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Rubber and Ceramic Lagging
w w w . f o r e c h . c o m
Conveyor Belt when slips causes significant damage to the drive pulley and the belt. Such damages are not only expensive to repair, but also time consuming and cause enormous loss due to down time.
The life span of a conveyor system primarily depends on
its being suitably equipped for the specific application
and the standard of servicing and maintenance. The
conveyor systems often have to perform in the most difficult conditions. For example, rain and sludge,
which cause slippage between the conveyor belt and pulleys because of the low friction co-efficient
between the two.
specially developed rubber materials and their
plain and patterned surfaces have proved to be very effective in water shedding, preventing material build
up and controlling belt slippage.
Belts need good traction with the drive pulley to prevent
slips that can cause major damage.
Forech offers both plain and patterned pulley lagging with
All lagging products can be provided with a Bonding Layer for easy
installation with cold glues. In addition, Forech also offers a buffed and plain surface to suit your particular
needs and budget.
A very special range of ceramic pulley lagging is offered by Forech to provide very high levels of drive and
wear resistance for conveyor pulleys that operate in medium to heavy duty applications in wet and muddy
conditions.
Why Pulley Lagging?
• Prevents slippage-reduces pulley wear
• Prevents material build up on pulley
• Reduces chances of mistracking
• Reduces damage to the conveyor belt
• Allows for easy drainage of water and slurry
w w w . f o r e c h . c o m
Lagging
Drive Pulley Standard Arcs of Contact
Tq
180°
210°
Pulley
Reducing Tension- Belt Contraction
Conveyor BeltMaterial Carry Side
High Tension Carry
Low Tension Return
T1
T2
STRIP LAGGING
FORECH-HILTON Diamond Profile and Plain Pattern Pulley Lagging Strips have been specially developed for covering of conveyor pulleys.
These easy to use Lagging Strips can be fitted to the Pulleys with the help of cold bonding adhesives in the workshop or at the conveyor site itself, providing extraordinary saving in terms of expenses incurred on account of down time and usage of autoclave. It has been proven that similar adhesion levels can now be achieved with cold bond adhesives as with vulcanization.
FORECH-HILTON Strip Lagging is available in a variety of designs, to suit the various application requirements. These are manufactured with 60 to 65 Durometer rubber compound, having an excellent abrasion resistance. All the designs offered by FORECH-HILTON have excellent water shedding characteristics. Supplied in Roll sizes ranging from 10 to 85 metres in a width of 205mm, they can be custom fitted to any pulley size with minimal wastage.
Range of profiles and dimensions
Patte
rned
Str
ip P
ulle
y La
ggin
g
FORECH-HILTON offers a comprehensive range of Patterned Sheet Pulley Laggings to suit every conceivable conveyor installation . The Pulley Laggings offered by FORECH- HILTON are produced in different thicknesses, rubber qualities and patterns to ensure selection of the most appropriate type, to suit all application requirements.
The Sheet Pulley Laggings offered by FORECH-HILTON come with CN Bonding Layers for better adhesion levels as also with buffed surface. The profiled patterns on the top surface, in diamond or square embossing improve belt grip and tracking on conveyors, while reducing belt wear. The Sheet Pulley Lagging is available in various grades of rubber, including FRAS and oil resistant grades.
BENEFITS· Easy to install· Minimum wastage and economically priced· Reduced adhesive use due to Bonding Layer· Shorter lead times· Maintains friction grip under unfavourable drive
conditions· Increased friction coefficient between the pulley and
the conveyor belt· Extremely helpful while running in wet conditions· Prevents dirt build up in pulleys
Profile dimensions and range
Patterned Sheet Pulley Lagging
B
L
D
S
T
0.8mm Bonding Layer (Optional)
Forech range of rubber compounds for lagging
Fire resistant anti
static (FRAS) and oil
resistant lagging is
also available
in approved rubber
compound grades
w w w . f o r e c h . c o m
Profile Large Diamond Small Diamond Mini Diamond Square
LD-1 LD-2 SD MD SPProfile Diagonal B 88 88 47 33 28Profile Diagonal L 51 51 27 17 28Gap Between the Profile S 6 8 6 6 4.5Depth of Profile D 4 6 4 3 3Minimum Thickness T 8 10 8 7 8Product Width 1400 1500 1500 1000 1500 1500 2000 2000
1500 2000 1800 1200 2000 20001650 2000 15001800 200020002030
Finish on face Fabric Plain Plain Fabric Plain Fabric Plain FabricFinish on the Pulley Side With Bonding Layer (Adhesive/Tie Gum Layer)
Without Bonding Layer - Grinding Finish or SmoothStandard Roll Length (m) 10* 10* 10* 10* 10* 10* 10* 10*
*Length upto 50 m can be supplied on request.
Profile
BENEFITS
FEATURES
·
·
·
·
·
·
·
·
·
·
Easy to fit
Minimises wastage
Outstanding wear and abrasion resistance
Reduced labour
Supplied in a 205mm wide strip
Rolls of 10 to 85 metre strips
Diamond & Plain Pattern
CN Bonding Layer, Plain or with Buffed Back options
Reduced adhesive use
Reduced down time
S. Properties Units Compound Code
No. R-1605 R-1624 R-1616 R-1625
1 Tensile Strength Mpa 20.0 Min 15.0 Min 12.0 Min 15.0 Min
2 Elongation at Break % 450 Min 400 Min. 400 Min 450 Min
3 Shore Hardness °A 60 ± 5 60 ± 5 60 ± 5 60 ± 534 Density g/cm 1.10 ± 0.03 1.13 ± 0.03 1.14 ± 0.03 1.21 ± 0.03
35 Abrasion Loss mm 90 Max. 140 120 Max. 200 Mx.
6 Crescent Tear N/mm 80 Min. 60 Min. 40 Min. 30 Min.
From the second relationship in the diagram (T1/T2 = eµØ ) we see that the tension on the belt (T1) increases significantly as coefficient of friction (µ) increase. Increasing the coefficient of the friction therefore has the following benefits:
• Reduced belt tension required
• Reduced slip and therefore less wear on belt and lagging.
• Reduced load on shaft and bearings
The frictional force is significantly increased in the ceramic lagging due to the mechanics of the dimples. However care has been taken that this does not damage the conveyor belt.
Coefficient of Friction
Co efficient of
Friction-
Rubber Lagging Ceramic Lagging
Dry 0.50 0.75 Wet 0.35 0.55
Bare SteelPulley0.250.15
The maximum tension T1, generated in any conveyor belt is the tension which is required to be imparted on the belt in order to transmit, through traction, at the belt-pulley interface, the tension, Te, necessary to overcome all the system resistances and convey the desired through put at stipulated operating parameters in the diagram. The residual tension T2, is responsible for maintaining the integrity of the belt run and limits the inter-idler sag of the belt to permissible limits. The three tension values are related through mathematical equations, namely.
T1 - T2 = Te, and T1/T2 = eµØ
µ = Coefficient of friction between belt and pulley, Ø = Arc of contact between belt and pulley
The value of µ is determined using the dynamic test rig as shown below. A section of belt is wrapped around a pulley (180 degree Arc of Contact) with a constant load on one end. A motor applies a torque force to the pulley. At a threshold torque the pulley begins to rotate.
Comparison Table for Co-efficient of friction
Ceragrip Ceramic Lagging
Forech ceramic pulley lagging provides the best grip for your drive pulley. The ceramic inserts in the lagging surface provide both high friction and high wear resistance-providing the best protection for your pulley and belt in the most demanding conditions. Ceramic pulley lagging is ideally suited for wet and muddy conditions where belt slippage can be a major problem.
The high co-efficient of friction of the ceramic tile inserts with the belt also allows for belt tension to be reduced. This also improves the life of the belt, as well as that of the other belt components as they come under less stress.
The surface of the lagging is profiled similar to that of profiled rubber pulley lagging. This allows for effective drainage.
Forech Ceramic Lagging is offered as easy to install strips. These come with a bonding layer backing, or a buffed surface as per your needs and budget.
Ceramic tiles embedded in rubber, are also supplied in Fire Resistant Anti Static (FRAS) approved grades of rubber compound for underground applications.
Typical conditions suited
to the use of Forech
CeraGrip ceramic
lagging include wet
and dirty conditions
where belt slippage is a
problem or high tension
applications where the
wear life of plain rubber
lagging is limited.
w w w . f o r e c h . c o m
Test Rig for Determining Coefficient of Friction
Conveyor Belt
180°
Arc of Contact
Lagged Pulley
T1
Ceragrip Lagging with Square Ceramic Tiles
Profile and Range
Standard range of strips and rolls
Code Strip Strip Description Orderwidth (mm) Thk (mm) (unit lots)
CLNSP55050 385 12.5mm Forech cerstr 550CL/950RL suit 500mm belt Strip
CLNSP65060 385 12.5mm Forech cerstr 650CL/1050RL suit 600mm belt Strip
CLNSP70065 385 12.5mm Forech cerstr 700CL/1100RL suit 650mm belt Strip
CLNSP75070 385 12.5mm Forech cerstr 750CL/1150RL suit 700mm belt Strip
CLNSP85080 385 12.5mm Forech cerstr 850CL/1250RL suit 800mm belt Strip
CLNSP95090 385 12.5mm Forech cerstr 950CL/1350RL suit 900mm belt Strip
CLNSP105100 385 12.5mm Forech cerstr 1050CL/1450RL suit 1000mm belt Strip
CLNSP110105 385 12.5mm Forech cerstr 1100CL/1500RL suit 1050mm belt Strip
CLNSP125120 385 12.5mm Forech cerstr 1250CL/1650RL suit 1200mm belt Strip
CLNSP1450140 385 12.5mm Forech cerstr 1450CL/1850RL suit 1400mm belt Strip
CLNSP1550150 385 12.5mm Forech cerstr 1550CL/1950RL suit 1500mm belt Strip
CLNSP1650160 385 12.5mm Forech cerstr 1650CL/2050RL suit 1600mm belt Strip
CLNSP1850180 385 12.5mm Forech cerstr 1850CL/2250RL suit 1800mm belt Strip
CLNSP2050200 385 12.5mm Forech cerstr 2050CL/2450RL suit 2000mm belt Strip
CLNSP2250220 385 12.5mm Forech cerstr 2250CL/2650RL suit 2200mm belt Strip
CLNSP2450240 385 12.5mm Forech cerstr 2450CL/2850RL suit 2400mm belt Strip
CLNSP2550250 385 12.5mm Forech cerstr 2550CL/2950RL suit 2500mm belt Strip
CLNSP2650260 385 12.5mm Forech cerstr 2650CL/3050RL suit 2600mm belt Strip
CLNSP6500 385 12.5mm Forech cerstr 6500CL Roll
CLNSP10000 385 12.5mm Forech cerstr 10000CL Roll
Ceragrip Lagging with
triangular Ceramic Tiles
Profile and Range
Water Shedding Action
Standard range of strips and rolls
Code Strip Strip Description Orderwidth (mm) Thk (mm) (unit lots)
CLNTP54050 203 12.5mm Forech cerstr 540CL/940RL suit 500mm belt Strip
CLNTP67560 203 12.5mm Forech cerstr 675CL/1075RL suit 600mm belt Strip
CLNTP74065 203 12.5mm Forech cerstr 740CL/1140RL suit 650mm belt Strip
CLNTP74070 203 12.5mm Forech cerstr 740CL/1140RL suit 700mm belt Strip
CLNTP87580 203 12.5mm Forech cerstr 875CL/1275RL suit 800mm belt Strip
CLNTP94090 203 12.5mm Forech cerstr 940CL/1340RL suit 900mm belt Strip
CLNTP1080100 203 12.5mm Forech cerstr 1080CL/1480RL suit 1000mm belt Strip
CLNTP1080105 203 12.5mm Forech cerstr 1080CL/1480RL suit 1050mm belt Strip
CLNTP1280120 203 12.5mm Forech cerstr 1280CL/1680RL suit 1200mm belt Strip
CLNTP1485140 203 12.5mm Forech cerstr 1485CL/1885RL suit 1400mm belt Strip
CLNTP1550150 203 12.5mm Forech cerstr 1550CL/1950RL suit 1500mm belt Strip
CLNTP1685160 203 12.5mm Forech cerstr 1685CL/2085RL suit 1600mm belt Strip
CLNTP1890180 203 12.5mm Forech cerstr 1890CL/2290RL suit 1800mm belt Strip
CLNTP2090200 203 12.5mm Forech cerstr 2090CL/2490RL suit 2000mm belt Strip
CLNTP2295220 203 12.5mm Forech cerstr 2295CL/2695RL suit 2200mm belt Strip
CLNTP2495240 203 12.5mm Forech cerstr 2495CL/2895RL suit 2400mm belt Strip
CLNTP2565250 203 12.5mm Forech cerstr 2565CL/2965RL suit 2500mm belt Strip
CLNTP2700260 203 12.5mm Forech cerstr 2700CL/3100RL suit 2600mm belt Strip
CLNTP6490 203 12.5mm Forech cerstr 6490CL Roll
CLNTP10000 203 12.5mm Forech cerstr 10000CL Roll
w w w . f o r e c h . c o m
Summary Results of Pulley Lagging Adhesion Tests
Lagging with CN bonding layer
Lagging withoutCN bonding layer
Time(hour)
Rubber tometalAdhesion(N/mm)
16
14
12
10
8
6
4
2
0
0 1 3 5 24 48 72 168
Pulley Lagging Selection Chart
Criteria Plain Sheet Diamond Sheet Rubber Strip Ceramic Strip
Lagging Lagging Lagging Lagging
Dry Performance Very Good Excellent Excellent Excellent
Wet Performance Average Very Good Very Good Excellent
Wear Life Very Good Very Good Very Good Excellent
Ease of Installation Good Good Excellent Excellent
Fire Resistance Yes Yes Yes Yes
Drainage Grooves No Yes Yes Yes
CeraGrip Ceramic Lagging Features: CeraGrip Ceramic Lagging Benefits:
ü
ü
ü
ü
ü
ü
ü
ü
ü
Square/Triangural Tiles with Improved traction as dimples grip beltRaised Dimples Improved belt tracking due to positive grip
Reduced belt tension required due to increased co efficient of friction.
92% Aluminium Oxide tile material Extreme wear resistance
Rubber Compound blended with Outstanding adhesion:CN polymers - Rubber to Ceramic
- Rubber to Metal- Rubber to Rubber
Low Sulphur rubber compound Minimal change in rubber hardness with age
Ceramic Tiles fully encapsulated and Tiles more resistant to cracking or “pull out”chemically bonded to rubber on 5 sides
Special Rubber compound to meet FRAS Suitable for use in underground minesand MSHA requirements
Supplied in 205, 385 and 418mm wide Easy to install with less joinsStrip forms with bonding layer and buffedback surfaces
Supplied in continuous rolls of upto One product suits all pulley face widths 10 metres long or as ordered
Can be supplied as individual strips For customers who prefer a rubber edged with rubber section at each end of pulley laggingCeramic section
Ceramic Tile Specifications
Test Specification
Aluminium Oxide (min) Al 0 92%2 3
Density (g/cc) 3.65
Hardness (R 45 N) 79 min.
Cold Crushing Strength (Mpa) 2050 min.
Flexural Strength at 240 min.Room Temp. (Mpa)
Water absorption 0%
Abrasion by impingement 0.05 grams max.
Abrasion by Rubbing 0.1grams max.
Base Rubber Specification
Compound Code R-1608
Polymer SBR
Specific Gravity 1.13 +/– 0.03
Shore Hardness °A 60 +/– 5
Elongation at break % Min. 450%
2Tensile Strength 17.5 N/mm
3Abrasion Loss 150 mm at 10N
w w w . f o r e c h . c o m
Hot Bonding of
precured Rubber &
Ceramic LaggingForech Lagging is also available, and is specially
manufactured strips that allows it to be hot bonded onto pulleys. This unique innovation allows for press cured strip lagging to now have the additional advantage of
hot bond to the steel pulley. The high physical properties that are achieved from a press-cured
sheet, manufactured under heavy tonnage, can now be incorporated in a hot bond
application, thereby achieving the greatest possible bond
strength.
All information and indications given in this brochure are correct to the best of our knowledge and represent a true reflection of our current technology and experience. Due to ongoing developments, however, certain details may soon become obsolete. We can accept no responsibility for errors or omissions in recommendations given in the brochure.
w w w . f o r e c h . c o m
FORECH INDIA LIMITED
Registered Office‘Hilton House’ S-23, Green Park Extension, New Delhi-110016Phone : +91-11-26960868, 26961275, 26514019Fax : +91-11-26862373, 26534269Email : [email protected]
Branch OfficeChennaiG-1, "Hayagreeva", 85 Velachery Main RoadGuindy, Chennai-600032Phone : +91-44-22352902Fax : +91-44-22351585Email : [email protected]
KolkataMerlin Links, 1st Floor, 1 G&F, 166-B S.P. Mukherjee RoadKolkata-700026Phone : +91-33-40605557 / 40605558Fax : +91-33-24632234Email : [email protected]
Works• Village & P.O. Rai, Distt. Sonepat, Haryana-131029
Phone : +91-130-2366571, 2366572 Fax : +91-130-2366384Email : [email protected]
• Village Dhaturi, Distt. Sonepat, Haryana-131002Email : [email protected]
• 1, SIPCOT Industrial Park, Vill. Mathur-Mangal, Post Cholavaram, Taluk Cheyyar, Distt. Thiruvannamalai, Tamilnadu 631 701Phone : 04182 - 306832; 306835; 306843Email : [email protected]