Advancements in Basalt Fiber-Reinforced Composites: A Critical Review

Recent comprehensive research (2023–2024) on basalt fiber-reinforced composites (BFRCs) has meticulously documented significant progress across diverse applications, including protective coatings, high-performance concrete, reinforcement bars, and advanced laminates. The central theme of these developments revolves around innovative composite design strategies that strategically incorporate basalt fibers to markedly enhance mechanical properties, durability, and protective capabilities against environmental challenges. Key advancements in synthesis methodologies highlight that the integration of BFs substantially improves abrasion and corrosion resistance, effectively inhibits crack propagation through superior fiber-matrix bonding, and confers exceptional thermal stability, with composites maintaining structural integrity at temperatures of 600–700 °C and demonstrating short-term resistance exceeding 900 °C. The underlying mechanisms for this enhanced performance are attributed to both chemical modifications—such as the application of silane-based coupling agents which improve interfacial adhesion—and physical–mechanical interlocking between the fibers and the matrix. These interactions facilitate efficient stress transfer, leading to a breakthrough in the overall multifunctional performance of the composites. Despite these promising results, the field continues to grapple with challenges, particularly concerning the long-term durability under sustained loads and harsh environments, and a notable lack of standardized global testing protocols hinders direct comparison and widespread certification. This review distinguishes itself by offering a critical synthesis of the latest findings, underscoring the immense application potential of BFRCs in critical sectors such as civil engineering for seismic retrofitting and structural strengthening, the automotive industry for lightweight yet robust components, and advanced passive fireproofing systems. Furthermore, it emphasizes the growing, innovative role of simulation techniques like finite element analysis (FEA) in predicting and optimizing the performance and design of these composites, thereby providing a robust scientific foundation for developing the next generation of high-performance, sustainable structural components.