Cast basalt

Basalt casting was used as a replacement for iron and steel, which were in short supply after WWII. The crushed natural basalt is heated back to molten lava and then poured into molds to make components such as pipes and floor tiles, which are incredibly hard-wearing and abrasion-resistant.

Cast basalt can be formed into a diverse range of shapes and surface patterns, including bespoke designs (min 325m²). During the cooling process, the surface of the material achieves a glass-like patina, with an iridescence and texture that is unique to each piece.

Key Advantages

• Exceptionally high wear resistance
• Unlimited resistance to humidity
• High compressive strength and resistance to nearly all acids and alkalis
• Full corrosion resistance
• Maintains a smooth and even surface (favorable coefficient of friction for bulk solids)
• Excellent price/performance ratio (preventive and economical)

Cast basalt is produced by melting selected natural basalt – broken into sizes of 20–50 mm – in shaft furnaces at temperatures around 1,300°C, followed by casting into the desired molds. Of fundamental importance is the subsequent tempering process, in which the molten basalt forms uniform, spherulitic crystals that contribute to its physical properties such as extreme hardness and abrasion resistance.

Areas of Application

Cast basalt is the most frequently used wear protection material. The main areas of application are the wear-resistant linings for:

Bunkers, Silos & Tanks

The walls and outlets of bunkers, silos, and other tanks used for the storage of bulk materials are subject to strong abrasive wear. Strong friction wear occurs when emptying is compounded by impact wear during the filling process.

A wear-resistant lining with hexagonal or rectangular cast basalt tiles has proven to be a successful and economical solution. Special form pieces are manufactured for the flutes and the bunker saddles. Circular bunkers and silos are lined with radial, rectangular, or hexagonal form pieces that precisely match the required circumference.

To improve adhesion, corrugated wire mesh is spot-welded to the vertical steel walls.

Cyclones, Separators & Classifiers

• Screening, separating, grading, classifying – increased abrasive wear is frequently encountered during these processes. Cast basalt linings are often a standard component.
• Expertly manufactured form piece linings that are precisely adapted to the steel casing of the plant component (frequently in the form of radial hexagonal linings)
• Cyclones and separators: Manufactured according to customer drawings, complete with steel and built-in wear protection lining
• Larger separators and cyclones: Lining installed according to the steel construction drawings of the manufacturer

Cast Basalt Lined Piping

The transport of abrasive media, in fact of virtually all granular materials, in enclosed pipelines has the advantage that it is non-polluting, generates neither dust nor smell, and even saves valuable space. Completely lined pipes can be manufactured with the following maximum lengths:

Cast basalt lined piping is extremely wear-resistant and is used wherever highly abrasive materials are conveyed pneumatically or hydraulically, for example: