Rebar

Basalt rebar

Basalt rebar is a bar with continuous spiral ribbing formed by means of winding by basalt strip oiled in highly durable polymeric compound.

Basalt rebar is a perspective composite material with a wide range of application in construction.

The rebars are resistant to corrosion and aggressive chemical compounds, is extremely light and durable.

Research results have shown that long life of constructions where basalt rebars were used considerably exceeds the life of similar constructions where other materials were used.

Characteristics:

  • Temporary tensile strength
  • Modulus of elasticity
  • Density
  • External view

Units:

  • МПа
  • МПа
  • gr/cm³

Norms:

  • 1100
  • 70000
  • 1,9
  • From dark brown to black

Control methods:

  • ГОСТ 12004
  • ГОСТ 12004
  • ГОСТ 15139
  • Technical checkup (visual)

Technical advantages:

  • Low specific weight: 4 times lighter than steel rebar
  • Resistance to corrosion, rotting, and warping
  • Unique chemical resistance (potash environment, hydrochloric acid, alkali, sea water and other aggressive environments)
  • Low thermal conductivity
  • Working temperature range 70 – 100 °
  • Long overhaul period for constructions
  • Considerably lower maintenance and repair expenses
  • Higher operational reliability and long life of constructions and products
  • Possibility to carry out installation and routine maintenance works without special load lifting mechanisms and machinery
  • Lower expenses for transporting constructions and elements of constructions to the place of installation due to lower weight of the product

Basalt rebar is a composite material of the future, which has its adherents in many countries of the world. According to forecasts, this material will occupy a permanent niche in the construction industry in the near future. Although the term composite material is not new for specialists, people for quite a long period of time have been feared the new material and conservatively continued to use metal.

What is a composite rebar?

Composite rebar is a non-metallic rod made of glass, basalt, carbon and aramid fibers in combination with polymer compounds. While the fiberglass rebar was introduced to the market long time ago, basalt rebar is a relatively new product that is actively gaining public trust and is applied time and again in various projects every year.

Basalt rebar is manufactured by using continuous basalt roving. Externally it is a carrier rod with a continuous spiral ribbing formed by means of winding of basalt strip oiled in highly durable polymeric compound.

Since 2004 Technobasalt-Invest, LLC has been one of the world leaders in the production of continuous basalt fiber, and since 2009, also in the production of basalt rebar. Basalt rebar under the trademark technobasaltTM has the marking ANPB (nonmetallic basalt rebar of a periodical profile), which corresponds to the reference document DSTU B V.2.7-312: 2016.

Technobasalt-Invest, LLC as a manufacturer that values its reputation, produces all the products in accordance with the technical conditions registered in the Ukrainian Ministry of Regional Development and Construction. Our products have a code of construction products and are certified in UkrSEPRO. The quality management system complies with the international standard ISO 9001: 2015.

To understand the product better you need to know how it is produced, therefore, we will mention briefly the technology of basalt rebar production. It can be divided into the following main stages:

  • installation of basalt roving bobbins on the bobbin holders;
  • impregnation of roving with resin;
  • formation of a periodical profile at the winding unit;
  • rebar cooling;
  • formation of rods’ length on the rebar cutting unit;
  • packing of rebar in bundles and marking.

The basalt rebar has unique technical characteristics that ensure its positive effect on the concrete structures where it is used.

So, the basalt rebar:

  • 3 times stronger than steel rebar (the strength of basalt rebar is 800-1400 MPa, depending on the diameter, whereas steel rebar has the strength of 360-400 MPa);
  • 4 times lighter than steel rebar for the similar diameters and 7-9 times lighter for an equally strength replacement;
  • has high corrosion resistance;
  • doesn’t conduct heat;
  • non hygroscopic;
  • dielectrical;
  • does not require welding at the site;
  • it is tied of a usual binding wire or plastic clamp;
  • has the similar thermal conductivity with concrete, thereby increases the durability of cement-concrete structures.

Basalt rebar of technobasaltТМ passed a series of tests in specialized state institutes and organizations.

Tests for adhesion of basalt rebar (ANPB) to concrete were carried out. Research results have shown that the general form of the stress-strain shear curves for ANPB corresponds to the similar curves for steel rebar, and the obtained shearing stress values ​​for 8 mm, 10 mm, 12 mm comply with the requirements of EN 1992-1-1. It was also proved that the bonding characteristics of ANBP to concrete are close to the relevant characteristics of the A-type rebar, and for calculating ANPB (B) anchoring in the concrete  can be used the calculated dependencies for steel rebar of the periodical profile.

Also, ANPB samples were tested for determination of tensile strength. The test sample of the 10mm rebar collapsed along the main rod under the metal tube, and the temporary tensile at break of the ANPB with a diameter of 10 mm was 1405.5 MPa.

Tests of basalt rebar on fatigue strength showed that the fatigue endurance based on tests of 2 • 106 cycles varies from 31.5 to 33.0 kg / mm2 (315 to 330 MPa) with a static strength of basalt rebar 1080 MPa, which corresponds to the strength limit of high-strength (A-1000 class) steel rebar. Linear strain of the basalt rebar is in the range from 1.9 to 2.2%, which is comparable with the linear strain of the A-1000 rebar.

Today, in Ukraine there are a number of standards that allow the use of basalt reinforcement for construction purposes:

  • DSTU B.V.2.6-145: 2010 “Construction of buildings and structures. Protection of concrete and reinforced-concrete structures against corrosion. General technical requirements”.
  • DSTU-N B V.2.6-185: 2012 “Instructions for design and production of concrete structures with non-metallic composite reinforcement based on basalt and glass roving”.
  • DSTU-N B V.2.7.-312: 2016 “Non metallic composite basalt rebar of periodical profile”
  • M 42.1-37641918-759: 2017 “Method of calculation of concrete structures of bridges reinforced with basalt rebar for endurance”
  • M 42.1-37641918-756: 2017 “Method of calculation of concrete structures of bridges reinforced with basalt rebar against low-cycle loads”
  • Р В.3.2-03450778-830: 2013 “Recommendations on the use of nonmetallic rebars for the reinforcement of structural constructions of span bridges structures”
  • Р В.2.3-03450778-846: 2014 “Recommendations on the design of basalt-concrete structures of bridges and pipes”

Basalt rebar usage in the world is standardized by the following documents: ACI 440R-07 CAN / CSA-S806-02, CAN / CSA-S6-06, CNR-DT 203/2006.

Today, the most popular application spheres for basalt rebar are road industry, civil and industrial construction, special constructions that work in an aggressive environment, architectural cement-concrete products.

There are such areas where it is impossible to cope without this innovative material, namely: erection and repair of water treatment and purification facilities, sites of storage, processing and utilization of domestic solid and liquid wastes of human settlements, reinforcement of concrete structures operating under high voltage electromagnetic fields and potential differences (boxes of MRI, supporting structures of high-voltage lines and electric power substations, etc.), construction of bridges, hydraulic structures, strengthening of coastlines, reconstruction of structures that are under constant influence of water or other aggressive factors, etc.

As a result of recalculation of projects with steel rebar to alternative ones with basalt rebar a 30% economic effect was achieved, and moreover  markedly qualitative technological characteristics. In addition, the use of basalt rebar helps to minimize the  transportation, handling and repair works costs. Usage of basalt rebar does not require an additional protective concrete layer, since this product does NOT corrode.

If you want to keep up with the times, be always first and qualitatively different from competitive organizations, then it’s time to step out of the comfort zone and start using the innovative materials.