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Features & Applications Silica Fiber Products

Features:

  • Asbestos Replacement
  • Resilient Fireproof High Temperature Insulator
  • Resists Molten Metals and Radiant Heat
  • Compatible with Most Chemicals
  • Low Halogen Content
  • High Dielectric Strength
  • Minimal Smoke Emission
  • Low Thermal Conductivity
  • No Known Health Hazards
  • Amorphous Structure
  • Cost Effective

Applications:

  • shipbuilding and repair,
  • power plants and utilities,
  • metal fabrication,
  • foundries,
  • petroleum and petrochemical plants,
  • chemical processing,
  • nuclear energy,
  • glass plants,
  • appliance manufacturing,
  • aircraft and aerospace,
  • electronics and communications,
  • heat treating and other areas where thermal insulation is essential to performance, safety and cost.
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Silica – Nonwovens

Product Description: 

Silica Needlemats are made from special glass fibers with a filament diameter of 6-9 microns. They represent a modern product generation that, in any aspect, meets with all stringent requirements as to temperature consistency and environmental health standards. Silica glass fibers consist of nearly 95% SiO(2). Because of their low thermal conductivity they are the ideal raw material for the production of flexible insulation mats formed mechanically without the use of chemical bonding agents. These mats keep a very high chemical and physical stability up to 1,800 degr. F. (For application temperatures not higher than 1,200 degrees F, we recommend the more cost efficient E-Glass Needlemat).

The easy handling of the mats allow the cutting of the material into any desired shape and form.

Please click on image to enlarge

SilicaMatThermoConductivitySilicaMat

 Applications: 

  • Industrial ovens
  • Chimneys
  • Kiln furnaces
  • Boilers
  • Steel Industry
  • Gas exhaust systems
  • Laboratories
  • Fire protection

 

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Silica – Fabrics

Product Description:

Silica fabrics are consisting of special glass fibers with an average filament diameter of approx. 6 micron. They represent a modern product generation that, in any aspect meets with all stringent requirements as to temperature consistency and environmental health standards. Approx. 95% of the Silica glass fibers consist of SiO(2). They are the ideal raw material for the production of fabrics and tapes with very high chemical and physical stability of up to 1,800 degr. F. As per customers specification these Silica fabrics can be finished with various coatings.

 Applications: 

  • Fire blankets
  • Welding blankets
  • Removable Insulation covers
  • Insulation pads
  • Industrial and laboratory ovens
  • Household– and boiler industry
  • Heat– and fire protection
  • Steel Industry
  • Automotive Industry
  • Flexible expansion joints
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Definition Basalt Rebar

From Wikipedia, the free encyclopedia

Rebar (short for reinforcing bar), also known as reinforcing steel, reinforcement steel,[1] is a steel bar or mesh of steel wires used as a tension device in reinforced concrete and reinforced masonry structures to strengthen and hold the concrete in tension. Rebar's surface is often patterned to form a better bond with the concrete.


The above description from the Wikippedia does not include Basalt, but nowadays, Basalt is available, as well.

Below are a few highlights utilizing Basalt instead of e.g. the commonly used Steel:

Highlights: 

  • Higher specific strength
  • Approx. 10% of Basalt Rebar needed to achieve the same results as with Steel Rebars
  • Resistant to corrosion or deterioration caused by natural elements
  • Alkaline and acide resistant
  • Same thermal expansion as concrete, reducing the formation of cracks

Suitable Applications: 

  • Concrete
  • Highway
  • Construction

 

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Basalt – CNC

Basalt-CNC

Given the right form, basalt can be also machined with CNC equipment.

The picture illustrates a basalt board which we asked to get machined in a shop in USA.

This allows for a lot more applications and to venture into completely new markets.

E.g. Gaskets for motors, appliances, doors, ovens, or for  insulation of pipes, just to mention a few.

The board we offer can certainly also be dye-cut or cut with a "box cutter".

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Basalt Mesh Fabrics

Mesh Fabric, made from Basalt fiber

As its preferred use is in outdoor applications, it is also considered to be a Geotextile.

Technically, not all meshes are woven; the first picture is a leno woven, but picture two, three & five are not woven;

Following advantages make this product superior over an E-Glass Mesh: 

  • Ecologically safe
  • Withstands very high temperature of molten asphalt
  • Very high strength and durability
  • Alkali-resistant and chemically inert
  • Corrosion-resistant
  • Will not damage tires if exposed to road surface
  • 2.7 times lighter than metallic mesh, for easier handling and reduced transport costs
  • Up to 47% increase in asphalt surface life on roads and highways.

Basalt Geo-Mesh is also ideal for soil and embankment stabilization and land-fill coverings, due to its high strength and environmental and ecological safety.

Meshes can be offered with and without resin coatings.

Standard constructions:

5mm x 5mm (1/4″ x 1/4″) squares

10mm x 10 mm (3/8″ x 3/8″) squares

25mm x 25 mm (1″ x 1″) squares

50mm x 50 mm (2″ x 2″) squares

Additional Technical information:

Technical Data Sheet

Basalt Meshes

Window Sizes 5mm, 10mm, 25mm, 50mm

 

Window Size 5mm 10mm 25mm 50mm
Total Weight/ Area 220 grams/sq. meter 110 grams/sq. meter 350 grams/sq. meter 370 grams/sq. meter
6.5oz./sq. yard 3.85oz./sq. yard 10.26oz./ sq. yard 10.85oz./ sq. yard
Weight Resin Coating 20 grams/sq. meter 10 grams/sq. meter 36 grams/sq. meter 38 grams/sq. meter
0.7oz./sq. yard 0.35oz./sq. yard 1.3oz./sq. yard 1.35oz./sq. yard
Thickness 0.6-0.7 mm 0.6-0.7 mm .08-.09 mm .08-.09 mm
0.021-0.025 in. 0.021-0.025 in. 0.032-0.035 in. 0.032-0.035 in.
Maximum Load-Warp 48,000N/meter 24,000N/meter 80,780N/meter 114,000N/meter
3,290lb. force/ foot 1,645lb. force/ foot 8,483lb. force/ foot 7,813lb. force/ foot
Maximum Load-Weft 45,000N/meter 20,000N/meter 78,900N/meter 86,000N/meter
3,084lb. force/ foot 1,371lb. force/ foot 5,415lb. force/ foot 5,894lb. force/ foot
Elongation at break-Warp 6.67 % 6.67 % 6.67 % 6.67 %
Elongation at break-Weft 3.53 % 3.53 % 3.53 % 3.53 %
Breaking Elongation-Warp 13.54 mm 13.34 mm 13.34 mm 13.34 mm
0.53 inch 0.53 inch 0.53 inch 0.53 inch
Breaking Elongation-Weft 7.07 mm 7.07 mm 7.07 mm 7.07 mm
0.28 inch 0.28 inch 0.28 inch 0.28 inch
Standard Roll Dimensions 1 meter x50 meters 1 meter x50 meters 1 meter x50 meters 1 meter x50 meters
3.28 ft. x 164 ft. 3.28 ft. x 164 ft. 3.28 ft. x 164 ft. 3.28 ft. x 164 ft.

Different widths and roll lengths available on special order

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Basalt Board & Metal

Combining Board with metal casings can provide favorable integrated system solutions.

Applications can be

  • Oven Doors
  • Oven Lids
  • Fire Doors
  • Underlayer for Dutch Ovens
  • Coaster for Laboratory hot items
  • Black Smith applications
  • Construction in Building systems
  • Replacement for Ceramic Insulation systems (up to 1,600 degrees F)
  • ... and many more

 

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Basalt Board

A Needled Blanket is compressed into a board with the help of a Phenolic resin. This value added treatment allows the material to be dye-cut or molded into almost any common shape.

While the board could be used in almost identical applications as the Basalt Needlefelt is used in, it also allows for additional markets, such as  in pipe wrappings, ladles, furnaces, or high temperature insulations, up to approximately 1,600 degrees F in general.

In highly competitive markets, this board can be used in conjunction with insulation materials of lower K-values, at lower cost. In those instances, the board serves as high temperature facing layer, with the purpose in lowering the temperature far enough for the second layer to withstand. In this example, the second layer could be a fiberglass Needlemat. In other instances, there may be even a third and a fourth layer.

In order to recommend the best insulation system, it will be required to know exactly about the environment this material will be facing.

Applications: 

  • Ovens
  • Kilns
  • Furnaces
  • Whiteware
  • Transportation
  • Refractory applications
  • In general for application up to 1,600 degrees F
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Basalt – Multi-Axial Products

Examples for Multi-Axial Products: 

Density: 13.2 oz/syd (450 g/sm) or 19 oz//syd, (650 g/sm)

Fiber Orientation: +45 degrees, -45 degrees or 0 degree, 90 degrees

Fiber size: 13 mcm

Roll length: 54.70 linyd (50 m)

Width: 50″, (127 cm)

Tri-Axial

Density: 28.7 oz/syd (980 g/sm)

Fiber Orientation: 0 degrees, +45 degrees, -45 degrees

Fiber size: 13 mcm

Roll length: 54.70 linyd (50 m)

Width: 12.6″, (32 cm)

Quad-Axial

Density: 19.9 oz//syd, (680 g/sm)

Fiber Orientation: 0 degrees, 90 degrees, +45 degrees, -45 degrees

Fiber size: 13 mcm

Roll length: 54.70 linyd (50 m)

Width: 50″, (127 cm)

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Basalt Unidirectional Fabrics

Basalt Fabrics in general can be applied where E-Glass, sometimes S-Glass or Carbon Fabrics can be used, as well. As Basalt is more expensive than E-Glass, but cheaper than Carbon Fibers, typically it finds implementations, more suitable to its particular properties and fills an important gab when it comes to cost-performance ratios.

You can find a comparison to E-Glass, S-Glass or other materials by clicking here: Basic Comparison To Other Fibers.

Knowing how Basalt compares to other fibers allow to precisely engineer an optimal solution, which could also be in form of a hybrid (combining Basalt with other Fibers made from Glass, Carbon, Kevlar, etc.)

An Example of an Engineered FRP. 

In Fiber Reinforcement Products (FRP) the engineer chooses the fiber, based on the desired outcome. E.g. if lighter weight requirements at identical strength to currently used fibers are required or if higher strengths are necessary while staying within the weight specifications.

There are other examples relevant to durability, corrosion resistances, break strength, chemical resistances, thermal applications, etc.

Engineers often choose unidirectional fabric when strength mostly in one direction only is required. This then presents a more lightweight and cost attractive solution.

Standard offering: 

Weights: 5.9 oz/syd – 8.8 oz/syd

Widths: 23.6″

Length: 54.5 yd

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About Multi Axial Fabrics

Multi-Axial Fabrics consists of a numerous amount of layers stitched together.

Each single layer may be of a different, individual construction, whereas it can be a woven fabric, a unidirectional fabric or any other version. The choice of materials may be different. E.g. it could be a combination of Glass & Basalt, or Carbon & Kevlar & Glass.

In Multi-Axial Fabrics, often the manufacturer takes advantage of positioning the layers of fabric to where the main fiber direction points into a different angle to the previous or the following layer.

This allows for optimal utilization of the fiber properties, in most cases the strength requirements.

Following graph illustrates one example of a Muli-Axial Fabric:

3

 

A four layer Multi-Axial Fabric would be called a Quadraxial fabric. it Can have the main fiber direction of the layers point in 3 or four different directions (degrees).

2

 

The following graph illustrates the necessary stitching-assembly process.

1

Curtesy of netcomposites.com

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Carbon Fiber – Applications

AEROSPACE

Rising fuel costs, environmental regulations and an increase in airline traffic have helped drive the increasing use of composite materials in the aerospace industry. Composites are used in military, business and commercial aircraft of all sizes, including spacecraft.

ARCHITECTURE

The architecture community is experiencing substantial growth in the understanding and use of composites. Composites offer architects and designers performance and value in large-scale projects and their use is increasing in commercial and residential buildings.

AUTOMOTIVE

The automotive industry is no stranger to composites. In addition to enabling groundbreaking vehicle designs, composites are also being used to reduce vehicle weight and cut CO2 emissions.

ENERGY

New advancements in composites are redefining the energy industry. Composites help enable the use of wind and solar power and improve the efficiency of traditional energy suppliers.

INFRASTRUCTURE

Composites are used all over the world to help construct and repair a wide variety of infrastructure applications, from buildings and bridges to roads to and railways.

MARINE

The marine industry has experienced a steady rise in the use of composites. In addition to helping hulls be lighter and more damage-resistant, composites can be found in many more areas of a maritime vessel–from interior moldings to furniture on super yachts.

MILITARY

Military-grade composites are used in a number of applications for their low weight, long life and ability to help protect people and equipment from harm. Aerial drones, armored fighting vehicles, submarines and body armor can contain composites materials.

SPORTS & RECREATION

From football helmets to hockey sticks to kayaks to bobsleds, composite materials help athletes reach their highest performance capabilities and provide durable, lightweight equipment for weekend warriors.