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REPAIRING CONVEYOR SYSTEMS
Ripped and torn areas
- Rebuild torn belt edges without removing the belt.
- Repair rips along the belt's length, even where extensive damage has been done.
- Large or small repairs can be put back in service with only two hours downtime.
Problem: Conveyor belts often suffer from rips and tears due to impact and mechanical damage. If these rips and tears are left unchecked they will inevitably lead to the loss of the cover of the belt. The conventional repair method of hot vulcanizing is time consuming and expensive, especially when accessibility to the repair area is difficult.
Belzona Solution: Belzona 2000 Series Elastomers provide cost-effective, rapid repair of problem areas, thus reducing downtime and out of service costs. Working procedures and product options can be obtained from your local Belzona Technical Consultant.
WORN AREAS
- Restore frayed surfaces to "like new" condition.
- Restore worn surface layers of belting.
- Replace damaged ply fabric by incorporating Belzona Reinforcement Tape.
- Restore damaged layers of reinforcement.
Problem: The surface or cover of conveyor belts can often become worn and frayed due to abrasion. This exposes the reinforcement layer within the belt, which, if left will absorb moisture and lead to the complete delamination of the top cover of the conveyor belt. This would in turn necessitate the complete renewal of the belt.
Belzona Solution: The Belzona 2000 Series Elastomers consists of flexible fluid grade materials which have the ability to resurface these worn areas on-site and in-situ, in a fraction of the time that it would take to make a conventional repair.
JOINTS AND SPLICING
- Join belt ends together without clips or hot vulcanizing to create endless belt.
- Most belt types can be joined using a cold-curing process without the need for specialized equipment.
- Solid woven belts can be finger spliced.
- Repair damaged areas and delaminated fingers.
- Replace damaged or lost filler strips.
Problem: The ends of conveyor belts are normally joined together using a hot vulcanizing process or by the use of metallic clips. Hot vulcanizing is an established process, but is very time consuming and often very expensive. Metallic clips on the other hand provide a good emergency system, but if damaged by corrosion or impact, the clips can cause extensive damage to the belts and conveyor rollers.
Belzona Solution: Belzona 2000 Series Elastomers have very high tensile strength compared with original belt substrates and therefore can be used to successfully join and splice conveyor belts or rebond filler strips in vulcanized joints. Working procedures for this type of repair as well as product options can be obtained from your local Belzona Technical Consultant.
FASTENER SEALING AND PROTECTION
- Protect clips from mechanical damage.
- Protect clips from corrosion attacks.
- Seal clip joints to prevent spillage and contamination.
Problem: Clip joints are often used to join conveyor belt ends in an emergency or as a temporary measure. However, metallic lips are subject to damage from corrosion, impact and abrasion. Should a metallic clip become damaged and become entangled with a belt scrapper for instance, then damage to the conveying system and belt can be extensive.
Belzona Solution: Belzona 2000 Series Elastomers are used to seal metallic clips and thus protect them from corrosion and mechanical damage extending the life of clip and also the life of the conveyor belt.
REPAIRING AND BONDING CLEATS
- Repair ripped or torn rubber cleats in place.
- Modify standard belts in-house to produce flighted belts.
Problem: Cleats are used on elevated conveyor belts in order to prevent product from rolling back down the belt. However, they are subject to a wide range of damage including impact, abrasion and disbondment from the belt. In addition to this, new cleated belts are extremely expensive.
Belzona Solution: Belzona 2000 Series Elastomers can not only repair and rebond existing cleats, they can be used to bond new home-made cleats into position, thus giving the customer the ability to convert a flat belt into an elevator belt. Working procedures for this repair as well as product options can be obtained from your local Belzona Technical Consultant.
ABRASION RESISTANCE
BONDING, AND GROUTING TILES AND PLATES
- Attach wear-resistant tiles and plates without mechanical fasteners.
- Affix wear-resistant plates without welding.
- Apply a wear-resistant grouting material.
- Provide an impact-resistant bonding layer for brittle, wear-resistant tiles.
- Repair localized damage on basalt linings.
Problem: Chutes and hoppers handling abrasive solids are normally lined with wear resistant tiles. These tiles are extremely expensive and difficult to install especially where the shape of the chute or hopper is of complicated design. Consequently, the surface is usually uneven and this can cause bridging in the hopper.
Belzona Solution: Belzona 1000 Series Metallic Polymers feature abrasion resistant products which can be used to either bond and grout these wear resistant tiles or infill complicated shapes and areas within the hopper. Working procedures for this repair technique as well as product options can be obtained from your local Belzona Technical Consultant.
WORN PIPE ELBOWS
- Seal "blow-outs."
- Bond wear plates in place.
- Coat replaceable elbow backs.
Problem: Pipe elbows are subject to abrasion and wear on the inner surface of the outer circumference of the bend due to the change in direction of the abrasive material flowing through the pipe. Conventional repair necessitates the complete shutdown of the system and cleaning prior to welding and this can cause excessive downtime of the whole system.
Belzona Solution: The Belzona 1000 Series Metallic Polymers range include abrasion resistant products which can be used to either line the bend for protection purposes thus extending the life of the component or to cold bond reinforcement patches over the area subject to abrasion damage.
DAMAGED RUBBER LININGS
- Repair rubber linings in place without heat or removal from site.
- Carry out complete lining replacements or patch repairs on either steel or rubber substrates.
Problem: Many vessels are rubber lined in order to protect the steel surface from abrasion damage. Damage to this rubber lining can allow abrasive solids or corrosive fluids to come into direct contact with the steel shell of the vessel leading to eventual failure of the vessel.
Belzona Solution: The Belzona 2000 Series Elastomers feature abrasion resistant products which can be used to repair localized damage thus extending the life of the component.
LOBE-TYPE PUMPS
- Recast damaged rubber lobes in-house.
- Apply chemically resistant coatings.
- Apply abrasion resistant coatings for higher solids flow situations.
Problem: Lobe pump rotors are generally manufactured from rubber in order to cope with the harsh environment in which they are expected to perform such as sewage effluent duties. However, should the apex of the lobes become damaged, the positive seal is lost and the pump no longer operates.
Belzona Solution: The Belzona 2000 Series Elastomers range features fluid grade materials which can be used to recast and remold new rotors.
SLURRY PUMPS
- Protect pump casings with abrasion resistant lining materials.
- Protect pumps from chemical attack.
Problem: Slurry pumps subject to abrasion damage from all manner of abrasive fluids.
Belzona Solution: Belzona 1000 Series and the Belzona 2000 Series products - dependent upon the slurry being pumped - can be used to rebuild and protect, thus extending the useful service life.
CONTROLLING FRICTION
POSITIVE GRIP SYSTEMS
- Eliminate slippage on conveyor drive rollers.
- Provide safe, positive grip on forklift grab-arms.
- Create a long-lasting, positive footing surface on any equipment step areas.
Problem: Slippage and loss of traction in any area of industry can be disastrous in terms of personal injury or machinery damage.
Belzona Solution: Belzona 1000 Metallic Polymers are widely utilized to produce tough, durable grip systems to provide a positive grip on any surface - be it a warehouse floor, a tank top or a conveyor belt drive drum. Working procedures for this type of application, as well as product options can be obtained from your local Belzona Technical Consultant.
IMPROVED FLOW SYSTEMS
- Reduce sticking and build-up of powders and solids in chutes, hoppers, duct work, and bucket conveyors.
- Provide corrosion and abrasion protection in chutes, hoppers, duct work, and bucket conveyors.
Problem: Chutes and hoppers handling dry powders often become blocked due to bridging and caking of the dry powder, especially when moisture has entered the system.
Belzona Solution: Belzona 1000 Series Polymers are used to internally coat chutes and hoppers providing corrosion and abrasion protection and also preventing the dry powder product from sticking to the sides of the chute.
SCREW CONVEYOR SYSTEMS
- Abrasion protection for auger shafts.
- Rebuild and protect troughs and channels.
Problem: Auger and auger shafts are used in many industries for transporting solids and as a consequence are subject to abrasion, corrosion and impact damage.
Belzona Solution: The Belzona 1000 Series Metallic Polymers feature abrasion protection products which can be used to protect the metallic surfaces of the auger thus extending its service life. Working procedures for this repair as well as product options can be obtained from your local Belzona Technical Consultant.