Products

RockRebar®

is “glass state basalt fiber in epoxy, spiral wound, quartz coated rebar.

RockRebar® was originally designed as a non-rusting alternative to steel for marine construction and roadway sections exposed to salt and freeze-thaw on bridges.

Our products are based on only one single homogenous component, “natural volcanic basalt lava rock” processed into continuous fiber tendons. As a result, our products are at or very near carbon footprint neutral.

The cross section of each rod of RockRebar® (basalt rebar) consists of 10’s of 1,000’s of these very tenacious continuous Basalt filaments. Each filament is coated with a preparatory epoxy polymer.

In the production of RockRebar®, all filaments are stretched equally taut and compressed together parallel to each other forming a tight stiff hexagonal lattice that results in a premium BFRP rebar composed 80% of continuous basalt fiber, 18.5% by volume of a preparatory epoxy. Our epoxy polymer matrix adhesive not only solidifies the fibers together into a solid stiff RockRebar® it also enhances the natural chemical bonding with Portland cement. Before setting the epoxy coated fiber bundles are wrapped with a visible white Dacron winding. This winding is not a structural component rather it produces spiral deformations in the uncured fiber polymer matrix that provide optimum mechanical lock within the concrete. At the time of curing to set the epoxy resin, the bundle is coated in quartz sand and cured into RockRebar® too become a sustainable, totally non-rusting concrete reinforcement. RockRebar® is conservatively 2.2 times the tensile strength of series 60 steel at only 1/4th the weight.

RockMesh®

has several uses in civil engineering.

The aggregate of the roadbed should be stabilized by 1-1/2”x1-1/2” RockMesh® rather than rusty steel.

RockMesh® is state of the art for the structural reinforcement of Pervious concrete. Pervious Concrete is 20-25% open to allow standing water to pass right through and a sustainable alternative to standard concrete in that it reduces stormwater runoff and improves water quality. The application of pervious concrete helps municipalities meet requirements of the Clean Water Act as well as helping to achieve the United States Green Building Council’s LEED [Leadership in Energy & Environmental Design] status for new construction. The system allows for storm water to be managed onsite via retention and detention devices and only engaging the drainage system when those become full. After a rainfall event, the stored runoff will either evaporate from storage or infiltrate into the ground, helping the client save millions of dollars in pumping and environmental impact fees.

RockStirrups®

are designed to be the lateral support to RockRebar®, the method by which 90-degree corners are produced and the containment cages to assemble beams and columns.

RockStirrups® are produced through the application of 360-degree layer wraps of continuous basalt fiber and epoxy tapes. The result is fully closed Basalt (BFRP) Stirrup where the corners are as strong as the sides. This layer wound continuity of basalt fibers is a clear performance advantage in the efficiency of the composite reinforcement.

RockStaples™

are an enhancement to the concept of white fiberglass “fiber create” used for some years now. Most common concretes are brittle and crack during the curing process which is normal. Concrete just cracks easily in tension; this is why rebar and mesh are placed within the concrete. Under load, the concrete takes the compressive forces and the mesh and rebar the tensile loads with both working as a system to carry shear forces. Think of RockStaples™  as a refined form of tiny basalt rebar with high tensile strength and excellent adhesion that ties the cement, sand, and aggregate together at a micro level to further reduce cracking.

RockStaples™ have a density balance with concrete so they do not float and they do not sink. RockStaples™ do not “clump” like fiberglass. Like the aggregate itself, RockStaples™ uniformly distribute within cement paste during mixing. As a load is applied, concrete containing RockStaples™ distributes the stress throughout the concrete in all directions. As Portland based concrete inevitably shrinks and cracks during the curing phase RockStaples™ significantly reduce the size of the cracks. RockStaples™ “staple” the concrete components together thereby raising the flexural tensile strength.

The strength enhancement RockStaples™ add is purely that of the number of fibers crossing the various shrinkage stress points, more fibers = higher strength.  We recommend minimum dosages of 10 pounds per cubic yard for crack control and increasing residual strength after cracking by about 3 Mpa. In cases where rebar and mesh are not possible, we have seen great success with dosages to 160 pounds per cubic yard resulting in about a 15 Mpa improvement in residual strength after cracking