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Construction and Building Materials 164 (2018) 589–602

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Construction and Building Materials


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Review

Application of chopped basalt fibers in reinforced mortar: A review


R. Ralegaonkar a,b,⇑, H. Gavali a, P. Aswath b, S. Abolmaali c
a
Department of Civil Engineering at VNIT, Nagpur, India
b
Material Science and Engineering Department, University of Texas, Arlington, United States
c
Department of Civil Engineering, University of Texas, Arlington, United States

h i g h l i g h t s

 Application of chopped basalt fibers for mortar design was reviewed extensively.
 Chopped basalt fibers were assessed for several properties.
 Mix design of fiber-reinforced mortar was analyzed from the studied literature.
 Physico-mechanical, durability and dynamic properties of mortars were reviewed.
 Application of suitable chopped basalt fiber proportion in mortar is examined.

a r t i c l e i n f o a b s t r a c t

Article history: Appropriate mortar design is one of the key challenges as connections between two structural elements
Received 15 June 2017 play a significant role in building construction. Appropriate design refers to the selection of suitable con-
Received in revised form 6 November 2017 stituents with their relative proportion for producing mortar of required workability, strength and dura-
Accepted 29 December 2017
bility in a cost effective manner. The mortar designed with suitable fiber reinforcement shall significantly
Available online 6 January 2018
help to enhance the fresh, mechanical, durability and dynamic properties. In view of the significance of
chopped basalt fibers (CBF) for mortar strengthening, the present study elaborates the application of CBF
Keywords:
for mortar design. The CBF manufacturing, the engineering properties and relevant advantages of its
Chopped basalt fibers (CBF)
Reinforced mortar design
application are elaborated in the study. The study is extended further with relevant literature indicating
Physico-mechanical the challenges of mix design of appropriate CBF reinforced mortar, various test methods and standards
Durability and dynamic properties used to evaluate its performance and possible applications in civil engineering. The improved perfor-
mance of the CBF reinforced mortar not only signifies its potential use for the application, but also is help-
ful to standardize the process of reinforced mortar design.
Ó 2018 Elsevier Ltd. All rights reserved.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
2. Chopped basalt fibers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
3. Mortar reinforced with chopped basalt fibers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
4. Discussions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
5. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

⇑ Corresponding author at: Department of Civil Engineering at VNIT, Nagpur, India.


E-mail addresses: rvralegaonkar@civ.vnit.ac.in (R. Ralegaonkar), aswath@exchange.uta.edu (P. Aswath), abolmaali@uta.edu (S. Abolmaali).

https://doi.org/10.1016/j.conbuildmat.2017.12.245
0950-0618/Ó 2018 Elsevier Ltd. All rights reserved.
590 R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602

1. Introduction

0.01–0.03
Conventional mortar in construction primarily contains binder
and fine aggregate in a specific proportion along with water.

S
Although, it is being used to bind two structural elements like brick
to brick or any end connection of beam and column, due to high

0.01–0.03
compressive strength, there is always a challenge for the applica-
tion due to its brittle behavior, easy to crack because of the shrink-

Cr
age of the materials, concentration of stress, low tensile strength
and weakness in impact resistance, etc. [1]. As a result, the struc-

0.01–0.04
tures begin to suffer degradation after a specific time. To develop
a sustainable engineering structure, a number of previous studies

Zr
have shown that the optimum percentage and type of fiber can
increase the workability, slump flow prevention, setting time,

0.02–0.04
fluidity [2–4] and mechanical properties like impact resistance,
splitting tensile and flexural strength [5,6] of mortar. The use of

Sr
fibers in the mortar can also significantly enhance the bond
strength between the old substrate and the repair materials, which

0.03–0.05
is one of the most important requirements for a successful repair
[1,7–10]. In addition, utilizing fibers in the mortar also substan-

Ba
tially improves the fracture toughness and flexural post cracking
behavior of the mixture. Likewise, the presence of fibers also lowers
width and number of cracks in the mortar due to bridging action

0.02–0.08
of them [11,12] and improves the durability properties of mortar,
like abrasion resistance and freeze thaw resistance [13,14].

B
The present study briefs the possible application of various
cement composites reinforced with chopped basalt fibers. The

0.05–0.1
paper further elaborates the origin and development of chopped
basalt fibers. The physico-mechanical property investigation of

P
chopped basalt fibers is also discussed. To enhance the properties
of chopped basalt fibers, several studies indicating the desired

0.1–0.2
treatments are studied further. The influence of these chopped

Mn
basalt fibers for various mix designs of several mortar mix is briefly
discussed along with relevant tests related to fresh, mechanical,
durability, functional and dynamic mortar properties including 0.4–0.6
specific civil engineering applications. The findings of the literature
Ti

study signify the potential use of chopped basalt fibers as better


reinforcement to cement mortar. It also helps to standardize the
0.1–1.6

design process of reinforced mortar.


Mg
1.4–1.8

2. Chopped basalt fibers


K

In order to improve the structural integrity, conventional mor-


tar needs to be reinforced with fibers. Although, various fibers such
2.1–2.3

as carbon, organic, glass, and synthetic may be applied for the


Na

strengthening of mortar, the present paper, reviews the application


of chopped basalt fibers as they are extracted from volcanic basalt
4.0–4.5

rock, and thus is natural and need lesser energy. Chopped basalt
fibers are manufactured by thermo-chemical process with the vol-
Ca
Element ratios of high temperature basalt rock ore [15].

canic basalt rock as the raw material (Tables 1 and 2). Basalt fibers
are manufactured by melting the washed acidic basalt rock (silica
6.0–6.6

>46% white) at around 1400 °C. The major examples of the con-
Fe

stituent mineral of considered an igneous (basalt) rock includes


plagioclase: Na (AlSi3O8)-Ca (Al2SiO8); pyroxene: XY2[(Si, Al)2O6]
(where X represents Ca, Mg, Fe2+ and Y represents Fe3+, Al, Ti);
8.7–9.3

and olivine: (Fe, Mg)2 SiO4 [15]. The rheological characteristics


Al

such as primarily surface tension, density, crystallizability, the vis-


cosity and behavior of basalt melts determine the elemental
23.5–28.8

chance of producing a continuous fiber from it [16]. The melted


material is forced through a platinum-rhodium bushing. The fibers
Si

are then extruded under hydrostatic pressure and are formed in a


certain range of temperature and viscosity. Corresponding to these
Wt (%)

phenomena, the melt’s viscosity at the outlet of the bushing and its
Table 1

temperature is considered as the lower limit of the operating vis-


cosity and the upper limit of the operating temperature range
R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602 591

respectively [17]. The larger fiberizability (proportion of viscosity

0.01–0.03
to surface tension) leads to much stable process. Using the cut
machines, the produced continuous basalt fibers are chopped fur-

SO
ther for desired composite application. The fiber dimensions are
generally in the significant range 10–20 mm in diameter and 3–

0.01–0.05
130 mm in length [18]. Application of chopped basalt fibers has
advantages as can be used in varying geometrical parameters (i.e.

Cr2O3
diameter and length) and in random orientation. The prior investi-
gations also reveal that the surface properties and morphology of
basalt fibers avoid any harmful or carcinogenic impacts and cause
0.02–0.05
no hazard to people [19,20]. Another significant advantage is man-
ZrO2

ufacturing process of basalt fiber consumes less energy and is


cheaper than glass or carbon fibers [21].
The various previously mentioned engineered basalt fiber prop-
0.02–0.06

erties could suitably be determined using experimentation [22,23].


Cerny et al. [22] determined the content of SiO2 by gravimetric
SrO

analysis, that of TiO2, Fe2O3 and P2O5 by UV–visible spectrometry,


FeO and Al2O3 content by volumetric analysis, and content of MnO,
0.03–0.07

MgO, Na2O, and K2O by atomic absorption spectrometry. In addi-


tion, the chemical composition of prototype basalt fibers was
BaO

obtained using electron micro analyses. Actual cross-sections of


the fiber tows were determined from microscopic observation of
0.1–0.3

the metallographically polished specimens with filaments


B2O3

mounted perpendicularly to the polished surface. The X-ray


diffraction (XRD) was used to detect structural changes, which
may occur during thermal treatment of the investigated fibers.
0.1–0.3
P2O5

The fibers were studied by the powder diffraction method. The


samples were powdered in ethyl alcohol and mounted onto silicon
diffraction-free sample holder. The data were obtained in the con-
0.1–0.3

tinuous scanning mode between 20 and 100° at 2 theta angles with


MnO

step 0.05° and counting time 250 s. The obtained data were ana-
lyzed using the High Score software.
As per thermal gravimetric analysis (Fig. 1) the basalt fiber’s
0.7–1.0

(B1) thermal stability (around 40 °C more) is better than glass fiber


TiO2

(G1) [24]. The crystallization behavior and presence of iron oxide


in the production of continues basalt fibers influence the heat tem-
0.20–2.5

perature stability [25,26]. The thermal stability and crystallization


MgO

of basalt fibers was examined with the effect of ZrO2 and 5–7% wt
for modifying the same was recommended by Lipatov et al. [27].
Kim [28,29] studied the option of using chopped basalt fiber to
1.8–2.1

form thermally stable composites with an epoxy based bicompo-


K2O

nent resin system (20%–50% of epoxy content with 10% of basalt


fiber) and benzoxazine monomer or bisphenol F type epoxy resin.
2.8–3.3

Tabi et al. [30] concentrated the attention on poly-lactic acid (PLA)


Na2O
Oxide equivalent composition ratios of high temperature basalt rock ore [15].

composites, which were strengthened with chopped silane basalt


fibers. Using injection and extrusion molding techniques the fiber
composites were prepared. Dynamic mechanical analysis, SEM
5.5–6.8

observations, melt flow index analysis, differential scanning


CaO

calorimetry, dimensional stability test and heat deflection temper-


ature analysis were carried out. Based on experimental data
FeO + Fe2O3

obtained from three-point bending, tensile and dynamic mechani-


8.0–9.7

cal tests it was observed that the treated chopped basalt fibers are
efficient in reinforcing PLA composites than natural fibers.
Egerhazi et al. [31] made the comparison of long and fiber rein-
forced composites with chopped basalt fiber (13 mm diameter (Ø),
16.1–19.2

10 mm Length (L)) reinforced PLA composites formed by using the


Al2O3

conventional dry mixing, extrusion and injection molding tech-


niques. In case of 20% weight reinforcement, the flexural, tensile
and the average impact strength increased by 1.26, 1.27 and 2.7
57.1–61.2

times, respectively, indicating better mechanical properties of the


long basalt fiber than short basalt fibers. Typical Physico-
SiO2

mechanical properties related to specific basalt fiber were specified


by Jian-Jun Table 3 [32].
Wt (%)

Reza Khalili et al. [33] prepared a matrix by mixing chopped


Table 2

basalt fiber with a polypropylene–clay mixture. It was observed


that the yield strength and modulus of elasticity have been signif-
592 R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602

Basalt Fiber Glass fiber


Fig. 1. X-ray diffraction patterns of the pristine and heat-treated to 650 and 750 °C basalt and glass fibers [24]. Note: cpx – clinopyroxene, sp – spinel.

Table 3
Physico-mechanical properties of basalt fiber [32].

Performance Density (g/cm3) Elongation (%) Modulus of elasticity (E) (GPa) Tensile strength (MPa)
Basalt Fiber 2.65 2.4–3.0 95–115 3000–4500

icantly improved due to this approach. Due to ductility and ease of due to the presence of sulfate ions. The application of thick coat-
availability, basalt has been used for reinforcing the matrix. Basalt ings of zirconium dioxide (ZrO2) and titanium dioxide (TiO2) over
has higher tensile strength as well as elongation at break. It can the basalt fibers could improve its durability when exposed to var-
enhance the environmental sustainability and impact resistance. ious chemicals like Ca(OH)2 and NaOH. Rather than alkaline resis-
Botev et al. [34] studied the tensile strength properties of chopped tance, the other authors demonstrated higher confrontation of the
basalt fibers treated with the polypropylene-g-maleic anhydride. It basalt fibers in the acidic environment [40,41]. Corrosion of basalt
was shown that the bonding between basalt fiber and the matrix fibers can be controlled using alkaline solution, the ZrO2 coating
increases due to hybridization that ultimately improves the [42] on the surface of the fiber. Furthermore, the coated (alkaline
mechanical properties [35,36]. solution) and uncoated basalt fibers were incorporated in a cement
During the chemical durability study of basalt fibers, it was matrix for reinforcements. The phase composition, the morphology
observed that, it has poor acid resistance, but better alkali attack of the fiber was studied by using different analytical methods
resistance [37]. After corrosion treatments, the mechanical behav- before exposure to alkaline media as well as after exposure. The
ior of basalt fibers found to be better than glass fibers [38]. The corrosion behavior of TiO2 and ZrO2 coated basalt fiber in Ca
degradation in E-glass fibers was seen to be extreme. Myadara- (OH)2 and NaOH solutions was also examined [43]. It was shown
boina et al. [39] worked on the durability of basalt fiber in a variety that the oxides coating retards corrosion and concluded that rather
of chemical solutions (sodium hydroxide, sodium chloride, sodium than TiO2, ZrO2 is more effective to improve the corrosion resis-
sulfate and combinations of the three). The effect on durability was tance of basalt fibers.
measured by calculating the weight loss after soaking fibers in dif- For the composite products, rather than glass, the basalt fibers
ferent solutions over a period of 62 days. The condition of the fibers are a good substitute. The density of basalt fiber is more than glass
was also examined by scanning electron microscopy (SEM, Fig. 2). fiber (2.80 versus 2.56 g/cub. cm), but the mechanical properties of
It was concluded that neither chloride ions nor sulfate ions alone it are better as compared to that of glass fibers. Moreover, basalt
have any deleterious effect on the basalt fibers. However, in an fiber has the properties such as high thermal stability, better flex-
alkaline environment equivalent to a pH 12.5, severe degradation ibility and stability in alkaline and acidic media [38,40]. As com-
was observed. Degradation increased in an alkaline environment pared to glass fibers, the elastic modulus (E) of basalt fiber is

Fig. 2. SEM images of BF after 62 days treatment with (a) 3% NaCl, (b) 10% Na2SO4, (c) 1 M NaOH, (d) 1 M NaOH + 3% NaCl, (e) 1 M NaOH + 10% Na2SO4, (f) 1 M NaOH + 10%
Na2SO4 + 3%NaCl.
R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602 593

(1.06 times) more [44]. The manufacturing process of basalt fiber thereby increasing the efficiency of the particulate reinforcement
consumes less energy, desires no additives, and is cheaper than in the cement. The results of the X-ray diffraction data confirm
the manufacturing process of glass fiber process [45]. the electron microscopy data. They also point to the growth rate
of tumors gel (calcium hydro silicate type C-S-H (I and II)). Estab-
lished features of the cement-sand mortar structure, which was
3. Mortar reinforced with chopped basalt fibers modified basalt microfiber reinforcement, allowed to explain the
increase in physico-mechanical properties of the dispersion-
Although basalt fibers have enough engineering properties, its reinforced mortar.
association with cement mortar and reduction in cross section dur- Quattrociocchi et al. [50] investigated the physico-mechanical
ing cement hydration is a primary concern. Stupishin et al. [46] and micro-structural properties of mortars reinforced with fibers.
examined the level of basalt fiber destruction in a cement medium Two kinds of basalt fibers were used for designing different mor-
using an optic and electronic microscope concluded that the dam- tars. The hydraulic binders chosen for the mortars were Portland
age of the structure was nominal. Chatterji et al. patented the limestone, cement (complying EN 197-1: 2011) [51], labeled as
application of basalt fiber for reinforced mortar design [47]. He ‘‘PIIa” and ‘‘PIIb” indicated as cement for structural and renewal
suggested the use of different types and blends of cement (Ordi- applications respectively. The ratio of binder to aggregate was cho-
nary Portland cement, gypsum cement, pozzolana cement, slag sen as 1:2 by weight. The fine aggregate used for the study was the
cement, silica cement, high alumina content cement and combina- siliceous feldspathic sand having a particle size range between 180
tions thereof), with sand, water, foam, super plasticizer, etc. Pre- and 600 lm. The basalt fibers (6.35 mm length, and diameter in
ferred basalt fibers were having a diameter and length in the the range of 10–19 lm) added to the matrix was in the proportions
range from about 9–13 mm, and 3–6 mm respectively. Fiber pro- of 1%, 3% and 6% by weight. In order to determine the best working
portion within the mortar in the range from about 0.1–1.5% wt of condition, the different mixing parameters were used to assess the
the cement was recommended. Palou et al. (2013) performed dif- workability and dispersion of fibers. For each composition three
ferential thermal analysis (DTA) and thermogravimetry (TG) anal- mortar specimens were prepared as per the standards UNI EN
ysis on fiber-reinforced cement composites [48]. Experimentation 1015-11: 2007 [52]. The ratio of binder to aggregate was kept con-
was done by using cement 42.5, high alumina cement 70, silica stant, assuming the fibers as a part of the aggregate. The water to
fumes, blast furnace slag in proportions by weight of 54:23:23:0 binder ratio was also maintained in order to ensure the best work-
& 54:23:14:9, and basalt fibers (0.01%) along with water. The spec- ability. The mechanical properties and water absorption of the
imens were steam cured at 100 °C for 30 min. The hardened spec- mortars were evaluated as per UNI EN 1015-11: 2007 [52] and
imens were demolded immediately after the pre-curing procedure. UNI 1015-18: 2004 [53] respectively. The dispersion of relatively
Later, the specimens were kept in an autoclave for durations of 1, 3 large fibers was found more difficult with increasing content in
and 7 days with incremental pressure of 0.3 MPa–2.0 MPa. Further, the mixture, in turn reduced workability of the mix. Thus, the addi-
these samples were immersed in the temperate water at a decided tion of water demand for the mix subsequently resulted in a poten-
time of autoclaving. Mechanical properties were tested after the tial increase of porosity. Thus, it was concluded that beyond a
curing periods of 1, 3 and 7 days. A few fragments were used for threshold the addition of fibers will not contribute to toughen
the SEM test (for analysis of microstructure) after drying them in the material. The optimum fiber content for the performed study
a vacuum oven at 100 °C to study the morphology of hydrated was reported as 1 wt%.
product. The Thermogravimetry analysis was carried out on the Yun-Wang et al. [54] evaluated the influence of fluidity proper-
dried sample having a diameter and weight not more than 10 ties of (basalt) fiber reinforced blended cement composite. For a
mm and 2 g respectively. The pore structure parameters of the mixing study of the basalt fiber in the mortar, the fluidity proper-
composite were estimated using Mercury intrusion porosimeter ties were evaluated for the six-replacement ratios of fly ash (10, 20,
(MIP). Microstructure analysis, thermal analysis and MIP of fiber- 30, 40, 50 and 60% by mass), five levels of super plasticizer (1.3, 1.5,
reinforced binder composites evaluated the phases that occurred 1.7, 1.9 and 2.1%) and for the five levels of liquid urethane (0.2, 0.4,
during adopted curing. The porosities by crystallization pressure 0.6, 0.8 and 1.0%). Also, the fluidity evaluation was carried out
could be enhanced in hardened pastes, which reduce compression using high volume fly ash (50 percentage by mass) for three basalt
strength. At an earlier period of hydrothermal curing, due to the fiber lengths (6, 20 and 30 mm). It was resulted that the viscosity
chemical process, the formation of hydrated products like C–S–H, agent is much better than super plasticizer in improving the fluid-
C3AH6 and AH3 occurs preferentially at low pressure. In the later ity for fiber dispersion.
curing period under higher pressure, the secondary reaction occurs Dong et al. [55] demonstrated that drying shrinkage can be
from C–S–H and AH3, which forms C2ASH8. The partial thermal reduced for the cement mortar by reinforcing it with the basalt
decomposition of C3AH6 into C3AH1.5 at high pressure and at later fibers. Fiber reinforcement not only increases the toughness of
curing period occurs preferentially causing the carbonation of the the mortar, but also increases the resistance to shock and plastic
sample. C3AH6 was partially carbonated, while C3AH1.5 completely shrinkage cracking. Besides, the basalt fiber reinforced mortars
carbonated. The reaction between C-S-H and AH3 at increasing were observed to have more early compression and flexural
pressure and time of curing forms newer stage. Whereas, during strengths than plain mortar, but results in a lesser strength at
the early stage AH3 converted C3AH6 through reaction with CA. 28-days age. Vyacheslava et al. [56] targeted the development of
As the binder solidifies crystallization, pressure is developed that masonry mortars with hollow ceramic microspheres and reinforc-
leads to other physico-chemical processes. Gurieva and Belova ing fibers with improved properties. The effect of various types of
(2016) studied the mortar stone structure by comparing the sam- fibers on the properties of mortar such as the average density,
ples of the basalt fiber reinforced solution and the solution without compressive strength and tensile bending strength were studied.
reinforcement [49]. Investigation of the slurry microstructure A binder material CEM II/A-W 42.50H (Holcim) Portland cement
revealed that administration of a modified microfiber basaltic com- (9.80% granulated slag added) was used for the experimental work.
position reduced the size, pores, cracks and defects. This was Lightweight filler, hollow ceramic microspheres with fractions of
because of the presence of a carbon nano-modifier, the acerous cal- 10–500 lm was used. The water plummeting mediator, melamine
cium silicate neoplasms that were formed fills the voids in the sulfonate in powdered form was used. To increase the mortar’s
stone structure and helps to seal it. The interface reinforcing micro- adhesion strength as well as its tensile and compressive strength,
fibers and a cement-sand matrix was characterized by a tight grip, the redispersible powder of a copolymer of vinyl acetate and ethy-
594 R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602

lene Vinnapas 8034H was added into the mortar. The anionic high by processing flexural test curves. The results obtained confirm
molecular surfactant was used to design lighter density mortar. that there was a considerable improvement in toughness of rein-
This study used the basalt fibers with the fiber length of 6 mm forced mortars. The best results were obtained for the addition of
and 12 mm. They were varied in the proportions from 0.2 to 1.2% 2% glass fiber, both for the maximum strength (around 2.41 MPa)
by mass of mortar mix at an interval of 0.2%. The basalt fibers with and the toughness (0.08 MPa). As examined the designed rein-
fiber length of 12 mm with the dosage of 1% by mass of the binder forced mortars indicated a compatibility with existing structures
mass showed the greatest increase in strength as compared with and concluded it to be a material for repairing the structures.
the reference composition. For the mortar reinforced with the Li et al. (2012) presented the use of cement mortar containing
basalt fibers, the compressive strength increased by 47% basalt fiber as repairing transition layer to improve the crack resis-
and the tensile bending strength (Fig. 8) increased by 55% as com- tance performance between old and new concrete repaired struc-
pared with the reference composition. The microstructure analysis ture [66]. Basalt fiber with short cut, random fibers having an
of the masonry mortar with basalt fibers showed that the destruc- average length, filament diameter, tensile strength, modulus of
tion of the fibers occurred in one cross-section with the cement elasticity and density as 5 mm, 9 lm, 2322 MP, 129 GPa and
stone. Fibers were not visible on the fractured surface of the sam- 2.80 g/cm3 respectively were used in cement mortar in proportion
ple, which depicts that the strength of adhesion of basalt fibers of 0.6 wt%. The basalt fiber-defoaming agent, i.e. dispersant
with the cement stone of the fibers was more than the tensile (methylcellulose) was dissolved in water and stirred until the
strength. fibers were mixed uniformly. After that, it was mixed with cement,
Jiang et al. (2016) studied the behavior of mortar with respect to silica fume, sand and water. Then, the super plasticizer early
the addition of basalt fibers for repair applications [57]. The various strength agent was added and stirred for 5 min. Experimentally,
properties of reinforced mortar were investigated as the fresh, it was observed that 30% of the maximum crack width could be
mechanical and durability properties. Fresh properties such as controlled. The deflection was also under control. It was inferred
workability (EN 1015-3 [58]), slump flow prevention, setting time that, the designed product has practical significance for the struc-
(EN 480-2 [59]) was found. The mechanical like flexural and com- tural repairs.
pressive strength (EN 1015-11 [60], bond strength- (DL/T5150- J. Ma et al. (2013) studied the performance of basalt fiber rein-
2001 [61]) and the durability like drying shrinkage (ASTM forced cementitious composites [67]. The matrix ratio used in this
C1148-92 a [62]), abrasion resistance (ASTM C1138/97 [63]), water experiment was of cement (OPC 32.5 MPa):sand (natural) = 1:3
permeability (DL/T5150-2001), freeze-thaw resistance (ASTM and 0.5 w/c ratio. The basalt fiber (diameter – 18 mm, length –
C666 [64]) was investigated. The other properties of basalt fibers 15 mm, density – 2650 kg/m3, tensile strength = 4150 MPa, E = 9
such as length of 20 mm, density – 2.7 g/cm3, modulus of elasticity 3 GPa, elongation rate = 3.1%) were added in the mix in proportion
93–110 GPa, diameter – 13 mm, tensile strength – 624 MPa, elonga- 1.0–4.0 kg/m3. In this experiment, the super-plasticizer (liquid and
tion at break – 3.1%, water absorption <0.5 was obtained. The rein- granular) content was 3, 6 and 15 g for one group of specimen. It
forced mortar (BFRM-Ordinary Portland cement 45.5 Grade (680 was observed that with the increase in fiber content the fluidity
kg/m3) as available in China, Natural river sand (1361.6 kg/m3), of reinforced mortar reduced by 18% (Fig. 4). This substantial
water 367.3 kg/m3 and super plasticizer-sulfonated naphthalene- reduction in fluidity is due to the formation of spatial network
formaldehyde with 2%–4% sodium sulfate (0.2%) with various fiber structure due to random distribution of the mixed chopped fibers
contents of 0.6, 1.6 and 2.6 kg/m3 were used for the test. The with mortar. At the first elastic stage the basalt fibers do not work
obtained results depict that incorporation of basalt fiber in the and the reinforced mortar matrix bears the loads. Second stage
mortar reduced the early workability but increased slump loss rate. indicated more cracks propagating and expanding in a steady state.
The bond strength of BFRM was increased by 10.60%–21.40% com- In the final state, the specimen finally breaks after development of
pared to the controlled mix and FRM showed lesser drying shrink- cracks. With an increase in proportion of basalt fiber, there was a
age, better abrasion resistance, freeze-thaw resistance and water decrease in compressive strength of reinforced cement matrix. As
impermeability. The abrasion resistance strength of controlled bigger specimens have weaker areas of interfaces than the small
mortar was enhanced by around 39% due to BFRM with maximum ones, the cubic compressive strength was found to be more than
fiber content. However, there was no considerable difference in the the axial strength by 0.775 times. There was a prominent improve-
compressive strength. Therefore, it was concluded that due to bet- ment of the toughness of reinforced mortar with 2% of basalt fibers.
ter abrasion resistance and bond strength, BFRM can be utilized for Vasconcelos et al. studied the performance of composite mate-
structural repairs. rial reinforced with different fibers [68]. Two types of textile fibers
To design binding materials for restoration of buildings, the (Length = 10 mm) were chosen, namely natural fibers (banana Ø =
microstructure and physico-mechanical investigations of lime- 204.64 m, tenacity = 0.31; and sisal Ø = 168.76 m, tenacity = 0.17)
based fiber reinforced hydraulic mortars were studied [65]. The and synthetic fibers (glass Ø = 13 m, tenacity = 0.61; and basalt-Ø
two combinations of mortar mixes were developed using a com- = 10 m, tenacity = 0.66). The raw materials used to prepare the com-
mercially available hydraulic lime as a binder (SO3  63% and free posite material were gypsum as the binder and the granulated cork
CaO  9%) and sand as a siliceous fine aggregate with the addition as the aggregate. To have a workable material of approximately
of fibers into the mortars. There were two types of fibers namely 150 mm, corresponding to a flow table [69], 80% and 0.1% of the
(a) basalt fiber (SiO2/Al2O3 – 5.2, strand-chopped, treat – Nil, length gypsum mass of water and citric acid was obtained respectively.
– 4–5 mm, diameter – 8–10 mm, modulus of elasticity – 84 GPa) To prepare the composite material, the raw materials used were
and (b) glass fiber (SiO2/Al2O3 – 6.25, strand-chopped, treat- the gypsum and the granulated cork, which was fixed at 5% of
sizing, length – 10 mm, diameter – 13 mm, modulus of elasticity the mass of gypsum. To have a workable material of approximately
– 75 GPa). A reference mortar with no latex and fibers was pre- 150 mm, corresponding to a flow table [69], the obtained percent-
pared and tested. Mortar mixtures (lime/sand – 1:3, water/solid ages of the gypsum mass of water and the gypsum mass of citric
– 0.18–0.22, fibers – 1–2%, latex – 1.5%) were formed. The water acid was 80% and 0.1% respectively. Experimentally the elastic
was added to obtain an average consistency and a good workabil- modulus, compressive strength and fracture energy were deter-
ity. For improving the workability and the placement of the mor- mined. The compressive behavior of both reinforced and unrein-
tars, polymeric latex was also added. The designed mortar forced composite materials was observed to be the same.
samples were cured for 28 days. Three-point flexural test was car- Although, a lower percentage of synthetic fibers were used than
ried out. Young’s modulus and flexural toughness were estimated the natural fibers, it resulted in better mechanical properties as
R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602 595

compared to natural fibers. The natural banana fibers performed was effective in imparting toughness (flexural strength) to hydrau-
better in terms of compressive and flexural strength, but the basalt lic lime-based mortars. However, reinforced mortar resulted in
fibers and synthetic glass fibers proved better for ductile behavior. higher compressive strength as compared to unreinforced mortar.
Basalt fiber was added to cement mortar in different proportion Lipatov et al. [73] studied basalt fibers and glasses having a con-
as 0.5, 1 and 1.5% by weight of cement to evaluate the mechanical tent of zirconia from 0 to 7 wt% range, obtained using ZrSiO4 as a
performance of brick masonry [70]. 53 grade ordinary Portland zirconium source. Fibers, sand and cement were mixed in propor-
cement, the natural sand and basalt fiber (Diameter – 0.016 mm, tions by volume as 0.5, 1500 kg/m3 and 500 kg/m3 respectively
length – 12.7 mm, tensile strength – 4150 MPa) were used with 0.6 water to cement ratio. It was observed that basalt fiber
(cement:sand: 1:6). The optimum mix obtained for reinforced with 5.7% wt ZrO2 had the best alkali resistance properties by
cement mortar was reported as 1% of basalt fiber with increase determining loss of tensile strength and weight after refluxing in
in the compressive strength and Young’s modulus as 1.82 and alkali solution. The weight loss was found equivalent to the com-
1.61 times, respectively. mercially available AR-glass fiber with 18.8% wt ZrO2. The AR-
Choi and Lee [71] studied the reinforced mortar for structural glass fiber after alkali treatment and Zirconia doped basalt fiber
properties viz., bonding and tensile strength. The mortar matrix resulted tensile strength as 1.4 GPa and 1.2 GPa respectively.
was prepared using alkali-activated slag as a binder, fine silica sand Girgin and Yildirim [74] performed the experimental compara-
(100 mm) as an aggregate, super plasticizer, anti foamer and water tive study for fiber reinforced mortar designs for spray-up and pre-
in 1:0.4:0.01:0.0002:0.34 proportion by weight. Three types of mix techniques. The chopped basalt fibers and glass fibers (L – 24
fibers, viz. basalt, polyvinyl alcohol (PVA) and polyethylene fibers mm each; Ø – 20 mm each; density – 2.8 g/cm3, 2.68 g/cm3; modu-
(Ø – 12 mm, 40 mm, 12 mm; L – 12 mm each; density – 2.65 g/ lus of elasticity – 89 GPa, 72 GPa; tensile strength – 4840 MPa,
cm3, 1.3 g/cm3, 0.97 g/cm3; tensile strength – 1773 MPa, 1202 3500 MPa and elongation – 3.15%, 4.5% respectively) were incorpo-
MPa, 2757 MPa; elastic modulus – 89 GPa, 41 GPa, 110 GPa respec- rated by 2% mix volume for the workability in premix design. CEM
tively) were used for the experiment. A single fiber pullout test II/B-L 42.5R cement (SiO2: 17.5%, CaO: 63.5%, Al2O3: 3.3%, Blaine
(Fig. 3) was performed to assess the interface properties. To ensure fineness 5840 cm2/g), fine silica sand 1300–150 lm in diameter,
complete debonding, the fiber embedment length was set at 4% acrylic copolymer and 1.3% polycarboxylate-based high range
approximately 1.0 mm. The results inferred good chemical bonding water reducer was used in the mixture with 0.33 water to cement
between the fiber and mortar matrix. The frictional bond and slip- ratio (w/c). In order to evaluate the brittle behavior in the samples
hardening coefficient of the basalt fiber was 3% and 24.4% higher with basalt fibers, the heat-rain test was performed. The four-point
than the PVA fiber respectively. It was observed that the tensile bending test resulted in reduction of strain capacity of basalt fibers
strength of basalt fiber decreased with an increase in the inclina- for the period of curing following 7 days aging. SEM observations
tion angle of fiber. The strength reduction coefficients of the basalt show that the surfaces of basalt as well as glass fibers were smooth
fiber were higher by three times and nine times than those of the after 50-cycles and did not show any sign of degradation on alka-
PE fiber and PVA fiber respectively. The brittle behavior of basalt line attack. The researcher mentioned the need for further research
fiber could be a limitation in terms of the fiber bridging capacity to improve the fiber-matrix interface for controlling the strain
as the basalt fiber reinforcing system had a higher cracking reduction. Using mineral additives the bond in the fiber-matrix
strength till cracking, after which it showed softening behavior. interface could be amended that can help mitigating brittleness
Santarelli et al. [72] studied basalt fiber reinforced hydraulic behavior caused by calcium hydroxide deposition.
lime-based mortars for the property and microstructure investiga- Orlovet et al. [75] studied the basalt fiber reinforced cement
tion. Different combinations consisting of three distinct types of based materials. The tensile strength of basalt fiber reinforced mor-
basalt fibers and aggregates were studied. The first mortar mix tar samples was studied with recourse to of different diameters
was prepared using commercially available natural hydraulic lime and dosages of fibers. For the experimentation a composition of
(NHL 3.5) and siliceous feldspathic aggregate (sand). The second cement (BFC 300) and sand in the ratio of 1:3 and w/c as 0.56
was prepared using dry premix of NHL 3.5 and inert aggregates. was used. The diameters of fiber used were 15, 20, 25 mm having
The third type of matrix was based on a dry premix of NHL 3.5 length 12 mm. The two-factor (X and Y) experiment was planned
and inert aggregates with the further addition of crushed tiles to assess the strength of basalt fiber reinforced mortar. X and Y fac-
and bricks. Furthermore, three types of basalt fibers viz., milled tor represented the diameter as 15, 20 and 25 mm and dosage of
basalt fibers (diameter – 10–17 mm), continuous filament roving fiber range values of 0.7, 1.1 and 1.5 kg/m3 of mortar mix respec-
(chopped to a 6.35 mm length, filament 10–19 mm diameter and tively. The results showed that basalt fiber increased the flexural
milled fibers were added. The binder to aggregate ratio for NHL strength by more than 1.5 times. The study concluded that basalt
specimens was fixed as 1:1. Basalt fibers were added at 3% and fiber could suitably be used for cement based materials having
10%. Reinforcement of fiber in the chopped form of 6.35 mm length optimal micro-reinforcement (0.7–1.1 kg/m3 and 20–25 mm diam-
eter range).
Ghazy et al. [76] studied nano-modified reinforced mortar
(NFRM) containing steel, basalt and basalt polypropylene hybrid
fibers (Length = 13 mm, 13 mm, 29 mm; diameter = 0.2 mm, 0.14
 0.80 mm, 0.66  1.34 mm; aspect ratio = 66.5, 16.6, 21.6; speci-
fic gravity = 7.85, 2.60, 0.92; tensile strength = 500 MPa, 3100
MPa, 550 MPa; young’s modulus = 210 MPa, 73 MPa, 8 MPa
respectively), with 1% in proportion by volume and investigated
its mechanical and durability properties [77–82]. Total mortar
mixtures prepared with OPC and slag (confirms to CAN/CSA-
A3001 were eight [83] standard). A commercial nano-silica sol
(Ns) (15% content of SiO2 solid particles) having the mean particle
size, viscosity, specific surface, density and pH as 5 gm, 8 cP, 80
m2/g, 1.1 g/cc and 9.5 respectively, dispersed in water solution.
The dispersing agent was added as 2% by mass of the total binder
Fig. 3. Single fiber pullout curve. in all mixtures. For all mixtures, the proportion of total binding
596 R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602

materials (OPC or ternary binder: OPC, GGBS and nano-silica – 700 strength results indicated that the concentrations of sodium
kg/m3) and water-to-binder ratio (w/b – 0.3) was kept constant. hydroxide needs to be controlled to 5.5 mol/L. The basalt fibers
Fine aggregate with a gradation of 0–600 mm and fineness modulus and E-glass indicated same deterioration (weight loss and loss of
of 2.9 was used in mortar preparation. The absorption and specific strength) under the alkali immersion than the carbon fibers and
gravity of sand were 1.5% and 2.6 respectively. The fibers were AR-glass indicating poor durability.
added at a proportion of 1% by volume to the mixtures. The In order to design the new cement based microwave-absorbing
water-reducing admixture (HRWRA) based on polycarboxylic acid material the aim was to combine the concept of space wave impe-
[84] was added in the range of 2–4% by mass of the binder to retain dance matching with space electromagnetic wave propagation
a comparable target flow [85]. After 3 days, the increase in com- principle [89]. Considered materials for the experimentation were
pressive strength of NFRM was resulted as 168% and 108% more Portland cement (42.5 grade), perlite (average particle size – 0.8–
with and without slag respectively. Between 7 and 56 days, the 1.5 mm, bulk density – 88 kg/m3, ball rate – 80%, porosity by closed
development of compressive strength for the NFRM having steel, pore – 95%, water absorption – 60%), graphite having average vol-
basalt and hybrid fibers with slag was significantly increased by ume size of 38–40 lm and continuous basalt fiber having 9–22 lm
82%, 133% and 140% respectively. At the age of 14 days, marginal diameter and length of 15 mm. Cement:Perlite:Graphite:Basalt
increase in flexural strength was observed as compared to control Fiber: 33:60:5:2 with 0.35 water/binder ratio was the considered
mix. Compared with control specimens (C-S and CG-BP), the mix proportion by volume. By adopting reflection methods in the
increase in flexural strength for the NFRM with and without slag microwave chamber the sample cubes were tested for microwave
was resulted as 7% and 10% respectively. An increase in flexural absorbing property, reflection attenuation R (Reflectivity) as R = 20
strength of the NFRM samples, including basalt fibers was maxi- log|(N 1)/(N + 1)|, where N is normalized input wave impedance.
mum than that of the samples containing steel and hybrid fibers. A cement based microwave absorbing material was characterized
The load carrying capacity was determined for the basalt fibers with better microwave absorbing properties having the minimum
prisms (with or without polypropylene). Due to the high tensile reflectivity as 11.8 dB with better compressive strength (16.9
capacity of basalt fibers, it gained stiffness with a reduction in MPa) and bending strength (2.27 MPa). Basalt fibers were used as
the prisms’ load carrying capacity. Because of the fiber’s short intensive and toughening constituents of microwave absorbing
length and small aspect ratio, the ultimate fiber reinforced speci- material because that holds higher specific strength properties
men failed at lesser deflection value. Related to mortar mix with than glass and metal fibers which results in higher thermo-
OPC, the shrinkage of the NFRM with slag & steel, basalt and hybrid chemical and alkaline medium exposure stability. As the basalt
fibers was reduced by 23%, 25% and 26% respectively. The addition fiber contains less amounts of metal oxides (Fe2O3, TiO2) that is
of fibers to mortar or concrete had also reported in enhancing the characterized with magnetic and dielectric loss property which
permeability. It was concluded that the strength of the reinforced in turn increases electromagnetic wave losses when used in
NFRM with the addition of nano-silica helped to gain early strength cement network.
and improved the salt-frost scaling resistance as well. As compared Asprone et al. [90,91] investigated the natural hydraulic mortar
to OPC based specimens, the cumulative shrinkage of the NFRM reinforced with basalt fibers for dynamic performance. The studied
specimens containing slag and different types of fibers was signif- mortar was composed of a natural hydraulic lime (NHL 3.5), sand
icantly decreased. The enhanced mechanical and durability perfor- and chopped strand fibers (Ø – 8–10 mm, L – 4–5 mm, density –
mance of the NFRM along with fibers and nano-silica indicates the 2.75 g/cm3, Young’s modulus – 84 GPa, tensile strength – 4.84
promising application of repair and rehabilitation of concrete GPa and failure elongation – 3.15%). Polymeric latex (Mapei) was
structures. added in the proportion of 1.5% (w/w) to improve the workability
Kencanawati and Shigeishi [86] studied the fracture behavior of of the fiber-reinforced mortars. To attain the similar consistency
high strength basalt fiber reinforced mortar subjected to compres- (flow value 140 ± 10 mm) the water content for each of the mor-
sion. Basalt fibers were used in the mortar mixes in different quan- tars was varied accordingly. Using 1:3 (w/w) a binder to aggregate
tity and length (3–9 mm). The high strength mortar powder was ratio, basalt fibers in two weight percentages 1% and 2% were used.
mixed with water, which was produced for shotcrete material. To study the morphology of the mortar reinforced with basalt
The composition was the cement (type I), sand (maximum diame- fibers mercury intrusion porosimetry and SEM was performed.
ter – 5 mm) and micro-silica (8% by weight of total cement). The Using a hydro-pneumatic machine and a modified Hopkinson bar
proportion was varied from 1, 3 and 5% by weight. Based on work- apparatus, the dynamic tensile failure tests were carried out for
ability, water-cement ratio was ranged from 0.4 to 0.7. The prism high and medium strain-rates. The ratio of the dynamic values over
specimens (40 mm  40 mm  160 mm) were tested for compres- the quasi-static tensile strength defines the dynamic increase fac-
sive and flexural strength [87] at various ages of curing (1–91 tor and signifies the peak strength. At a high strain rate (100/s), the
days). After exceeding the peak load in the samples the cracks were dynamic increase factor was increased up to 5 (Fig. 14). Dynamic
nucleated. Results indicated that there is no substantial effect fracture energy was also raised with the similar trend of the
observed in the behavior of the AE hit generation with variation strength. The experienced strain-rate sensitivity reported by Chan
in basalt fiber reinforced mortar. The First stage was before the and Bindiganavile [93] was more than the experienced. However,
peak load indicating no AE hit and no nucleation of crack. The sec- with reference to the other fiber reinforced cementitious mortars
ond stage was during peak load, where the cracks were detected (i.e. steel or inorganic fiber [93,94]), the presented study indicated
considerably shown by significant AE hits, and the third stage indi- higher strain-rate sensitivity.
cated the peak load had exceeded indicating the ductile behavior of The dynamic compressive strength of the mortars with basalt
the material. and glass fibers was evaluated and compared experimentally by
Funke et al. [88] focused on the durability and performance of Kruszka et al. [95]. Basalt fibers and glass fibers with the same size
the fibers reinforced alkali-activated binder matrix. At ambient (Ø – 14 mm, L – 12 mm) were added 3–5% by weight. Static and
temperature, the aqueous sodium silicate solution (SiO2/Na2O dynamic properties were studied for all specimens. It was con-
molar ratio: 2.1) and sodium hydroxide (2–10 mol/L) were mixed cluded that there was a substantial drop of fracture stress in a
as an alkali activation process for fly ash and granulated slag. dynamic range with 5% for basalt fiber, whereas no considerable
Basalt, carbon, alkali-resistant glass (AR-glass) and E-glass fibers effect due to addition of glass fiber. For both the loading (static
(0.5% by volume) were used for the study. The bending tensile and dynamic) conditions, based on the indicated fractured stress
R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602 597

the optimal content of the basalt fiber reinforcement was resulted 4. Discussions
as 3%. Further increase of the fiber proportion gave a drop of the
fracture stress. Basalt fiber was proposed as better reinforcement to the cement
Fenu et al. [96] also studied the dynamic behavior of reinforced matrices due to its valuable properties such as better modulus,
cement based mortars having both basalt and glass fibers of the high strength, higher strain to failure, better stability and
same length and diameter (L – 12 mm, diameter – 14 mm) [96]. thermo-chemical resistance. It is easy to process, non-toxic, natu-
The reference cement mortar was prepared using Portland cement ral, eco-friendly and cost effective material. With recourse to the
(CEM I, 52.5 R – 635 kg/m3) and sand (1270 kg/m3) with water to other competitive glass fibers the properties of basalt fibers are
cement ratio and binder to aggregate ratio as 0.5 each. The fiber better and are economical. It was observed that the addition of
reinforced specimens were prepared by the addition of a given basalt fibers increased flexural strength, toughness as well as the
fiber content (in weight) of glass (specific gravity – 2.6 g/cm3, mod- fracture energy of cement matrix composites [17,99]. As the basalt
ulus of elasticity – 72 kN/mm2, tensile strength = 1000–1700 N/m fibers indicated no chemical reactions when in contact with other
m2, softening point – 860 °C) in proportion of 3% by weight and chemicals, they proved to be an ecological friendly material
basalt fibers (softening point – 1050 °C, specific gravity – 2.6 g/ [100,101]. However, at the earlier stages of hardening, it should
cm3, tensile strength = 3800–4000 N/mm2, elastic modulus – 89– be noted that the high alkalinity of cement matrix causes the cor-
93 kN/mm2) in 5% by weight to the cementitious mixture. With rosion of basalt fibers. In turn, the degradation of the mechanical
reference to unreinforced mortar, the fracture energy was properties of basalt fibers and its reinforced cementitious products
increased by 4.6 and 7.2 times, respectively, by the addition of was a serious concern. One of the approaches to develop the alkali
3% and 5% glass fibers. The post-peak behavior was improved by resistance of the fibers in cement matrices include modification of
the addition of 3% basalt fibers. However, with respect to the refer- the fiber composition by adding an alkali-resistant component, e.g.
ence mortar the total energy resulted practically unchanged ZrO2 to the raw material, application of alkali-resistant coatings on
(slightly) due to the high peak stress. The addition of 5% basalt the fibers and modification of cement matrices through special
fibers resulted an increase in fracture energy by 2.2 times with additives [73]. In this case, an alkali-resistant coating is applied
respect to the reference mortar, indicating considerable improve- directly to the surface of reinforcing basalt fiber exposed to aggres-
ment in the post-peak behavior of the mortar. Under the dynamic sive media, which appears to be the most sensitive area, owing to
conditions at high strain rate, glass fibers performed better than this can limit the access of aggressive alkaline medium to the rein-
the basalt fibers. forcement, and hence, inhibits dissolution and destruction of the
Lai et al. [97] studied the dynamic properties of ultra-high per- fiber. Many materials can serve as alkali barrier coatings for basalt
formance fiber reinforced cement composites (UPFRC) subjected to fiber due to this advantageous approach accordingly most suitable
repeated impacts. The cement (PII 52.5) and sand (particle size – material can be selected.
2.5 mm and fineness modulus – 2.6) were blended in a mixer for Basalt is an alternative raw material to be converted as fibers
3 min. The water and super plasticizer (polycarboxylate based with because of its large-scale availability, relatively homogeneous
more than 40% water-reducing ratio) were mixed together fol- chemical structure, freedom from impurities and certainly, ability
lowed by the addition of a solution into the mix and mixed for to form fibers in the molten state. Basalt rock fibers are non-
additional 6 min. Three types of fibers were added in the mix con- combustible and have no toxic reaction with air or water. Further-
taining (1%) PVA fibers, (3–4%) steel fibers and (1%) basalt fibers. By more, basalt fibers have more chemical stability [41] and better
using a method of ultrasonic wave velocity, the damage under resistance to alkaline and acid exposure and weather. The basalt
dynamic loading to the UPFRC was determined after every impact. fibers can be used for comparatively high temperatures as well
By increasing the fiber volume fraction capacity of the UPFRC to for very low temperatures (i.e. in the range of 600–800 °C upto –
repel repeated impacts was enriched. With the increase of the first 200 °C) [102–104]. Basalt is superior to any other reinforcement
impact projectile speed the dynamic damage of the UPFRC was materials due to its chemical inertness, very low thermal conduc-
increased much faster and the dynamic strength was decreased. tivity and highly resistant to corrosion. The key factors that govern
Results indicated that the maximum stress and modulus of elastic- the role of fibers in composites are the essential mechanical quality
ity were decreased. However, the increase in numbers of impacts of the fiber, the volume fraction of fiber in the composite, the ori-
increased the peak strain and strain rate. entation, position and layout of fiber in the composite, the physico-
Zhong and Wei [98] studied the compressive stress-strain rela- chemical interaction between the resin component and fiber, the
tions and dynamic damage of ultra-high performance cementitious interface interactions, and its recyclability.
composites (UPC). Portland cement, blast-furnace slag, silica fume Researchers used several raw materials to evaluate the behavior
and fly ash were the cementitious materials used in the prepara- of chopped basalt fiber reinforced mortar such as ordinary Portland
tion of UPC in the proportion 40:10:25:25. The polycarboxylate cement, Portland pozzolanic cement, high alumina cement, Port-
based super plasticizer was used with 41% solids content. The land lime, cement, hydraulic lime, etc. Even partial replacement
water (0.15) and super plasticizer (0.02) were mixed together of OPC was attempted with silica fumes, fly ash, gypsum, slag,
and then added into the dry mix. The fibers used for the study were nano-silica, etc. The source of fine aggregate which were used in
steel, polyvinyl alcohol and basalt fibers (L = 13 mm, 15 mm, 6 different proportions were natural river sand, cork, bricks and tiles,
mm; diameter = 0.2 mm, 0.04 mm, 0.017 mm; E = 210 GPa, 40 perlite, graphite, etc. The range of chopped basalt fibers used for
GPa, 80 GPa; tensile strength = 2000 MPa, 1600 MPa, 3000 MPa, the study was 3–24 mm in length and 9–25 mm in diameter, which
respectively). The volume fraction of steel fiber was 0–4% and were added in various proportions with respect to dry weight or
hybrid fibers comprised of steel and PVA or basalt fiber as 3% volume of either binding material or dry mix of ingredients. The
and 1% of volume respectively. The damage was reduced by fiber various recommended test to design the optimum composition of
reinforcement, which was increased with the impact repetitions. reinforced mortar were categorized as fresh (workability/fluidity,
The dynamic modulus of elasticity and peak stress of UPC slum-flow prevention, setting time, etc.), mechanical (axial and
decreased, whereas the peak strain and strain rate was increased cube compressive strength [56,86,95]), ultimate stress-strain rela-
due to increase in repetitions of impact. The fiber (steel and hybrid) tion (Fig. 6 [74]), bond strength [57]), bending strength, modulus of
reinforcement resulted in increase of resistance against repeated elasticity, fracture strength, tensile strength [56], ductility, etc.),
impacts of UPC. durability (drying shrinkage [57], abrasion resistance [57], water
598 R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602

permeability[57], mortar porosity [10,91], carbonation, freeze- revealed the application of admixtures (super plasticizers) and vis-
thaw resistance, resistance to salt-frost scaling, heat-rain aging, cosity agents [48]. Suitable quantity of water along with desired
alkaline attack [88] etc.), dynamic tests (dynamic tensile strength, plasticizer can be added. Role of viscosity agent is more effective
fracture energy, stress rate of uniaxial tension, dynamic increase than super plasticizer. However, curing which plays significant role
factor [90,96]), etc.) and functional like microwave absorbing prop- needs to be done in a controlled manner. The study indicated that
erty. The standardization was primarily done using various codes steam curing [48] might not work out a feasible solution for fiber-
based on American, Chinese, European, Canadian, Indian, etc. reinforced mortar. Beyond the optimum percentage of fiber, the
[51–53,58–64,69,77–79,81,84,85,87,100,101]. It is significant that desired properties of fresh reinforced mortar shall indicate poor
based on availability of raw materials suitable dry mix are to be property [51,70,98]. For a higher percentage of fiber in a specific
prepared of desired grade. mortar shall not only increase the porosity but will also reduce
Although several combinations of available raw materials were the mechanical strength. The amount of basalt fiber does influence
attempted, workability was a major concern after mixing the the strength of mortar. Influence of fiber content on the compres-
desired ingredients in proper proportions with suitable fiber sive strength is shown in Fig. 5. Considering the constant flow test
dosage. The design mix for water content to the dry mortar mix value, specimens with lesser amount of basalt fiber requires the
can be addressed using fluidity test [54]. Fig. 4 [67] depicts the flu- minimum water content. Subsequently, the compressive strength
idity of basalt fiber reinforced cement composite (BFRCC) with dif- increases. The 1% of basalt fiber from cement weight has the high-
ferent basalt fiber contents. As the fiber content increases, the est compressive strength [56,86]. Moreover, under static and
fluidity of cement composite decreases. The reason behind this is dynamic loading conditions, the optimum content of fiber rein-
the formation of spatial network structure due to random distribu- forcement for fracture stress is equal to 3%. Further increase of
tion of basalt fibers. In addition to this, as the proportion of basalt the fiber content decreases the fracture stress [95]. However, as
fiber increases, more cement paste will be consumed to cover the the content of basalt fiber increases, bond strength (Fig. 7)
fibers that results in a smaller amount of paste for the fluidity. In increases, as use of basalt fiber in the mortar reduces shrinkage
order to improve the desired flow property various studies cracking in the interfacial transition zone and bleeding at the

195
190 12
Spray/Pre-mix (0, BF)
185 11
Ultimate Stress (MPa)

Heat Rain (0, BF)


Fluidity (mm)

180 10
175 9
170 8
165 7
160 6
155 5
150 4
0 1 2 3 4 5 0 0.2 0.4 0.6 0.8
Ultimate-Strain
Fiber Content (Kg/cum)
Fig. 6. Ultimate stress vs ultimate strain.
Fig. 4. Fluidity vs fiber content pattern.

120
Compressive Strength (MPa)

100

80

60

40

20

Fiber Content
Fig. 5. Compressive strength vs fiber content.
R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602 599

3.2 0.09
Control BF-0.6
0.08 BF-1.6 BF-2.6
3
Bond Strength (MPa)

Drying Shrinkage (%)


0.07
2.8
0.06
2.6
0.05
2.4
0.04
2.2
0.03
2 0.02
0 0.5 1 1.5 2 2.5 3 0 5 10 15 20 25 30
Fiber Content Curing Time (Days)

Fig. 7. Bond strength vs fiber content. Fig. 9. Drying shrinkage vs fiber content.

interface [57]. In addition, it increases the tensile bending strength


(Fig. 8) owing to its better tensile strength [56].
8.5
Addition of basalt fiber to the repair mortar leads to lower dry-

Abrasion Resistance Strength


8
ing shrinkage (Fig. 9), superior abrasion resistance (Fig. 10), water 7.5
impermeability (Fig. 11), and freeze-thaw resistance [57]. Intro- 7

(h/Kg/sqm)
ducing BF into mortar effectively reduces the formation of cracks 6.5
and its tendency in mortar, resulting in less capillary and water 6
5.5
penetration of the mortar. In addition, BF in the mortar shows
5
exceptional resistance against the damage caused by freeze-thaw 4.5
cycles. This may be due to the fact that randomly dispersed basalt 4
fibers in the mortar retrain the expansion of the mortar, which is 0 0.5 1 1.5 2 2.5 3
caused by pore water volume changes during freeze-thaw cycles Fiber Contents (Kg/cum)
and then decrease the damage. Presence of fibers leads to higher Fig. 10. Abrasion resistance vs fiber content.
porosity of the mortar with larger pores [10,91]. The fibers affect
pore size distribution along with open porosity as shown in
Fig. 12. For fiber reinforced alkali activated binder, basalt fiber
loses weight under alkaline condition (Fig. 13). This is due to the
reaction between SiO2 in basalt fibers, and the alkaline solution 14
Water penetration depth (mm)

0, 13.5
13
[88]. Furthermore, basalt fibers, recently widely investigated in
12
structural applications, are also expected to present good perfor- 11
mance in case of high strain-rate dynamic conditions. Dynamic 10 0.6, 10
Increase Factor (DIF), i.e. ratio of the dynamic values over the 9
8
quasi-static tensile strength was evaluated and shown in Fig. 14
7 1.6, 7
with maximum value 5.1 at a high strain rate (100/s) [90]. Average 6 2.6, 6
tensile strength values have been elaborated in terms of DIF that 5
signifies the peak strength [96]. 0 0.5 1 1.5 2 2.5 3
Basalt fiber reinforced mortar could significantly control the Fiber Content (Kg/cum)
crack width, cracking load and deflection [66]. The chopped basalt Fig. 11. Water penetration vs fiber content.
fibers showed good bond with mortar, reduced drying shrinkage,

3.5
Tensile Bending Strength (MPa)

2.5

1.5

0.5

0
6mm(0,0.2,0.4,0.6,0.8,1.2) 12mm(0,0.2,0.4,0.6,1)
Fiber Content
Fig. 8. Tensile bending strength vs fiber content.
600 R. Ralegaonkar et al. / Construction and Building Materials 164 (2018) 589–602

Porosity (%)

Mean Diameter (µm)


Fig. 12. Pore size distribution of reference mix, B1 (1% BF) and B2 (2% BF).

but it proved better strain rate sensitivity than steel. However, in


16 combination with cement, silica and super plasticizer, basalt fibers
14 showed improved compressive and bending strength, better resis-
Weight Loss (%)

12 tance to heat rain aging with respect to glass fibers. A hybrid com-
10 bination of basalt and polypropylene fibers (60:40) in nano-
8 modified fiber reinforced mortar showed better compressive, flex-
6 ural and tensile strength along with shrinkage control and
4 improved resistance to salt frost scaling with respect to basalt
2 fibers only. PVA fibers showed significant higher chemical and fric-
0 tional bonding along with estimated slip hardening coefficient
0 7 14 21 28
with respect to brittle basalt fibers [71,97]. Under dynamic loading
Time (Days) condition, the rate of damage of steel fibers was much less than the
Fig. 13. Weight loss (due to alkaline attack) of the fibers vs time duration.
hybrid combination of PVA and basalt fibers, however improved
resistance against repeated impacts of ultra-high performance
cementitious composites were observed [98].
5.1

4.4 5. Conclusion

Chopped basalt fiber was studied in detail and desired physical,


DIF

mechanical property investigation method of the same was dis-


2.2
cussed. Its application for the reinforced mortar design with vari-
1.6 1.7 ous raw materials was briefly studied. Following are the
1 conclusions drawn from the extensive literature review:

 Basalt fiber was proposed as better reinforcement to the cement


0.0001 0.001 0.01 0.1 1 10 100 1000
matrices due to its valuable properties such as, better modulus,
Stress rate (GPa/s)
high strength, higher strain to failure, better stability, reduced
Fig. 14. Dynamic increase factor (DIF) vs stress rate. drying shrinkage, improved toughness, ability to resist repeated
impact, thermo-chemical resistance.
 With respect to commercially available synthetic fibers, the
greater flexural and compressive strength in the early hydration chopped basalt fibers were found to be good in performance
period, improved toughness [55], having better alkali resistance of the evaluated properties. Production of basalt fiber consumes
[72], microwave absorption [89], dynamic fracture energy [92], less energy and is cost effective.
ability to resist repeated impact [98]. Certain studies recommend  Addition of basalt fiber has the negative effect on the fluidity of
the use of fiber reinforced mortar specifically for repair of hydrau- fresh mix, whereas it improves the flexural strength, toughness,
lic structures, historic structures and repair between old and new ductility as well as the fracture energy of cement matrix
concrete structures [57,65,66]. composites.
Several studies were attempted to compare the performance of  In order to improve its performance suitable treatments were
various mortar reinforced with (chemically treated/untreated) studied and elaborated. Corrosion of basalt fiber in the high
chopped basalt fibers along with other available synthetic fibers alkaline cement matrix can be reduced by application of
like glass [65,68,74,88,95,96,100], steel [76,93,97,98], polyvinyl alkali-resistant coatings on the fibers and modification of
alcohol (PVA) [71,98], polyethylene (PE) [71], carbon [88] and nat- cement matrices through special additives. It was observed that
ural fibers like banana, sisal [68], etc. In combination with lime, basalt fiber with 5–6% wt. ZrO2 had the best alkali resistance
sand, water and super plasticizer, mortar reinforced with glass properties.
fibers proved to have better modulus of elasticity, flexural tough-  The fresh and hardened properties of reinforced mortar greatly
ness and compressive strength [65,74,95,96] than the basalt fibers, influenced by the volume percentage, length and diameter of
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