Cast basalt linings are engineered wear protection solutions manufactured from molten basalt, providing outstanding resistance to abrasion, impact and corrosion in demanding industrial applications.
Cast basalt lining is a wear resistant solution that is based on minerals. It handles and processes the components that convey abrasive elements. The cast basalt liners and tiles are manufactured by melting volcanic rocks. They are then casted in the form of different shapes including cylinders and tiles.
Basalt casting was used as a replacement to iron and steel which was in short supply after WWII – the crushed natural basalt is heated back to molten lava and then poured into moulds 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.
Strong friction wear is caused when emptying the bunker and silos and, in addition, impact wear occurs during the filling process. This abrasion sometimes destroys cement bunker walls within a relatively short time. In practice, cast basalt tiles wear-resistant linings have proved to be an economical solution.
Basalt casts are considered the best lining materials for industries dealing with abrasion resistance. The other application areas of basalt casts are bends, lining pipers and trenches.
Basalt tiles can be placed and jointed in cement or specially-defined bonding agents, as demanded by the intended application. Basalt tiles can be provided with a central hole that is countersunk for individual bolting, or as ready-made liner plates and pipes.
Cast basalt tiles is mainly used in thermal power plants, steel mills, mines and other parts with heavy wear, such as raw coal bunkers, mine bins, coal unloading trenches, hoppers, ore troughs, flotation machines, chutes and other parts.
These very hard tiles are made for very heavy industrial use, but also feature a beautiful metallic sheen. Originally used for sewerage systems or piping pieces, these pavement tiles are made by melting natural basalt and casting it into metal moulds.
| Cast Basalt Pipe DN (mm) |
Standard Steel Pipe OD (mm) |
Cast Basalt Thickness (mm) |
Length (mm) |
|---|---|---|---|
| 80 | 159 | 25 | 4000 |
| 100 | 168 |
17.5 20 |
4000 6000 8000 |
| 125 | 195 | ||
| 150 | 219 | ||
| 175 | 245 |
6000 8000 10000 12000 |
|
| 200 | 273 | ||
| 225 | 300 | ||
| 250 | 325 | ||
| 275 | 345 | ||
| 300 | 377 | ||
| 350 | 426 | ||
| 400 | 478 |
20 25 |
|
| 450 | 529 | ||
| 500 | 600 | 25 | |
| 550 | 650 | ||
| 600 | 720 | 30 | 6000 |
| 650 | 770 | ||
| 700 | 820 | ||
| 750 | 870 | ||
| 800 | 920 |
Other specifications of cast steel pipe lined with basalt can be manufactured according to customer technical requirements. Suitable for large-diameter basalt lining steel pipes with a nominal diameter greater than 800mm. Generally, according to the running status of the pipeline, different cement is used to fix the basalt brick inside the finished steel pipe to complete the basalt lining steel pipe. Its advantages are good wear resistance, wide range of use, basically not limited by the size of the pipeline and low cost of pipeline installation.
Comparison of Ceramic lines with few other materials under standard conditions :
| Material | Thickness(mm) | Approx life ( Months ) |
|---|---|---|
| Mild Steel | 10 | 3-5 |
| Cast Iron | 20 | 6-8 |
| Ni-Hard | 20 | 12-14 |
| Cast Basalt | 30 | 20-25 |
| Ceramic | 10 | 35-40 |
Hard & Compact Smooth & Inner Withstands High-Abrasion & Corrosion In any of the process industries especially Sled and Cement corrosion and abrasion lead to significant downtime of the plant. Further, the useful life or the equipment itself may get impaired because of the high abrasive nature of the materials being used. Thus, ‘wear mechanism’ results in hut down, replacement, etc., which is costly, resulting in loss to tilt: tunic of millions of dollars.
The bend radius should be minimum 3 times of the nominal bore. At discharge end of each bend, cast basalt lined straight pipe of length 5 to 12 times the nominal bore must be used.
Cast basalt is a highly wear-resistant and corrosion-resistant lining material widely used in pipes, chutes, bunkers, cyclones, and hoppers.
Usage
Installation
Cast basalt has become the global standard for ash slurry pipelines in fossil-fuel power stations and other heavy industries. It significantly extends equipment service life in environments with severe abrasion and corrosion.
It is commonly used as a cost-effective lining material for steel, cast iron, rubber, or polyurethane equipment, offering 5–10 times longer service life than traditional materials.
