Cast Basalt Manufacturer

We are Manufacturer, Supplier, Exporter and Dealer of Cast Basalt, Cast Basalt Cylinder, Cast Basalt Tiles, Cast Basalt Bends, Cast Basalt Lined Pipes. Our setup is situated in We are Manufacturer, Supplier, Exporter and Dealer of Cast Basalt, Cast Basalt Cylinder, Cast Basalt Tiles, Cast Basalt Bends, Cast Basalt Lined Pipes. Our setup is situated in jamshedpur, jharkhand, India. India.

Cast Basalt is produced by melting of naturally available basalt rock and cast into tiles and cylinder. The casting is so produced is then subjected to heat treatment cycle to produce Re – crystallized basalt the resultant product is called as fused cast basalt which has excellent wear resistant properties against sliding and friction induced abrasion and also inherits the inertness of parent material.

1 .Introduction

Cast Basalt Pipes are engineered pipelines manufactured by melting natural basalt rock (~1250°C), casting into molds, and annealing to form a highly wear-resistant ceramic material.
Usually supplied as basalt-lined steel pipes (mild steel outer shell + cast basalt inner lining) to combine strength with abrasion and corrosion resistance.
Purpose → To extend service life in slurry transport, pneumatic conveying, and highly abrasive/corrosive material handling systems.

2. Technologies Includes

Raw Material Processing – Crushed basalt rock as feedstock.
Melting & Casting – Electric/coal furnaces for melting; precision molds for pipes, bends, and fittings.
Annealing – Controlled cooling to improve toughness.
Machining & Finishing – Grinding ends, preparing joint faces.
Lining Techniques –
- Monolithic cast basalt pipes (up to 1m length).
- Steel pipes lined with basalt tiles/segments for larger diameters.
Joining Technologies –
- Welded steel shells.
- Rubber/metallic couplings.
- Flanged joints with gaskets.

3. Applications

Power Plants → Fly ash, coal dust transport.
Cement Industry → Raw meal, clinker, gypsum, fly ash conveying.
Steel Plants → Slag granulation, sinter dust, blast furnace gas cleaning.
Mining & Mineral Processing → Ore slurry, tailings, concentrate transport.
Chemical Industry → Acid/alkali resistant pipelines.
Pneumatic Conveying Systems → Abrasive powder handling (silica, alumina, lime).
Hydraulic Transport → Sand, gravel, slurry pipelines.

4.Specification

• Nominal Bore: 32 to 600 mm
• Thickness Ranging: 20 to 30 mm
• Length: 500 mm

• Friction Resistance : As more material is passed over Cast Basalt it gets polished up thereby reducing friction further. Cast Basalt improves in service after getting polished. Wetting also improves its performance in practical applications.

• Impact Resistance : Direct Impact Resistance at 90 degree is low like all other ceramics, but it can be increased with proper installation by reducing the angle of impact. Cast Basalt is the best wherever sliding abrasion exists. Moreover, external impact strength of composite basalt pipe (enclosed in M.S. Shell) is always more than that of bare Ni-hard Pipe.

• Chemical Resistance : Cast Basalt is almost absolutely acid/alkali resistant (except Hydrofluoric Acid) and hence corrosion resistant.

• Weight and Sizes : Basalt Tiles are available in regular shape square of 200 x 200 x 30 mm thick, weighing approx. 90 kg/sq m; whereas bends and pipes are lined using Basalt Cylinders of various standard sizes from 50NB upto 500NB.

• Temperature : Cast Basalt withstands temperature up to 4500 C

5 .Technical Description

Sr. No.	Particular	Specifications
1.	Item	Cast Basalt
2.	Chemical Resistance	Absolutely acid/alkali resistant (except Hydrofluoric Acid)and Hence corrosion resistant
3.	SPECIFICATIONS OF CAST BASALT
a.	Cast Basalt Thickness	20 +_– 2 mm thk
b.	Max. Operating temprature	350 Deg. C
c.	Bulk Density	2.9 to 3.1 gm/cc
d.	Water Absorption	Max. 0.5%
e.	Hardness to Mohs	8
f.	Compressive Strength	500 – 550 Mpa
g.	Flexural Strength	40-50 Mpa
h.	Coefficient of expansion	6-8 * 10 ^-6 1/K
i.	Grout Thickness	Min. 15-20 mm

6. Site Parameters (Selection Criteria)

Operating Temperature → Continuous: up to 350°C, short-term: 450°C.
Operating Pressure → Typically ≤ 25 bar (depends on steel shell).
Particle Hardness → Mohs hardness ≥ 3 → basalt recommended.
Flow Type → Steady slurry/powder flow (abrasive, corrosive).
Impact Level → Low to medium (not suitable for heavy impacts).
Pipe Lengths → Usually 0.5–1.0 m per piece (multiple joints needed).

7. Safety Features

Personal Safety
- Use PPE (gloves, goggles, helmets) during handling/installation.
- No hammering (risk of fracture/sharp splinters).
- Mechanical lifting aids for heavy segments.
Operational Safety
- Pressure relief valves in system.
- Expansion joints for thermal stress control.
- Corrosion-resistant external coatings on steel shells.

8. Quality Features

Dimensional Accuracy → Proper ID/OD tolerances.
Surface Smoothness → Low friction inner surface (reduces material buildup).
Material Properties → Hardness 8–9 Mohs, compressive strength > 3000 kg/cm².
Joint Integrity → Leak-proof couplings/flanges.
Testing
- Hydrostatic pressure test.
- Spark test for lining cracks.
- Visual inspection of basalt lining.

9. Cost Parameters

Initial Cost → Higher than mild steel or cast iron (~2–4×).
Installation Cost → Slightly higher due to multiple joints/handling care.
Operating Cost → Lower (low maintenance, less downtime).
Lifecycle Cost → 3–5× cheaper than steel when considering service life.
Replacement Cycle → 3–10 years depending on medium (vs 6–12 months for mild steel in abrasive flow).