FIRE STRUCTURAL RESISTANCE OF BASALT FIBRE COMPOSITES

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1 FIRE STRUCTURAL RESISTANCE OF BASALT FIBRE COMPOSITES T. Bhat 1,2, V. Chevali 1,2, X. Liu 2,3, S. Feih 1 and A.P. Mouritz 1 1 Sir Lawrence Wackett Aerospace Research Centre, School of Aerospace, Mechanical and Manufacturing Engineering, RMIT University 2 Cooperative Research Centre for Advanced Composite Structures Ltd (CRC-ACS) 3 Advanced Composite Structures Australia Pty Ltd

2 Outline Introduction to Basalt Chemical composition and fibre manufacturing process Advantages and potential applications Research scope Testing and modelling approach Test results and discussion Fibre bundle tests Thermal response of composite Fire structural tensile tests Softening mechanisms of the composite Conclusion and future work

3 What is Basalt? Generic term for solidified volcanic lava, and it can be melt extruded into continuous filaments using process technology similar to the production of glass fibres Source: US Geological Survey Source: lbie Source: Nitrex Exlosives Figure 1: Basalt fibre manufacturing process Source: Compositesworld

4 Advantages and Applications Inert, non-toxic and non-carcinogenic and recyclable replacement to asbestos Maintains Geometry integrity at high temperatures Fire proofing and high temperature insulation (HTI) Higher breaking load and Young s Modulus than E-glass fibres Composite reinforcement Tough and long-lasting, fibres deliver excellent acid, alkali, moisture and solvent resistance construction industry Immune to nuclear radiation, UV light, biologic and fungal contamination making them more durable Price range between E-glass and S-glass Fire Proof Clothing Basalt Geo Mesh Interior finishing (non structural applications) Source: Basfiber Source: GBF Source: GBF Figure 2: Various applications of basalt fibres

5 Research Questions Basalt reinforced composites have been used since the late 196s Mechanical characterisation of basalt fibre reinforced polymer (BFRP) composites show superior tensile strength and modulus Do the superior thermal properties of basalt fibres translate into higher fire structural resistance for BFRP composites? What roles do the fibres and matrix play in the loss of strength at high temperatures? How can they be improved? What matrix system is suitable for high temperature composite applications?

6 Objectives Conduct high temperature tensile tests on basalt fibres to assess strength loss mechanisms Conduct small scale fire structural tensile tests to assess the fire performance of basalt reinforced composites Use thermo-mechanical prediction models developed by Feih et. al (27) and apply them to basalt composites

7 Materials and Experimental Methods The basalt fabric was plain woven by the supplier (Zhejiang GBF Fiber Co. Ltd.) using 3 tex tows to an areal density of 35 g/m 2 Vinyl ester (SPV 1349 Nuplex Composites) was chosen as a suitable resin system Composite made using vacuum bag resin infusion (VBRI) process The tensile properties of basalt fibre tows were measured at high temperature Elevated temperature tensile tests on the basalt composite were conducted in accordance with ASTM D-339 Small scale fire structural tensile tests were performed on basalt fibre composites Adapted the thermo-mechanical model developed by Feih et. al (27) and used them for basalt composites Figure 3a: GBF Basalt fabric 3b: VBRI setup

8 RESULTS AND DISCUSSION

9 Residual Basalt Tow Strength (%) Residual Glass Tow Strength (%) Fibre Bundle Tests Property Units Basalt E-glass Weave Pattern - Plain Plain Areal Density g/m Linear Density tex C 25 C 35 C C 25 C C C 45 C 65 C Heating Time (s) Figure 4a: Basalt tow tests 2 45 C 55 C 65 C Heating Time (s) 4b: Glass fibre tow tests

10 Tow Softening Rate (%/s) Tow Failure Stress (%) Fibre Softening Rate 1 basalt tow glass tow 1 basalt tow glass tow Temperature ( o C) Figure 5a: softening rates of fibres Temperature ( o C) 5b: effect of increasing temperature on residual strength of fibres The thermal softening rate was approximated by assuming the failure load decreased at a linear rate with heating time before reaching minimum failure load. The results indicate no significant differences between the softening rates and strength loss for basalt and glass fibres. This indicates that the tensile response of the basalt and glass composites in fire should also be similar.

11 Temperature ( C) Temperature ( C) Thermal Response of Basalt Composite To Fire (q = 25kW/m 2 ) 6 basalt fibre composite hot surface 6 glass fibre composite 4 middle cold surface 4 hot surface middle cold surface Heating Time (s) Figure 6a: Thermal response of basalt composite Heating Time (s) 6b: Thermal response of glass composite The temperature of the hot face increased more rapidly and reached a higher temperature than the E-glass composite. Middle and back face temperatures were also higher than the E-glass composite.

12 Temperature ( C) Temperature ( C) Thermal Response of Basalt Composite to basalt fibre composite Fire (q = 5 kw/m 2 ) 8 ignition point hot surface 8 glass fibre composite 6 middle cold surface 6 hot surface middle 4 4 cold surface Heating Time (s) Figure 7a: Thermal response of basalt composite Heating Time (s) 7b: Thermal response of glass composite The higher emissivity caused the basalt composite to reach a sufficiently high temperature and decomposition rate that it ignited and burnt at the heat flux of 5 kw/m 2. This did not occur with the glass laminate exposed to the same heat flux because it was cooler.

13 Applied Tensile Stress (MPa) Applied Tensile Stress (MPa) Fire Structural Tensile Tests 5 4 matrix softening effect 3 glass fibre composite 2 1 basalt fibre composite Rupture Time (s) 4 matrix softening effect glass fibre composite Figure 8: Fire structural test results basalt fibre composite Rupture Time (s)

14 Tensile Strength (MPa) Softening Mechanisms 6 basalt fibre composite 5 glass fibre composite 4 glass transition temperature Temperature ( C) Figure 9: Composite softening mechanisms

15 Conclusions Basalt fibre composites have inferior fire structural resistance than E-glass composites No significant differences between the softening rates and strength losses for the basalt and glass The basalt composite heats up faster and reaches higher surface temperatures due to its higher emissivity This causes the composite to undergo softening and decomposition of the polymer matrix and fibres at a faster rate, hence resulting in inferior resistance compared to E-glass composites The adapted thermo-mechanical model accurately predicts the fire performance of both E-glass and basalt composites

16 Future Work Low emissivity coatings may improve fire resistance of basalt reinforced composites Basalt fibres with a different chemical composition may also result in superior fire resistance properties Strength loss mechanisms of basalt fibres at high temperatures need to be investigated Compression under fire and also post fire performance of basalt fibre composites need to be investigated.

17 Acknowledgements This work was undertaken as part of the Composites Fire Performance project of Cooperative Research Centre for Advanced Composite Structures Ltd (CRC-ACS), established and supported under the Australian Government's Cooperative Research Centres Program I would like to thank CRC-ACS for the provision of a PhD scholarship I would also like to thank Mr. Robert Ryan and Mr. Peter Tkatchyk from RMIT for their technical assistance through the course of this project Lastly, I would like to thank all my supervisors for their excellent guidance and support.

18 Thank you Questions?

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