CF6792 Basalt Untwisted Roving

Basalt Untwisted Roving Description

Basalt untwisted roving consists of continuous, parallel filaments extruded from molten volcanic basalt rock, with diameters precision-controlled between 9–17 μm to optimize resin infiltration and mechanical interlocking in composite structures. Each filament is uniformly coated with a multi-resin silane sizing—typically epoxy-functional silanes blended with phenolic-compatible additives—designed to form covalent Si-O-C bonds with thermoset matrices like epoxy, vinyl ester, and phenolic resins. This tailored surface treatment ensures rapid wet-out (often <60 seconds in epoxy at 25°C) while maximizing interfacial adhesion to prevent delamination under stress.

The inherent mineral composition grants extraordinary thermal resilience, maintaining structural integrity across extreme temperatures (–260°C to +700°C) without pyrolysis or strength degradation, critical for high-temperature curing cycles (120–180°C) and demanding end-use environments such as aerospace components or engine parts. Mechanically, the roving delivers tensile strength of 0.60–0.68 N/tex and an elastic modulus of 91–100 GPa, exceeding E-glass by 25–30% in rigidity while retaining 2.8–3.3% elongation to avoid brittle fracture. When woven into fabrics or infused with resins, it elevates interlaminar shear strength by 40% and flexural modulus by 50% compared to glass-reinforced equivalents.

Chemically inert with an amorphous structure, the roving exhibits near-zero moisture absorption (<0.1%), preventing hydrolysis-induced weakening in humid conditions. Its innate resistance to acids, alkalis, seawater, and organic solvents—enhanced by the sizing’s hydrophobic properties—ensures decades-long durability in marine, chemical, and offshore applications. Electrically non-conductive and inherently flame-retardant (LOI >75%), it complies with stringent fire-smoke-toxicity (FST) standards for aircraft interiors and tunnel linings.

The untwisted architecture and ultra-low fuzz level (≤10 mg/kg) enable flawless processing in weaving looms, producing high-strength fabrics (e.g., biaxial grids, unidirectional tapes) without filament shedding. This combination of properties—superior bundling integrity, corrosion immunity, fatigue resistance (2× longer lifespan than glass in cyclic loading), and UV stability—makes it indispensable for structural composites in wind turbine spars, pressure vessels, bridge reinforcements, and marine hulls where lightweight performance and sustainability converge (30% lower CO₂ footprint than glass fiber).

Basalt Untwisted Roving Applications

Wind Energy extensively utilizes this roving for critical load-bearing components such as spar caps and root reinforcements in turbine blades. Its high tensile strength (0.60–0.68 N/tex), fatigue resistance (2× greater than E-glass), and modulus (91–100 GPa) significantly extend blade lifespan while enabling longer, more efficient designs that withstand extreme weather cycles. The roving’s rapid epoxy wet-out capability accelerates vacuum infusion processes, reducing production time by 25% for multi-megawatt turbines.

Aerospace and Defense sectors employ the roving in structural composites for radomes, missile casings, and cabin interiors. Its flame-smoke-toxicity (FST) compliance (LOI >75%), combined with thermal stability (–260°C to +700°C), ensures safety in high-temperature environments. When woven into unidirectional fabrics, it achieves 40% higher specific strength than carbon fiber in satellite components while providing EMI shielding and radar transparency.

Marine Engineering leverages the material’s immunity to saltwater corrosion in hull laminates, decks, and offshore platform reinforcements. Its resistance to hydrolysis (<0.1% moisture absorption) and chemical degradation prevents delamination in seawater-saturated composites, tripling service life compared to glass fiber equivalents. The roving’s low fuzz (≤10 mg/kg) also enables smooth weaving of high-density boat-building fabrics.

Civil Infrastructure applications include reinforcing grid fabrics for bridges, tunnels, and seismic retrofits. When embedded in epoxy or vinyl ester matrices, basalt-reinforced composites demonstrate 50% higher crack resistance than steel rebar while eliminating corrosion risks. Its compatibility with phenolic resins further supports fireproof cladding and structural panels in high-rise buildings.

Pressure Vessels for compressed natural gas (CNG) and hydrogen storage exploit the roving’s high hoop strength and cyclic pressure endurance. Wound via filament winding machines, it achieves 30% weight reduction versus carbon fiber tanks while maintaining Type IV vessel integrity at 700-bar operating pressures.

Emerging Uses include automotive leaf springs (60% lighter than steel), high-voltage insulator cores (dielectric strength >35 kV/mm), and 3D-printed continuous fiber composites for robotics. The roving’s sustainability profile—30% lower CO₂ than glass fiber and recyclability via pyrolysis—accelerates adoption in green technology sectors seeking circular economy solutions.

Basalt Untwisted Roving Packaging

Our products are packaged in customized cartons of various sizes based on the material dimensions. Small items are securely packed in PP boxes, while larger items are placed in custom wooden crates. We ensure strict adherence to packaging customization and the use of appropriate cushioning materials to provide optimal protection during transportation.

Packaging: Carton, Wooden Box, or Customized.

Kindly review the packaging details provided for your reference.

Manufacturing Process

1.       Testing Method

(1)    Chemical Composition Analysis - Verified using techniques such as GDMS or XRF to ensure compliance with purity requirements.

(2)    Mechanical Properties Testing - Includes tensile strength, yield strength, and elongation tests to assess material performance.

(3)    Dimensional Inspection - Measures thickness, width, and length to ensure adherence to specified tolerances.

(4)    Surface Quality Inspection - Checks for defects such as scratches, cracks, or inclusions through visual and ultrasonic examination.

(5)    Hardness Testing - Determines material hardness to confirm uniformity and mechanical reliability.

Please refer to the SAM testing procedures for detailed information.

Basalt Untwisted Roving FAQs

Q1. What is Basalt Untwisted Roving?

A direct, silane-coated basalt fiber bundle with parallel filaments (no twist), engineered for epoxy, phenolic, and vinyl ester resins. Its optimized sizing ensures rapid resin wet-out (<60 seconds) and superior strand integrity for weaving high-performance composites.

Q2. Why choose this over E-glass roving?

Basalt offers 25-30% higher tensile strength (0.60-0.68 N/tex), 3× better corrosion resistance, thermal stability (-260°C to +700°C), and 40% greater interlaminar shear strength in composites. It's a 30% lower CO₂ footprint that enhances sustainability.

Q3. How does it perform in weaving processes?

Ultra-low fuzz (≤10 mg/kg) and high bundling cohesion enable smooth processing on rapier/needle looms (15-25 N tension). It weaves flawlessly into biaxial grids, unidirectional tapes, and 3D fabrics without filament shedding.

Related Information

1.       Common Preparation Methods

The production begins with rigorous selection of high-purity volcanic basalt rock, which undergoes crushing, washing, and magnetic separation to remove metallic impurities, yielding uniform 5–20 mm granules. These raw materials are charged into gas- or electric-fired furnaces operating at 1,460–1,500°C, where basalt melts into a homogeneous, viscosity-controlled lava. The molten material flows into platinum-rhodium alloy bushings featuring precision-engineered nozzles calibrated to 9–17 μm diameters, where it is attenuated into continuous filaments under high-speed traction and rapid air-quenching—a critical step that locks the amorphous molecular structure essential for achieving tensile strengths of 0.60–0.68 N/tex.

Immediately after formation, filaments pass through an aqueous sizing bath containing a multi-resin silane formulation—typically blending epoxy-functional silanes (e.g., γ-glycidoxypropyltrimethoxysilane), phenolic-compatible additives, and film-forming polymers—applied at 60–80°C via immersion rollers. This coating uniformly encapsulates each filament to optimize chemical bonding with thermoset resins while reducing inter-filament friction; the absence of twist during subsequent processing preserves parallel alignment crucial for composite reinforcement. The sized filaments are gathered into untwisted bundles under micro-tension control (15–25 N), with linear density precisely adjusted between 600–4,800 Tex through modulation of bushing orifice counts and winding speeds.

Continuous rovings undergo infrared pre-drying at 100–120°C to evaporate surface moisture before entering multi-zone convection ovens, where the sizing undergoes thermal crosslinking at 130–150°C for 30–50 minutes, activating covalent bonding sites for epoxy/phenolic matrices. Throughout this stage, electrostatic sensors monitor filament alignment while laser micrometers verify diameter consistency (±0.5 μm tolerance). The rovings are then wound onto perforated polymer bobbins under a nitrogen atmosphere to prevent oxidative degradation, with tension control ensuring zero twist insertion.

Final quality assurance employs thermogravimetric sizing analysis (0.5–0.9 wt%), resin wet-out trials (validating <60-second epoxy infusion at 25°C), and mechanical testing for fuzz resistance (≤10 mg/kg) and strand integrity. Rovings meeting tensile strength (>0.60 N/tex), moisture content (<0.1%), and thermal stability (–260°C to +700°C) standards are packaged in aluminum-coated moisture-barrier bags under inert gas purge, ensuring 12-month shelf stability for weaving into composite fabrics or direct reinforcement in wind energy, aerospace, and marine applications demanding corrosion immunity and fatigue resistance.