RawEnergyMaterials Corp

Don R. Smith

RawEnergyMaterials Corp.

April 26, 2009

One positive thing that can be said for an economic downturn is that it promotes cost reduction creativity.

Such is the case with regards to production and a subsequent forming technique, RawEnergyMaterials Corp. (REM,) has developed for continuous basalt fiber (CBF.)

Volcanic basalt has long been considered to be a green, renewable, and sustainable alternative for replacement of steel in many applications.  However basalt structural materials have not been taken seriously as they have not been considered economically viable… until now.

Our world economy has necessitated new looks which have resulted in exciting innovation showing that  basalt is not only economically feasible in replacing steel, it provides relief and reward on numerous levels.

Advantages of RockRebar™

over Steel or Fiberglass

1.  Much higher tensile strength than steel or fiberglass rebar of the same diameter.  Even after considering a conservative rating to allow for any possible material flaws or misuse;  RockRebar™ is still only ¼ the weight and well over 2.2 times stronger in tension as compared to grade 60 steel!

2.  High strength + perfectly balanced thermal expansion with Portland cement + Zero rusting ever = RockRebar™ being the best tensile reinforcement for panels, decks, beams and pilings. 

3.   Since Rock Rebar™ is not metallic and does not absorb water it cannot rust!,

4.  No rusting allows RockRebar™ to be placed with only a ¾” spacing between the rod and the surface of the concrete as per ACI 440-6. This reduction in coverage requirements could allow for thinner projects and more flexible designs resulting in less heavy and expensive concrete. 

5.  RockRebar™ is the perfect reinforcement for today’s popular pervious concrete (low fines, porous, water passing concrete).  Pervious concreat reduces water retention or run off problems.  RR allows reinforcement with no fear of rust spalling (splitting).  (See new section) RockDNA™ “street grid”.

6.  NOT ALL! But in most cases the cost to adopt RockRebar™ as compared to steel concrete reinforcement will benefit by using RockRebar™ in smaller diameters.

            NOTE: Very high tensile strength allows for smaller diameter reinforcement rods.  Since there is no rusting issue, RockRebar™ may be placed within only 0.75” of surfaces where it’s very high tensile strength and high cycle tenacity can add stiffness without weight. Generally speaking, as opposed to larger diameter reinforcement we recommend that more rods in smaller size be installed in critical structural designs.  The inherent design flexibility in adopting RockRebar™ as non rusting reinforcement translates many creative options.  The placement of RockRebar™ near surfaces and offsetting it well away from bend axis also allows the addition of rods to offset Tensile Modulus issues if they arise in engineering calculations.

7.  RockRebar™ is much lighter than steel rebar. One man can easily lift a 500' coil of #3 (10 mm) RR. Many jobs will no longer require hoists or forklifts to handle reinforcement.  The result is much less fatigue for installation workers as compared to steel.  A reduction in injuries and medical expenses can also be expected. 

Example, a 40' piece of #5 steel

 weighs over 41 pounds  or nearly 19 kilos. 

A 40' piece of #5 (16mm) RockRebar™

 weighs about 12 pounds  or about 5.5 kilos.

Using RR the handeling weight by a whopping 29 lbs or 13 kilos!  Yet RR is at least 2.2 times stronger than steel in tension.  Looking at a tensile to tensile comparison, the weight ratio is

One lb of “RockRebar™" can replace 9.6 pounds of steel!

Perhaps reinforcement size can be reduced by adopting RockRebar™. For example #3 (10 mm) RockRebar™ is about a match in strength to grade 60 #5 steel.

We recommend a tighter grid of smaller "RockRebar™" to obtain the best price to performance.  Its light weight allows for much faster installation and a better overall job.

Our standard "RockRebar™" sections are 39'6" to ship in a 40' container; however diameters of up to 16mm can be coiled for shipment and used in long runs such as bridge decks and sea wall caps.  RockRebar™ coil material will naturally straighten when unrolled.

CAUTION!!!   IMPORTANT!!!

Since basalt is SO STRONG in tension and compression, it is not bendable in the way that steel is.  This is not a bad thing.  However, it must be understood.  While NOT normally an issue, engineers must consider Tensile Modulus when calculating the reinforcement layouts of highly loaded construction. 

“RockRebar™” is much lower in Modulus and higher in Tensile strength than steel IN SOME CASES RockRebar™ is NOT! a direct replacement! However, by capitalizing of much higher tensile strength as compared to steel and simply modifying the layout. Perhaps adding more rods in smaller diameters, perhaps closer to the surfaces than would be possible using steel because it rusts engineers find the calculations overcome the Tensile Modulus issue altogether and the cost of using RockRebar™ is less than coated or rust resistant steel products.

 (In the case of panels and slabs position RR just 3/4" from the surface that will be in tension).

8. RockRebar™ has exactly the same thermal coefficient of expansion as concrete.  

9. Regardless of cost as compared to any other possible tensile reinforcement for concrete.   The most attractive structural feature of RockRebar™ is that it loads up in tension precisely in step with the natural flex of Portland cement.  Non rusting aside that attribute make continuous basalt fiber the best possible answer to crack control!                                        

7. “RockRebar™” is naturally resistant to corrosion, rust, alkali, and acids.  RR cannot rust, so spalling of concrete from moisture penetration is totally eliminated! RR does not need a special coating to resist the high ph from exposure to concrete like fiberglass rod requires.

8. RR does not absorb and transfer moisture like glass fibers do.  Exposed fibers will not create a path for water to penetrate and destroy concrete.

9. Epoxy hole glue achieves and maintains optimum adhesion, yielding very high pull out.

10. Does not conduct electricity. This prevents electrolysis in marine applications.

11. Non magnetic, does not induce fields when exposed to RF energy, so it can be used in applications like MRI rooms and around RFID readers.

12. Easily cut to length in the field with common tools.

13. IMPORTANT - As compared to steel, “RockRebar™” has a lower Modulus of Elasticity.  Panel deflection will be the limit to application.  When pushed to its bending limit, it will just snap off cleanly.  From a practical stand point, when installed in a properly engineered pour, the bending limit will be much higher than the crush of the concrete, so in a properly engineered pour using (RR) it’s lower modulus is NOT an issue.  An example of how you can mishandle RR is attempting to pick up a panel by some exposed section of ”RockRebar™” (a hoop for example). 

In short, “RockReba™” is so strong in tension and allows for so little stretch, that it can exhibit a brittle, clean break right at the exit point of the slab or the hook point of the lifting devise.  As this can be dangerous, we strongly suggest workers be taught how to properly use and install RR.  We suggest feeling what is referred to as a “linear stress to failure curve” by the actually experiencing it. 

As an experiment to stress RR to its Ultimate Shear Strength, place a (#2 or #3) 8-10mm diameter piece in a vise and bend it until it snaps.  You will find it takes a surprising amount of force. “RockRebar™” will NOT stay bent unless it is held; once load is removed it returns to its naturally straight position.

Note: RockRebartm CAN NOT be heated and bent.  We “DO” make “RockRebar™” corners that may be wire-tied in the traditional manner.  Some people do mix steel corners with RR straight sections. We can mold special, custom cages if the volume warrants the set up cost.

We do make piling stirrups both round and square columns.

In MOST concrete reinforcement applications “RockRebar™” can be used as a replacement for steel rebar.  For specialty applications such as marine environments and chemical plants, where corrosion resistance is a major concern, no other product can come close to matching “RockRebar™” performance at a price even close!

For More Information Please Contact

Don Smith / Bill Flores bill@newrebar.com

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