Underground conveyor systems face demanding environments, including extreme humidity, airborne particulates, and corrosive gases such as CO₂, NO₂, NO, and SO₂. These factors pose significant risks to conveyor performance, as suboptimal lagging can quickly deteriorate, causing belt slippage, production interruptions, and higher maintenance costs. Consequently, meticulous control of the lagging installation process is essential.
Step-by-Step Guide for Effective Underground Conveyor Pulley Lagging Installation
Step 1: Pre-Installation Preparations
1. Environmental Assessment
Measure ambient temperature, humidity, and drum surface temperature.
Prevent condensation formation using heating or dehumidification equipment, which could otherwise hinder adhesion effectiveness.
2. Workspace Evaluation
Evaluate workspace availability. Limited space necessitates pulley removal and off-site lagging installation for safety and quality assurance.
3. Electrical Supply Verification
Confirm power supply adequacy, ensuring voltage and transformer capacities match tool requirements to prevent operational disruptions.
4. Tools and Materials Checklist
Tools: Angle grinders, tungsten carbide buffing discs, rubber mallets, pressure rollers, wire brushes, cleaning solvents, measuring tapes.
Materials: Conveyor rubber pulley lagging, cold vulcanizing adhesive, metal primer, seam sealant.
5. Site Condition Inspection
Ensure surfaces around the pulley are flat, dry, and clean. Minimize dust, debris, and moisture to guarantee optimal adhesion.
If temperatures are low, use halogen lamps or similar heating solutions to reach ideal working conditions.
Step 2: Surface Preparation
1. Surface Grinding
Utilize an angle grinder fitted with a tungsten carbide buffing disc to remove oxidation, existing residues, and create a consistently roughened surface texture for enhanced adhesion.
2. Thorough Cleaning
After grinding, use appropriate industrial cleaning agents to remove all debris, oils, and dust thoroughly.
3. Metal Primer Application
Apply a uniform coat of metal primer evenly across the pulley surface.
Allow complete drying of primer as per the manufacturer’s recommendations before adhesive application.
Step 3: Application of Cold Vulcanizing Adhesive
1. Adhesive Mixing
Carefully mix adhesive components at the manufacturer’s specified ratio (typically 100:4).
Utilize the mixed adhesive within two hours to preserve optimal bonding properties.
2. Adhesive Coating Procedure
Apply adhesive uniformly in two layers:
Allow the first layer to fully dry.
Apply the second layer and wait until it achieves a tacky, non-sticky texture before proceeding.
Step 4: Attaching Rubber Pulley Lagging Sheets
1. Lagging Sheet Preparation
Cut rubber pulley lagging sheets precisely to match pulley drum dimensions.
2. Adhesive Application on Lagging Sheets
Apply a uniform adhesive layer on the lagging sheet’s backside, allowing it to reach a tacky state naturally.
3. Lagging Sheet Installation
Position rubber lagging sheets carefully onto the pulley surface, starting from one end and proceeding slowly to prevent trapped air pockets and wrinkles.
Step 5: Compression and Edge Finishing
1. Pressing and Compaction
Use pressure rollers or rubber mallets to firmly press the lagging onto the drum surface, starting from the center outward, ensuring total surface contact and air removal.
2. Seam Sealing
Trim excess lagging material precisely to align perfectly with drum edges.
Fill any visible seams and joints meticulously with a professional-grade seam sealant to ensure durability and a seamless finish.
Step 6: Proper Curing for Maximum Durability
1. Controlled Curing Environment
Allow lagged drums to cure fully under controlled temperature and humidity conditions, strictly adhering to the adhesive manufacturer’s specifications.
2. Post-Curing Quality Check
Conduct a comprehensive inspection for potential adhesion issues, surface irregularities, or defects, and promptly rectify any detected concerns.
Step 7: Roller Reinstallation and Operational Testing
1. Pulley Reinstallation
Safely reinstall the lagged pulley into the conveyor system, ensuring proper alignment and tension.
2. Performance Testing
Conduct thorough no-load and full-load tests. Monitor for any signs of belt slippage, vibrations, or performance irregularities, confirming successful lagging installation.
Safety Standards and Material Compliance
Adherence to safety protocols is imperative during underground pulley lagging installations:
Implement adequate ventilation systems and fire-prevention measures.
Ensure adhesives, primers, and rubber compounds comply strictly with explosion-proof and flame-resistant standards
Regularly update safety training for personnel involved in installation procedures.
Conclusion: Maximizing Conveyor Reliability Through Expert Pulley Lagging
Professional conveyor pulley lagging installation significantly enhances frictional traction, minimizes downtime, and prolongs service life, particularly in challenging underground environments. By adhering to these meticulous installation and safety precautions, mining operations can achieve higher conveyor efficiency, operational safety, and overall cost-effectiveness.
Contact our industry professionals today for specialized conveyor pulley lagging solutions and expert consultation.
