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Thread: Ceramic Lagging Bonded Directly to Pulley

  1. #1
    snymanhl Guest

    Ceramic lagging bonded directly to pulley

    I am currently evaluating ceramic lagging for our conveyor drive pulleys.
    I understand that ceramic tiles embedded in rubber are commonly used in industry. However bonding the ceramic tiles directly to the steel of the pulley, using epoxy, is a relative new method used more and more.
    Is there any documented disadvantages of bonding the ceramic tiles directly to the steel of the pulley(Pulley life, belt life)?
    If any, please supply references to these documents.

  2. #2
    Lawrence K. Nordell

    Lawrence K. Nordell

    President and CEO

    Conveyor Dynamics Inc. [eDir]

    Conveyor Dynamics Inc.

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    The tiles are not bonded by epoxy directly to the pulley steel shell.

    Tiles are normally supplied in sheets with a rubber backing and rubber interlaced between tiles. The rubber backing is cold bonded with a chemical that fuses the rubber to steel.

    Manufacturers such as: Bellbane, Rema Tip Top, and Richwood have procedures for such. Contact them.

    Lawrence Nordell
    Coneyor Dynamics, Inc.

  3. Snymanhl:

    The industry has gone to ceramic tiles imbedded in rubber for the following reasons:

    1) The rubber allows the use of small flat tiles without creating problems on the circumfrence of the pulley.

    2) The rubber provides an impact cushion, which helps prevent tile breakage or loss when material gets caught between the pulley and belt.

    3) Production costs are lower if the tiles can be cast in sheet rubber pads.

    As far as documentation concerning the use of tile directly on the pulley is cincerned, I am not aware of any studies. I can however suggest two potential problems -- cost and service life. The cost to have tile made to fit the individual pulley circumfrences and to glue them in place individually is probably higher than what is acceptable. The service life of the tiles should be lower than that of the rubber backed ones due to the lack of cushioning.

    Finally, are you sure that you need ceramic lagging?

    Regards,
    Dave Miller
    ADM Consulting
    10668 Newbury Ave., N.W.,
    Uniontown, Ohio 44685 USA
    Tel: 001 330 265 5881
    FAX: 001 330 494 1704
    E-mail: admconsulting@cs.com

  4. #4
    Join Date
    Jan 01
    Posts
    8

    ceramic lagging tiles

    Hi all,

    We are finding a growing trend in South Africa, Australia and the U.K to bond ceramic tiles directly to drums with an epoxy adhesive.

    Large wearing companies like multotec ( South Africa ) CUMI Wulfenia ( Australia )and Kingfisher ( U.K ) have been pioneering this application.

    Our Eli-Bond FR961E1 is now an established product to bond these tiles down.

    Basically a strip of back bonded tiles is laid across the drum, and diagonally bonded with a two-part thermoset adhesive ( FR961E1 or similar ). A polyethylene rod ( approx. 25mm diameter ) is laid between the tiles to form a draining channel.

    We have found good results with no significant belt wear, slippage or tile loss.

    Reason for moving away from ceramic-embedded lagging sheets : poor quality product coming out of India which causes the tiles to " pop " out as the sheet is being bent around the drum.

    For more details, please visit :

    www.elichem.co.uk

    Regards,
    Aram Friedrich
    aram@elichem.co.uk

  5. Hello Aram,

    These have not shown up in the US yet (to my knowledge), probably because the lagging sheets are made properly.

    The strip method would get around the application time problem.

    I assume that the Eli-Bond FR961E1 has three functions -- bonding; cushioning; and void filling (to allow a flat tile to be bonded to a curved surface).

    Is there a reason for applying on an angle, as opposed to transversely?

    Regards and keep up the good work.
    Dave Miller
    ADM Consulting
    10668 Newbury Ave., N.W.,
    Uniontown, Ohio 44685 USA
    Tel: 001 330 265 5881
    FAX: 001 330 494 1704
    E-mail: admconsulting@cs.com

  6. #6
    Join Date
    Apr 03
    Posts
    12

    ceramic tiles onto steel pulleies

    Hi there,

    we concur with Elite with whom we developed adhesives which enable us to apply the ceramic pulley lagging directly onto the steel. Our experience has shown that the steel / rubber bond and ceramic / rubber bond is good so that under high shear force conditions, the rubber tears between the ceramic and the steel.

    If you contact me we can provide data, pictures and case studies showing why we have successfully converted all our many clients to the ceramic in epoxy systems.

    Our website, www.multotec.com shows detail under applications/wear linings/pulley lagging for reference.

    looking forward to your reply,

    regards

    Ken
    Ken Tuckey
    General Manager
    Multotec Kwazulu-Natal
    +27 82 901 5494 {mobile}
    kent@multotec.co.za

  7. Hi There..
    I have been doing a lot of comparisons with ceramic lagging here in South Africa over the last 6 years on numerous small as well as all of our very large installations.
    There can be no doubt from my results, that ceramic tiles of the correct size, bonded with the correct epoxy (very important) directly to the sand or shot blasted steel pulley shell is the only way to go.
    We are busy with Part 2 of SABS 1669 (pulleys) which deals with lagging at present.
    Please feel free to e-mail me at gspriggs@global.co.za for details of my findings if you like.
    Graham Spriggs

  8. Ceramic Tiles lagging Direct to steel shell

    Dear Sir,

    In normal chute application, the ceramic tiles directly embeded to steel sheets come out due to the poor bonding or practical difficulty in achieving the perfect bonding. For pulleys it may be more difficult than in chute due to the pressure by main belt. Since there is some system supplied we have to see the performance after put into operation for some time.
    It appears more difficult to maintain the perfect bonding with direct bonding.
    regards
    subra

  9. #9
    Join Date
    Apr 03
    Posts
    12

    ceramic pulley lagging bonded directly to steel

    Hi Mr. Subra,

    your response regarding the adhesion between ceramics and steel when applied directly to the steel of a pulley refers. Adhesion has always been a prime concern, and to this end we have developed a special Hi-bond epoxy which, after more than 1000 successful pulley installations, has not yet shown any signs of detachment, PROVIDED THE SURFACE PREPARATION HAS BEEN CORECTLY DONE, AND THE INSTALLATION OF THE EPOXY HAS BEEN CONTROLLED IN WORKSHOP CONDITIONS TO ENSURE CORRECT CURING REGIME'.

    regards

    Ken
    Ken Tuckey
    General Manager
    Multotec Kwazulu-Natal
    +27 82 901 5494 {mobile}
    kent@multotec.co.za

  10. Ceramic Tiles bonding to Steel

    Dear Mr Ken,

    It is interesting if proven design already available. can we have more details to suggest to our clients?
    regards
    Subra
    AE Automotion (M) Sdn.Bhd
    10&12 Jalan mas 6, Taman cheras Mas
    Cheras 43200 Selangor D.E.
    Malaysia.

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