Cast Basalt Composite Elbow

Heavy‑duty Abrasion Protection

Steel elbows reinforced with basalt composite lining to resist high abrasion, heat, and chemical attack in industrial pipelines.

Basalt Composite Elbow Cast Basalt Elbow Abrasion‑Resistant Elbow Chemical‑Resistant Pipeline +1 More

Download

Cast Basalt Composite Elbow

Heavy‑duty Abrasion Protection

Steel elbows reinforced with basalt composite lining to resist high abrasion, heat, and chemical attack in industrial pipelines. cast basalt composite elbows fuse steel and basalt fiber reinforcement for unmatched abrasion, heat, and corrosion resistance—ideal for slurry and ash pipelines.

Basalt Composite Elbow Cast Basalt Elbow Abrasion‑Resistant Elbow Chemical‑Resistant Pipeline +1 More

Download

Cast basalt composite elbows are engineered for extreme industrial environments where abrasive, hot, or chemically aggressive materials flow through piping networks. These elbows combine a sturdy steel body with a cast basalt liner and cement mortar inner layer, further reinforced using basalt fiber composites. This multilayer design results in a smooth, alkali-rich steel surface that resists corrosion while delivering robust mechanical strength.

The basalt composite—made from high-temperature melted basalt fibers and resin or cement—creates a seamless, high-hardness (~Mohs 7–8) barrier. Basalt fibers add tensile strength, improved crack resistance, and thermal stability, making these elbows ideal for conveying fly ash, slurries, slags, and chemical effluents in power plants, cement factories, mining, and chemical processing.

Available in standard sizes (DN15–DN400 and larger) and various bend angles (45°, 90°, custom), these elbows support flanged, welded, or flexible joint connections. Their composite structure allows operation under 350 °C temperatures, while the basalt lining’s self-polishing nature reduces friction and wear over time.

Compared to rubber- or ceramic-lined elbows, basalt composite elbows deliver longer service life (7–10× that of cast iron), excellent chemical resistance, and superior resistance to moisture without delamination. The inclusion of basalt fiber composites enhances impact resilience and reduces brittleness.

Customizable to your pipeline requirements, Sunny Steel’s cast basalt composite elbows undergo strict quality controls—ensuring liner thickness, dimensional accuracy, weld integrity, and pressure performance meet industrial and international standards. They’re a reliable, cost-effective solution for long-lasting, high-performance elbow fittings in wear-critical pipeline systems.

Main Specification Of Cast Basalt Lined Pipe and Fittings
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	20 25
500	600	25
550	650	25
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.

Cast Basalt Liners

What is Cast Basalt

Cast basalt is a volcanic mineral material known for its exceptional abrasion resistance, complete impermeability to moisture, high compressive strength, and resistance to most acids and alkalis. It is entirely corrosion-proof, making it ideal for harsh industrial environments.

It is produced by melting selected natural basalt, crushed into 20–50 mm fragments, in shaft furnaces at approximately 1,300°C. The molten basalt is then cast and crystallizes into a uniform phaneritic structure, resulting in excellent hardness and wear resistance.

Cast basalt has a minimum hardness of 8 on the Mohs scale (diamonds are rated 10), making it extremely effective for abrasion and erosion protection.

Like other ceramics, it is sensitive to impact. Under normal service conditions, cast basalt withstands temperatures from -40°C to +350°C, but it should not be subjected to thermal shock.

Sizes: Cast basalt products come in the form of tiles, formed pieces, and segments. Straight pipes are spun-cast with nominal bores from 32 to 600 mm, wall thickness 20–30 mm, and standard lengths of 500 mm. Smaller bores, pipe segments with radii of 40–3000 mm, and special formed pieces are usually sand-cast. Steel molds can be used for higher volumes, producing 30–40 mm thick linings.

Cast basalt-lined pipes are widely used in abrasive and ash handling systems such as chutes, troughs, funnels, silos, dust collectors, rotary flow machines, conveyors, and feeders. In chemical plants, they can be used to line pickling tanks or store corrosive substances.

Customized specifications and shapes are available to meet specific project requirements.

Performance Characteristics

Friction Resistance: Cast basalt becomes polished with use, reducing friction and improving flow, especially under wet conditions.
Impact Resistance: While direct 90° impact resistance is low, it can be improved through proper installation. Composite basalt pipes enclosed in mild steel offer better durability than bare Ni-hard pipes.
Chemical Resistance: Highly resistant to acids and alkalis (except hydrofluoric acid), ensuring long-term corrosion resistance.
Weight and Sizes: Standard tiles are 200 × 200 × 30 mm, weighing around 90 kg/m². Bends and pipes are lined with basalt cylinders from 50NB to 500NB.
Temperature Resistance: Operates effectively up to approximately 450°C.

Design Aspects

The bend radius should be at least 3 times the nominal bore.
A straight basalt-lined pipe 5 to 12 times the nominal bore should follow every bend to minimize turbulence and wear.

Cast Basalt Wear-Resistant Material

Refined into a finely crystallized glass ceramic, Sunny Steel’s cast basalt linings offer extremely durable protection for static plants handling large volumes of abrasive or corrosive media.

Available in both pipe and tile form, cast basalt is ideal for wet material handling systems with lower impacts, such as coal chutes, ash sluiceways, and pipelines at power stations. It provides excellent resistance to wear, corrosion, and temperatures up to ~400°C.

Laboratory

Our factory is equipped with professional technical research and design personnel who can provide product optimization design and services.

S6 JAGUAR Wavelength Dispersive X-ray Fluorescence Spectrometer

Pendulum Friction Coefficient Tester

XJJ-50 Single Beam Impact Testing Machine

HV-5 Vickers Hardness Tester

CMT-100 Microcomputer Controlled Electronic Universal Testing Machine

MSY-A Friction and Wear Testing Machine

Manufacturing Process

Industrial Technology

Processing Technology and Application of Cast Basalt Lined Pipe

Cast Basalt Production Process

Cast basalt is a silicate crystalline material manufactured through a high-temperature refining process. It is produced using natural igneous rocks such as basalt, diabase, or selected industrial waste slag as the primary raw material.

These materials undergo melting, casting, controlled crystallization, and annealing, resulting in a dense, highly wear- and corrosion-resistant product.

Cast Basalt Product Portfolio

Cast basalt slabs
Cast basalt pipes
Cast basalt lined steel pipes

Jacketed basalt pipes
Basalt-lined expansion joints and valves
Basalt powder and putty-based wear protection compounds

Industry Applications: These products are widely used in power generation mining coal handling metallurgy chemicals construction especially in areas exposed to heavy wear or chemical corrosion.

Structure of Cast Basalt Lined Pipe

A cast basalt lined pipe typically consists of three layers:

Inner Layer

Cast basalt ceramic for abrasion and corrosion resistance

Outer Layer

Steel pipe for structural strength

Intermediate Layer

Cement mortar for bonding and chemical passivation

Composite Benefits: This composite structure ensures high durability, pressure resistance, and corrosion protection.

The cement mortar creates an alkaline environment on the inner steel surface, forming a passive protective film that prevents corrosion. Overall, the cast basalt lined pipe is ideal for transporting abrasive or corrosive media in complex operating conditions.

Types and Customization

Available Pipe Types:

Straight pipes

Elbows

Tee & Cross

Reducers

Elbows are designed with turning radii and center angles based on user requirements and share the same diameter series as straight pipes.

Large Diameter Applications: For non-standard or large-diameter applications (DN ≥ 800 mm), cast basalt plates are bonded to the steel pipe's inner surface using suitable cement types depending on the operating environment.

Key Advantages

Excellent wear and corrosion resistance
Wide applicability across industries
Minimal limitations on pipe size and shape
Cost-effective for long-term use
Handles high pressure and temperature conditions

Application Area of Cast Basalt Products

Cast basalt can be used for the lining of pipework, chutes, bunkers, cyclones, and hoppers.

Usage

Install

It has become the global standard in areas such as ash slurry pipework, often used at fossil-fuel power stations. It is an all-round cost-effective and adaptable lining material that extends the life of equipment in pipe or tile form where affected by erosion.

Cast basalt is well-proven in a variety of industries as a cost-effective, long-lasting lining material used to extend the operating life of equipment manufactured or lined with lower-wearing materials such as steel, cast iron, rubber, and polyurethane.

Cast basalt lined steel pipe, as both a wear-resistant and corrosion-resistant material, has proven effective over 30+ years of practical use.

It is also widely used in cement plants for components such as air separators, chain conveyors, hoppers, nozzles, ducts, chutes, and more.