The Feature, Application and Installation of Ceramic Pulley Lagging

Ceramic Pulley Lagging Overview

Normal wear and tear, as well as unexpected damage, can occur during the long-term operation of the conveyor belts, leading to potential malfunctions that directly affect production. Industrial enterprises are actively seeking quick, efficient, and reliable maintenance techniques. One such solution is conveyor pulley lagging, which increases the friction coefficient between the conveyor belt and the roller surface, reducing mutual wear, enhancing traction, and extending the service life of both the conveyor belt and the roller.

Conveyor pulley lagging significantly improves conveyor systems’ operational efficiency by preventing belt slippage, ensuring synchronized movement between the roller and the belt, and supporting high-capacity operations. Additionally, it reduces material buildup on the roller surface, minimizing belt misalignment and wear.

BELTCARE SOLUTION’s ceramic pulley laggings are manufactured using advanced thermal vulcanization techniques. Abrasion-resistant ceramic tiles with textured surfaces are embedded in special rubber sheets, which feature a CN layer at the base. These pulley laggings are bonded to the roller surface using cold adhesive cement, replacing traditional rubber and improving the friction coefficient between the belt and the roller, extending the roller’s lifespan. The alumina ceramic tiles embedded in the rubber significantly increase the friction coefficient, making the ceramic pulley lagging far more wear-resistant than conventional rubber. Typically, rollers treated with ceramic pulley lagging can last over five years. Each ceramic pulley lagging contains hundreds of individual ceramic tiles, which are raised to provide better traction under the pressure of the conveyor belt, preventing slippage. The rubber base has elasticity, providing excellent impact resistance.

The unique grooves between the ceramic tiles give the roller a self-cleaning function, making it particularly suitable for wet working environments. Moreover, the installation of ceramic pulley lagging is convenient and can be carried out on-site without dismantling the roller, saving time and costs, and improving operational efficiency.

Ceramic Pulley Lagging Application Range:

1. Pulley lagging in extreme environments
2. Drive pulleys (CK)
3. Tail pulleys (CP)
4. Transporting various wet, sticky, muddy, and high-wear materials
5. High-strength, high-tension conveyor systems

Important Pre-Installation Guidelines

1. Before installation, familiarize yourself with the safety operating procedures for the equipment used and the safety regulations at the worksite.
2. Cut off the power supply to the conveyor and hang a sign reading “Under Operation, Do Not Switch On.”
3. If the equipment is located underground or in a confined area, check the levels of gas and dust before using an angle grinder, cutting torch, or welder. Proceed only if the levels are within safety limits to avoid accidents.
4. Before using an angle grinder, cutting torch, or welder, cover the conveyor belt with a fireproof cover to prevent damage.
5. After completing the installation, remove all tools, metal objects, and welding slag from the installation area and the conveyor belt before restarting the conveyor to avoid personal injury or damage to the belt.

Installation Steps for Ceramic Pulley Lagging:

1. Cleaning (Skip if a new roller): Remove any residual rubber or foreign objects from the roller surface. If previously rubber-coated, use an electric scraper, flat chisel, or hammer to remove the old rubber, then use an angle grinder with a polishing or steel needle wheel to expose the metal surface.
2. Rust Removal and Grinding: Use an angle grinder with a sanding wheel to evenly grind the roller surface until a metallic sheen is visible, ensuring no rust or threading.
3. Sweeping: Use a brush to clean the roller surface, followed by compressed air to remove any remaining dust.
4. Cleaning: Use a metal surface cleaner to clean the roller twice. Once the surface is dry, proceed to the next step. (If the site is dusty, cover the roller with plastic sheeting until the next step.)
5. Applying Metal Primer: Open the metal primer can, stir well with a screwdriver to mix the sediments, then pour the primer into a container (a small bowl or basin will suffice). Use a brush to apply an even layer of primer on the drum surface. Allow it to dry for an hour before proceeding.
6. Cutting and Roughening the ceramic pulley lagging: While waiting for the metal primer to dry, cut and roughen the ceramic pulley lagging. Based on the size of the roller, cut the rubber pulley laggings into two or three segments for easier handling (length between 800-1500 mm is ideal). The diagonals of each lagging should be equal. Use an angle grinder with a tungsten carbide buffing disc to roughen the CN layer of the rubber lagging evenly. Clean the roughened pulley lagging with a brush, and cover them with plastic sheeting until ready for use.
7. Marking: Use a right-angle ruler, steel plate ruler, and tape measure to draw lines on both ends of the roller corresponding to the rubber pulley lagging placement. Also, mark the center position on both the roller and the rubber sheets.
8. First Coat of Adhesive on Roller Surface: Mix SC2000/TRS2002 adhesive with a curing agent at a ratio of 100:4. Apply an even coat of adhesive on the first section of the roller where the rubber sheet will be placed.
9. Second Coat of Adhesive on Roller Surface and Ceramic Pulley Lagging: Once the first coat of adhesive on the roller is dry (after about 25 minutes), apply a second coat to the same area and a first coat to the Ceramic Pulley Laggings.
10. Adhesion: Once the second coat on the roller and the adhesive on the ceramic pulley laggings become tacky, cover the adhesive surface of the rubber pulley lagging with plastic sheeting. Four people (two for smaller sheets) should lift the pulley lagging using pliers (without touching the adhesive surface with bare hands) and place it on the roller surface with the plastic sheet in between. After positioning, remove the plastic sheeting and press the rubber pulley lagging onto the roller surface, starting from the center and moving toward the ends.
11. Compacting: Each person should use a rubber mallet to compact the sheet, working from the center outwards in two passes, and then along the edges. Ensure there are no missed spots, and do not compact the edges first.
12. Adhering Remaining Sheets: Repeat the process for the second and third sheets, leaving gaps between the sheets that reveal the chalk lines. If the last rubber pulley lagging is oversized, it can be trimmed on-site after adhesion.
13. Filling Joints and Trimming: Use a cutting knife to trim any excess pulley lagging from the edges of the roller at a 60° angle, ensuring a smooth finish. Grind the joints with an angle grinder to create a 60° bevel, about 12-15 mm wide at the top. Clean the bevel, apply a first and second coat of adhesive, and once slightly dry, fill the joint with T2 glue using a glue gun. Simultaneously, another person should use a roller to press the filled area 2-3 times. Once the filler has cooled, grind the surface flat with the rubber pulley lagging.

Required Tools:

1. Rubber Removal Tools: For cast rubber, use an electric scraper, two flat chisels, two hammers, one angle grinder, five grinding wheels, and five steel needle wheels. For cold adhesive, use two pairs of pliers, two cleaning knives, one angle grinder, and five steel needle wheels. For tile shell rubber, use four flat chisels, two hammers, one angle grinder, five grinding wheels, and five steel needle wheels.
2. Rust Removal and Grinding Tools: Two 150 mm angle grinders and 20 large sanding wheels.
3. Adhesive Application Tools: Two glue basins or buckets and six brushes.
4. Marking Tools: Two tape measures, one steel ruler, two chalks, and two white pencils.
5. Adhesion Tools: Four pliers, two rubber mallets, two cutting knives, and plastic sheeting equal to the area of the rubber sheets.
6. Joint Tools: One T2 glue gun, two compacting rollers, one angle grinder, and two tungsten carbide wheels. If there are many rollers or the timeline is tight, consider increasing the number of tools and personnel as necessary.

Before starting the installation, the team leader should prepare a construction plan, including basic information, personnel arrangements, and preparation.