TOTAL CONSUMPTION OF BASALT FIBER IS UP TO 3 KG PER 1 CUBE OF CONCRETE!
UP TO 55% HIGHER STRENGTH
UP TO 100% LESS CONSUMPTION OF REBAR
UP TO 80% LOWER COST
Reinforcement with basalt fiber is
an innovation in industrial floors
We refer to industrial floors all types of industrial multi-layer floors, for example, floors in factories, logistics centers, warehouses (including those with a high level of exposure to aggressive environments), industrial refrigerators, parking lots, etc. In addition, basalt reinforcement is widely and successfully used in screeds for floors of buildings and structures, as well as in other structures that transfer the load to the ground or solid foundation.
Using basalt fiber and / or basalt rebar you will get:
The floor strength increase
Experimentally, we confirmed that adding of basalt fiber to a cement-sand slab provides a + 55% increase in the strength compared to the same slab, but without fiber. We recommend that you make similar experiments with your materials because concrete strength indicators directly depend on the cement strength grade and impurities in it, as well as on the purity of sand and crushed stone.
Long-term economic impact
A solid base will last a long time without any repairs or additional maintenance. Renovation work is expensive.
A strength increase in the industrial floor’s concrete base is achieved primarily by the fact that at the micro level, basalt fibers reinforce the entire volume of cement mortar / concrete in all possible directions, thus creating 3D volumetric reinforcement (dispersed reinforcement).
For reference: 1 kg of basalt fiber provides over 74 million points of reinforcement!
Short-term economic effect
Reinforcement with Technobasalt® Fiber allows you to significantly reduce the amount of rebar, or even refuse it. Reinforcement with Technobasalt® Rebar allows achieving, in addition to a significant increase in structural strength, savings on materials, work and logistics.
Each project is unique and when it is impractical to use one material, it is likely that a combination of materials will be economically successful.
Resistance to aggressive environmental influences
Basalt materials are highly resistant to alkalis, acids, various types of corrosion and microorganisms. Basalt fibers are fire resistant material. The temperature of their application is up to + 680 °C. Reinforcement with basalt materials increases these indicators for the ready-made product.
Stronger than steel —
The basalt rebar has a number of clear advantages over steel. It is three times stronger at breaking, has high corrosion resistance, a coefficient of thermal expansion very close to concrete, very low ultimate elongation at break, which is 7-8 times less than that of steel and is approximately equal to its elongation at the yield point.
The disadvantages of basalt rebar include the modulus of elasticity, which is 2-2.5 times lower than that of steel rebar. This indicator is especially important in the manufacture of ceiling slabs and some other structures, but does not play a role in structures that work on an elastic foundation, such as industrial floors, where the rebar works in breaking.
More about industrial floors and screeds
about industrial floors
Industrial concrete floors are the most important element of modern buildings and structures. They perceive significant static and dynamic loads, must meet high requirements for resistance to temperature changes, resistance to an aggressive environment, have high strength and reliability. In addition, the aesthetic and hygienic aspects are also important. All these are provided by a universal reinforcing additive – Technobasalt® Fiber.
Basalt fiber is a universal reinforcing additive that significantly improves the quality characteristics of concrete and composite mixtures that are used for industrial floors pouring. In tension, basalt fiber is 3 times stronger than steel and has a temperature expansion coefficient identical to concrete’s. This fact prevents the appearance of microcracks during the concrete curing and its subsequent operation.
The classification of concrete industrial floors
is carried out according to their purpose:
- floors for production sites with a high level of humidity and other aggressive environments (car washes, storage of chemical products and fertilizers, greenhouse complexes, livestock and poultry farms, driveways, flyovers, sections of auto enterprises, elevators, open storage areas, loading and unloading areas, etc.);
- floors for warehouses, production sites, logistics terminals, material and technical premises, parking lots;
- floors for public premises – educational institutions, canteens, medical institutions, administrative centers;
- floors for rooms with increased load requirements;
- floors for industrial refrigerators and freezers;
- floors for sanitary inspection points in centers with high radiological hazards, in the nuclear industry, various decontamination centers;
- floors for areas with high requirements for explosion and fire safety, structures with antistatic basesваниями.
Industrial concrete floors
In general terms, an industrial floor is a covering and an artificial subfloor.
The coating undertakes all loads directly. Considering this, high requirements for strength and durability are imposed to the materials, which are used for its production. The coating can be either single-layer or multi-layer. Traditionally, heavy concrete is the main coating material. However, in the construction of modern industrial floors, fiber-reinforced concrete has recently been actively used. Fiber concrete is a concrete mixture in which fine fibers are mixed.
The artificial base transfers the load from the coating to the natural base and can also be either single-layer or multi-layer. The main functions of the artificial foundation are:
- strength function – load distribution over the soil base and its reduction to the design value;
- drainage of water from under the cover (drainage);
- in rare cases, thermal insulation of the earth foundation
The earth foundation (natural base) has a load-bearing function and provides the overall strength of the pavement structure. That is why its upper part, after the removing of the sod and humus layer, as well as after performing the planning works, is compacted to the density required by the project. On loose soils, crushed stone may be added to the surface layer during compaction.
In monolithic concrete pavements, a dividing layer is additionally spread between the pavement and the artificial base to reduce the stresses arising from the hardening of the concrete mass of the pavement, its shrinkage and temperature fluctuations. In addition, this separation allows you to form a smoother bottom surface of the coating and to reduce water withdrawal from the concrete mass of the base during the hardening period. As a rule, PVC films, parchment papers and their analogues are used.
We recommend adding basalt fiber to the concrete mix. This will significantly improve the physical performance of the industrial floor.
Adding of basalt fiber to concrete in a ratio of 1 kg / 100 kg of cement (1% of the bulk cement):
- increases the strength properties of the floor up to 55% (prevents cracking of the coating, strengthens concrete due to micro-reinforcement with its fibers);
- increases the reliability of the floor — the likelihood of cracks, chips and other damage to the structure because of time, static and dynamic loads is significantly reduced;
- increases the resistance to floor abrasion and significantly reduces dust formation;
- increases the fire resistance of the floor;
- increases the life period of the floor as it prevents the appearance of microcracks;
- reduces the cost and weight of the structure due to the possibility of reducing the thickness of the base layer.
General pouring process
of concrete industrial floors
Stage 1. Preparation of the base
Carry out the marking of the base according to the project.
For the soil base — plan and compact the soil, apply a gravel-sand pad and lay a waterproofing layer according to the project and technological regulations.
For a concrete base — fill open joints between floor slabs (if any) with mortar; after hardening, clean the entire plane from dirt, construction debris and dust; lay waterproofing.
Stage 2. Preparation of concrete
At the stage of sand feeding into a concrete mixer, it is necessary to add basalt fiber. For general cases it is approximately at the rate of 1 kg of fiber per 100 kg of cement. Then, without ceasing to mix, it is necessary to add cement, and then crushed stone. Mixing of fiber with cement is strongly recommended being carried out on a dry part of the technological process.
Make a concrete mixture according to the technological regulations.
Recommendations for reinforcing mixtures with fiber:
1. Mixes for the industrial floor base (bottom layer): fiber length is 24 mm, fiber moisture is 1%, sizing type is T10, fiber dosage is from 1 kg/m³ of the mixture.
2. Mixes for the industrial floor base (top layer): fiber length is12 or 24 mm, fiber moisture is 1%, sizing type is T10, fiber dosage is from 1 kg/m³ of mixture to 1% by weight of cement.
3. Mixtures for screeds (brands M100 and M150): fiber length is 12 mm, fiber moisture is 1% or 12%, sizing type is T10, fiber dosage is 1 kg/m³ of the mixture.
In all three cases, we recommend using a forced-action concrete mixer and uniform fiber dosing into the dry mix.
A distinctive feature of the ready-made concrete is the absence of its stratification and a more homogenized mixture.
During basalt fiber reinforced concrete production unlike steel, does not have any negative abrasive effect to the equipment.
Stage 3. Concrete logistics
Delivery of concrete to the facility is carried out by standard methods without any deviations from the technological regulations.
Basalt fiber does not have a negative abrasive effect on the nodes, mechanisms, and surfaces of delivery devices.
Stage 4. Pouring of industrial concrete floor
Pouring and leveling the concrete floor does not differ from the standard technological procedure.
After the concrete unloading onto the base from the transport sleeve, the concrete mass does not stratify and retains excellent plasticity, which makes it convenient to work with it.
In the process of hardening, due to the excellent reinforcement with numerous microfilaments, the concrete mixture does not form cracks and microcracks. However, one should not neglect the splitting of the concrete floor into segments according to the project.
Step 5. Surface polishing
If necessary, the surface of the industrial floor is polished.
The surface of the concrete layer reinforced with basalt fiber is perfectly polished with standard tools without increasing the consumables wear .
Unlike steel and polypropylene, basalt fiber does not break out of the surface layer of concrete and, accordingly, does not leave behind any damage.
How is it done
of industrial floors
Basalt fiber Technobasalt® proved to be highly effective in a project with a high intensity of parking lots and driveways operation, which was used to reinforce concrete floors with both earth and solid foundations in open and closed types of parking.
Nova Poshta Logistic center in Chernihiv
The uniqueness of the industrial floor construction at this facility is the fact that they completely rejected to use any reinforcement in favor to concrete reinforcement with Technobasalt® basalt fiber.
Help with calculations
The Technobasalt team together with numerous design institutes have brought together the entire range of data, necessary both for understanding the properties of the material and directly for performing design calculations.
You can download this guide using this link
In consultation with design institutes, design bureaus and designers, we have compiled several examples of calculations for industrial floors with uniformly distributed and point loads.
Examples of calculations can be downloaded at this link
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