
overcoming shock impact effect on the derived
element.
4.10. In concretes used for oil well completion.
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Types of chopped fibers used in concrete
reinforcement Fibers used in fibrous concrete
are divided into the following groups

• Metal fibers
• Chemical fibers (polypropylene,
  polyacrylonitrile,
• polyethylene and etc.)
• Mineral fibers (AR glass and Basalt fiber)
• Carbon fibers
• Natural fibers

To represent clearly the differences
between above listed fibers and their
effectiveness for use they should be defined by
their physical and chemical parameters
(comparison and compatibility). Also defining
concrete resistance facilitating factors towards
external conditions could improve concrete
technical parameters.
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Comparative table of physical and chemical
parameters of fibers used for concrete
reinforcement
Table 1
Type Thermal Conductivity, w/mk Unit weight m/cm3 Thermal expansion coefficient, m/m0kX10-6 Elongation coefficient E-module, GPa Adhesiveness in matrix Chemical stability Fiber Diameter, µ Heat resistance Mechanical strength, MPa
Steel 45 - 230 7-8 10-17 13-21 110-210 bad average 650-800 450-1000
Chemical 0,08-0,5 1,05-1,4 25-130 10-1000 1,2-4,0 bad high 30-50 70-280 25-600
Mineral 0,03-0,04 2,5-2,8 4,5-5,5 3,0-5,3 73-110 best high 6-21 (-270)-(800) 3300-4800
Carbon 22-102 1,7-1,9 5-7 1,5-2,0 200-600 bad high 5-15 300-2300 2200-7200
Natural 0,042 1,5 3-5 7-8 5 average low 10-25 140-160 250-390
Concrete 0,17-2,33 2,2-2,5 10-15 0,2(decrease) 15-40 average (-60)-(200) 0,8-2,8
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• In comparison with matrix, the metal fibers
  sharply high thermal conductivity coefficient and
  elongation percentage (in terms of large
  amplitude changes in temperature) create internal
  destructive forces, which contribute to
  superficial decay process of reinforced concrete.
  That is why, it is recommended to place
  reinforcement deep below the surface of the
  construction element.
• In order to get fibrous concrete characteristics
  - 15kg metal fibers need to be added to 1m³
  concrete due to the high unit weight of metal and
  large diameter of elementary fiber, which finally
  causes the price increase of concrete. This
  obvious disadvantage of metal fiber makes it less
  preferred in comparison to other reinforcement
  fibers and eliminates its indicator of high
  modulus of elasticity.
• For having high elongation percentage and low
  unit weight chemical fibers are prone to
  concentrate mostly on the concrete surface,
  which doesnt further to improvement of
  elasticity parameters in concrete. Therefore,
  this type of fibers are used only for surface
  cracks elimination.

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Specific points

• Mineral fibers and carbons show the best results
  when obtaining techno-economic impacts of fibrous
  concrete, but carbon fibers show up the negative
  indicator of adhesiveness and high thermal
  conductivity coefficient (due to which concrete
  heats-up in depth) in comparison with concrete.
  Moreover, the carbon filament has a notably high
  sell price. Therefore, despite having the
  highest elasticity modulus and the best chemical
  stability in concrete it has the most expensive
  price for fibrous concrete production
  (constriction elements designed on the basis of
  carbon fiber show the best bending strength
  parameters).
• Having good adhesive properties in concrete,
  mineral fibers reduce the effect of concrete
  elastic shrinkage. Usually, special organic
  additives are used to reduce elastic shrinkage
  effect of concrete, but this causes worsening of
  concrete strength parameters by 10-20!

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Metal fibers effect on concrete parameters

• Positive effect

• Negative effect

• Thermal expansion
• coefficient (good)
• Chemical stability (medium)
• High rate of elasticity module.

• Thermal conductivity
• Unit weight
• Large diameter of fiber
• Adhesiveness.

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Chemical fiber effect on concrete parameters

• Positive

• Negative

• Chemical stability.

• High thermal conductivity Lower unit weight,
  than of concrete
• High thermal expansion coefficient
• High elongation coefficient
• Low elasticity modulus
• No-adherent in concrete
• Large fiber diameter
• Low heat resistance
• Inefficient mechanical strength.

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Carbon fiber effect on concrete parameters

• Positive

• Negative

• Unit weight - close to that of concrete
• Low elongation
• Best elasticity modulus
• Best chemical stability
• Small fiber diameter
• Best thermal resistance
• Best mechanical stability.

• High thermal conductivity
• No-adherent in concrete
• A very high price.

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Mineral fiber effect on concrete parameters

• Positive

• Negative

• Low thermal conductivity
• Unit weight is identical to concrete
• Thermal expansion coefficient close to that of
  concrete
• Low elongation
• Best adhesiveness in concrete
• Good chemical stability
• Small fiber diameter
• A wide range of thermal resistance
• Good mechanical strength.

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Mineral fibers (AR-glass, Basalt fiber) effect
comparative analysis in concrete reinforcement

• Mineral fibers have absolutely positive influence
  and good compatibility with concrete compared to
  all other types of concrete reinforcement fibers.
• Its almost two decades, that in the world
  construction market is actively used one type of
  chemically stable glass fiber in especially high
  alkali concrete solutions (pH13) to which
  zirconium dioxide (ZrO2) is added.
• As for natural mineral fiber Basalt Fiber- it
  is being used in construction for several years.
  Its only in the last decade that extensive
  researches and tests have been conducted on this
  product with a view to its application in
  building sector.

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• The main factor, for chemical stability in
  mineral fiber reinforced concretes, is the
  presence of heavy metal oxides in its molecular
  structure, which prevent mineral fiber structure
  and the strength determiner SiO2 from alkali
  leaching (silicon dioxide) in high pH concrete
  solution.

Number of metal molecules in the fiber molecular
structure with respect to thousand molecules of
SiO2 Table 2
Oxides AR-glass Basalt fiber
Al2O3 2 78
Fe2O3 0,42 162
ZRO2 161  
Sum 163,42 240
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• Comparison of physical and mechanical parameters
  of mineral fibers with respect to the concrete
  (have equal importance).
• Table 3

Parameters AR-glass Basalt fiber Concrete
Thermal expansion coefficient, m/mK106 2 8 10
Elongation 4,7 3,15  
Elasticmodulus, GPa 70 110  
Temperature resistance, C 60 500 260 700  
Mechanicalstrength , MPa 3300 4800  
Comparison of these two types of fibers show us
clearly the expected better effect of basalt
fiber in concrete products, when comparing to
AR-glass. This makes the basalt chopped fiber
more desirable product to modern construction
technologies.
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Significant effect

• In addition to technical advantages, it is also
  important to point out, that much more elementary
  basalt fibers are spread in concrete matrix
  contributing to the binding process, than in case
  of other type of fibers.

Table 4
Fiber properties Metal fiber Polypropylene fiber Basalt fiber
Length 24mm Length 24mm Length 24mm
Diameter Ø0.62mm Diameter Ø0.52mm Diameter Ø14 mcrn.
Amount 30kg/m³ Amount 7kg/m³ Amount 3kg/m³
Amount of fiber in 1 m³ concrete 0.6 mln 1.7 mln 300 mln

• That large amount of chopped basalt fiber
  determine faster formation of cement stone in
  concrete.
• Therefore, the existence of 300 million alkali
  resistant elementary basalt fibers in 1 m ³ of
  concrete, unlike other reinforcement fibers,
  enable by 2 3 times intense binding process
  during continuous concreting, without using
  expensive accelerators.

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Additional comments regarding the certification
of basalt chopped fiber

• In relation to fiber reinforced concretes and
  cements basalt chopped fiber refer to alkali
  resistant mineral fiber class which is defined by
  C1666/C1666M-08 standard and the following
  important parameters have to be emphasized

Table 5
Basalt fiber producer basalt fibers LTD Standard norms Standard
1. Tensile strength 1,3 Gpa 1,01,7 GPa ASTM P2256 ISO3341 JISR3420
2. Maintenance of strength (min. pointer 96 hrs in water 80 C (176 F)) 380MPa 350 MPa For complete/integral fibers ASTM P4963 ISO 1887 JISR 3420 EN14849
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Some research information on advantages of
the basalt chopped fiber usage in concrete
reinforcement and its technical parameters improve
ment

• The fact that we are proposing the basalt
  fiber to customers is based on several years
  researches and tests which were conducted also
  on our products at one of the leading institutes
  in Europe. In details
• Cement grouts are used for oil well
• completion which are subjected to
• high pressures and temperatures as
• high as 200C. Therefore much
• attention is paid to their tensile strength,
  shock resistance and crack resistance. In
  such conditions usage of mineral fibers is
  the best and optimal choice and basalt
  fiber is one of the most attractive
  alternatives. (R. Felicetti, C Meyer and S.
  Shimanovich Department of Civil Engineering
  and Engineering Mechanics, Columbia University,
  New York)

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• Basalt fiber has some particular characteristics
  like crack resistance, freeze resistance, shock
  and impact resistance. Thanks to this properties
  it extends the operation time of concrete.
• Basalt fiber doesnt have any side effects while
• mixing, pouring and curing. It improves
• adhesiveness and prolongs stability of
  concrete.
• Basalt fiber increases concrete resistance and
• reduces its fragility, therefore it can be used
  
• in roads and bridges construction, so that
• to improve the quality of concrete.
• (Fibers Unlimited LTD. - Dutch research)

• Test results of Loads on square slab show that,
  when using 24 mm basalt fibers in 3,5kg/m³ mixes
  they get effective bending strength - 0,31 N/mm².
  This index is slightly less than of metal fiber
  reinforced concrete one - (0,38 N/mm2). (IBU
  Trier, Germany)

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Thank You For your kind Attention!!!