The Power of Basalt

It doesn’t look like much… brown fuzzy looking board in the frame of your DeckProtect, but in truth, it has a violent past. Deep below the Earth’ s surface, there is molten rock.  Some of this molten rock rises slowly toward the surface and cools slowly.  Over time, it hardens and crystallizes with large crystals and becomes what geologists call igneous rock. Granite is an example.  This is not the story with basalt. It rises to the surface in a volcanic eruption and cools quickly, forming smaller crystals.  Basalt is the most common volcanic rock, but not all basalt is the same. Depending upon its origin in the molten sub-crust level of the Earth it has different chemical content. The best basalt for us is high in silica content and low in iron content. 

The right kind of basalt is produced in only a few regions of the world… not in the U.S.  (It should be noted that, while DeckProtect is made in the U.S.with material sourced in the U.S., that does not apply to our basalt board.) So how does this volcanic rock that arrived the surface of our planet in a violent volcano become the product we use to make DeckProtect?  The rock is crushed and fed onto a conveyor, which feeds the crushed rock into an extremely hot furnace. When it reaches a temperature in excess of 2,500 degrees Fahrenheit, it is in a molten state (again). This is the part that stretches the imagination: it is pushed through specially engineered bushings with tiny openings. How tiny? … I have no idea how they make these bushings. What emerges is a filament finer than human hair. This filament is then piled up and pressed into a fibrous board 3/8″ thick

Two layers of this board become the core of our unique product. It is both extremely heat resistant and an excellent insulator. How heat resistant, and can we call it fire-proof? Yes we can call it fire-proof because it cannot possibly catch fire. However, it is not technically fire proof because extreme temperatures of 2,000 degrees Fahrenheit can degrade the material. But here’s the thing. Temperatures beneath even the hottest wood-burning fire pits will not rise above 600 degrees F. 

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