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What is RockRebar®

A Green, sustainable alternative to rusty, steel rebar

RockRebar® is based on one component, NATURAL Basalt (which is volcanic lava rock). Basalt covers 70% of the earth's surface, and unlike fiberglass you don't need toxic chemicals to create it and no contaminating waste is created from its production. Basalt is cost effective, naturally renewable and Eco-Friendly. This Basalt rock is crushed and loaded into a furnace where it’s melted at extreme temperatures. The molten rock is further processed by being drawn through platinum bushings. As the fibers are drawn from the bushings, they are stretched taut, decreasing their diameter up to 90 percent. Finally, the basalt exits the assembly as continuous, "glass-state" fibers,

We take thousands of continuous strands of Basalt fiber which are compressed until they form a cylinder-type shape. During this process, they are coated with our proprietary epoxy resin, which acts like adhesive to give the basalt rebar an enhanced bonding surface. Before the final setting, a Dacron strand is wrapped tightly around the fibers, creating a shape change to ensure it will grip with the concrete. A coating of sand is then applied to the bundle. The final result is RockRebar®, an industry recognized replacement for traditional, steel reinforcement.

Why Use RockRebar®

The June 2016 official printing of AC-454 now allows for basalt fiber reinforced polymers (BFRP) to be used in the reinforcement of concrete. Additionally, States are also mandated to consider “life cycle” costs of all future road and bridge products as written in the Moving Ahead for Progress in the 21st Century Act (MAP 21) passed on July 6, 2012.

 

Due to the fact that Basalt products never rust, we believe RockRebar® will meet the mandated requirements, vastly reducing the need to redo infrastructure and obtain very little maintenance costs over time. 

 

With its durability, strength and longevity, basalt has no true rival; it will no doubt be the last rock standing.

NEVER RUSTS

RockRebar® will never rust, the most important solution to modern construction technology and to preventative maintenance due to expensive repairs.

LESS WEIGHT

RockRebar® is only 1/4th the weight and over 2.5 times stronger than traditional steel rebar. Creating savings on shipping costs and labor, as well as safety on handling.

STRONGER MATERIAL

RockRebar® is an alternative to steel and fiberglass concrete reinforcement. Made from volcanic rock, basalt rebar is stronger than steel and has a higher tensile strength (2.5 times STRONGER).

NATURALLY RESISTANT

RockRebar® is naturally resistant to alkali, rust and acids. Moisture penetration from concrete does not spall. Needs no special coating like steel or fiberglass rods.

MARINE FRIENDLY

RockRebar® is perfect for marine environments and chemical plants where corrosion is a continuous problem. They are the only products in the marketplace that address “alkaline” and “PH”, allowing them to be used with salt water.

CONSTRUCTION SAVINGS

RockRebar® does not require expensive heavy lifting cranes on job sites, creating additional savings and easy to handle in remote construction sites where road access might be limited.

RADIO FREQUENCY TRANSPARENT

RockRebar® is transparent to radio frequency unlike that of steel.

STABLE CONDITIONS

RockRebar® is non-magnetic, non-conductive & UV stable, as well as excellent in high voltage areas.

LONG LIFE CYCLE

RockRebar® non-corrosive nature makes it extremely valuable in terms of lifecycle requiring far less replacments necessary and broadly applicable to the entire construction industry.

Why RockRebar® is a Superior FRP

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RockRebar® is a product that when tested, proved to be only 1/4th the weight of steel, yet proved to have a higher tensile strength than traditional steel rebar. The June 2016 official printing of AC-454 now labels continuous basalt fiber and a special manmade fiberglass E-CR (corrosion resistant) fiberglass as sufficiently similar in overall performance as to be interchangeable for use in producing FRP concrete reinforcements. Brown basalt fiber reinforced polymer BFRP rebar and the white fiberglass GFRP rebar are now the only two “glass state” structural fibers officially recognized for concrete reinforcement. Naturally, occurring basalt has several advantages.

With only a single component required to produce continuous basalt fiber, the quarry process to collect basalt rock requires less of a carbon footprint in comparison to mining a dozen minerals to produce man-made white silica based E-CR fiberglass.

Boron, a potentially toxic trace mineral, is present in white fiberglass. However, at the base fiber level, basalt is non-toxic and naturally boron-free. Basalt rock is naturally boron free and clearly basalt is time proven to remain “rock solid”, standing today when all other minerals have long since eroded away.