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Customized Solutions. Innovative Polymers
SOUCY HD IMPACT BAR Raise the Bar
1. Why Impact Bars
2. Impact Bars: Challenges and Concerns
3. Soucy HD Impact Bar
■ Exclusive construction
■ Features and benefits
■ Increase reliability
■ Save Time and Money
4. Soucy HD Impact Bar: Raise the Bar…
AGENDA
WHY IMPACT BARS?
■ Shortened belt life due to faster wear of cover
■ Carcass deterioration due to poor load support
at impact points leading to belt failure
■ Heavy maintenance of impact idlers
■ Spillage of material
■ Decreased plant safety
■ Impact Bed: full belt support at the loading area, the belt cannot deflect, allowing a
constant seal between belt and skirting.
■ Impact bed system: fixed impact bars, with low friction UHMWPE at the top and
impact absorbing rubber at the bottom
The loading station: Large amount of wear and tear on the conveyor system
Source: Fenner Dunlop
IMPACT BARS: CHALLENGES AND CONCERNS (1)
Soucy Plastiques conducted a wide survey (More than 500 respondents) with stakeholders
(including impact bed manufacturer and distributors) of the mining and quarries industry to better
understand their concerns and needs regarding the use of impact bars.
■ Increasing demand for handling higher tonnage of material, it has become
imperative to develop a more effective system that will absorb the high
kinetic energy of the transferred material.
■ Conveyor belts are often damaged due to uneven and inadequate support to
the belt at loading points.
■ Frequent replacement of the impact bars.
■ It is not easy to remove the T-bolt jammed in the aluminum frame.
According to many of the respondents, removing the T-bolt is a major pitfall.
IMPACT BARS: CHALLENGES AND CONCERNS (2)
■ Many international Mine regulations prohibit the use of aluminum in the underground structure
due to health and safety reasons (corrosion, rupture, sparks…)
■ Delamination: Because the UHMW-PE layer has low friction
characteristics for supporting the belt to slide, it is also difficult to
glue (hot and cold adhesive) directly to the rubber layer. In this
regard, the glued UHMW layer tends to delaminate even under
relatively low loading conditions.
■ Gluing UHMW-PE is one of the difficulties that plague
manufacturers (many production steps, manual labor and costly).
SOUCY HD IMPACT BAR: EXCLUSIVE CONSTRUCTION
1. The upper layer: 0.75" of Soucy proprietary blended UHMW-PE wear surface with a Coefficient of Friction:
0.1, providing a slick surface for the belt to skim over without undue friction.
2. Underneath the UHMW, the core layer: 2" highest quality 60 Durometer SBR (Soucy proprietary rubber).
3. The Bottom layer (aluminium frame replacement): 1.25" UHMW-PE wear surface with a Coefficient of Friction:
0.1 which replace the aluminum frame and could be machined (shaped) regarding customer fixing needs.
■ This sandwich construction effectively absorbs the impact from falling material, while the long-
wearing UHMW outer slider bar seals the load zone.
■ Soucy HD Impact bars : Totally unique concept bar designed to increase replacement
intervals and thereby increase productivity in the crushing circuit.
■ The Soucy HD Impact bars : manufactured in one-step compression molding process
utilizing proprietary formulas developed by Soucy Group (rubber and UHMW-PE).
■ One-Step Production by our unique DCM process
■ Metal Free : the bottom layer of UHMW-PE replaces
aluminium channel guide
■ Glue and adhesive Free (Unique DCM process)
■ Soucy proprietary blended UHMW-PE wear surface
■ Soucy proprietary Energy absorbing SBR rubber
UHMW-PE strip
(Sheet)
Rubber or
Urethane
Aluminium Frame
■ Many production steps
■ UHMW-PE strip is difficult to glue to the
rubber layer
■ Aluminium Frame: rust, corrosion and
spark issues
SOUCY HD IMPACT BAR: EXCLUSIVE CONSTRUCTION
STANDARD IMPACT BAR SOUCY HD IMPACT BAR
0.75" UHMW-PE
1.25" UHMW-PE
2.00 " Rubber
SOUCY HD IMPACT BAR: CHARACTERISTICS
■ Width of Impact Bar: 4"; other width on request
■ Height of Impact Bar: 3 and 4"; other height on request
■ Length of Impact Bar: 48-60-72"; other lengths on
request
■ Color: white, red, blue; other colours on request
The thickness and length specifications of the top and middle layer could be adjusted according to
your needs, to meet different belt speed and width, material properties and processing capacity.
Soucy HD Impact bars are suitable for most of the impact beds available on the market
and are interchangeable with other bars (tailored machined slots).
SOUCY HD IMPACT BAR: FEATURES AND BENEFITS
1. Exceptional wear and impact resistance, so drive energy requirements are minimized
(reduce drag). Low friction top layer allowing belt easy glide over the impact bars, while
providing resistance to most oils, grease and industrial chemicals.
2. Less Rebounding, High load absorbing : Obtaining the most interesting properties of
each material without assembly, gluing or welding thanks to our innovative DCM process.
3. Consistent load transfer offering improved seal between conveyor belt and impact
bed. The UHMW bottom layer (aluminium frame replacement), is flexible and has
memory so will deflect then snaps back to its original shape, offering improved.
4. Reduced maintenance downtime : Simple to install and replace, making the task of
changing bars safer, faster and easier.
5. Simple Retrofit: Availability for any impact bed type
SOUCY HD IMPACT BAR: LESS REBOUNDING, HIGH LOAD ABSORBING
■ Using extensive lab testing1.2.3, Soucy HD
construction demonstrates significant
improvement in deflection over the standard
competitor design: reduces load
deflection and increases bar strength
■ Soucy HD impact bar deflects the load by 0.23-
0.35” versus 0.6-0.98” deflected by both
competitor construction. One of the lowest bar
deflection in the impact bar market.
■ When the rubber flexes, it heats up. Soucy SBR
has an outstanding heat stability than both
competition bars.
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5.2
Competitor #1 Competitor #1 Soucy
(minutes)
Tem
pe
ratu
re (
°C)
D
efl
ect
ion
(m
m)
#2 #1 Soucy HD
1 Applying 5000 lbs load (2cycles/sec) upon a 48” impact bar 2 Competitor #1 Rubber starts burning (smell) we stopped the test 3 Competitor #2 delamination of the UHMW-PE layer
Less Rebounding, High Load Absorbing
SOUCY HD IMPACT BAR: COMPRESSION & DEFLECTION
SPRINGS BACK TO ITS ORIGINAL SHAPE
COMPETITOR BAR WITH ALUMINIUM FRAME
SOUCY HD IMPACT BAR: LAB TESTING
SOUCY HD IMPACT BAR: STRONG & RELIABLE BONDING
Samples always break (failure) at 720-730 psi in the rubber layer,
never in the DCM bonding between UHMW/Rubber
UHMW-PE UHMW-PE Rubber
* ASTM D638 - Standard Test Method for Tensile Properties of Plastics
SOUCY HD IMPACT BAR: EASY & QUICK TO REPLACE
ALUMINIUM CHANNEL GUIDE UHMW-PE MACHINED CHANNEL GUIDE
30 min/ Impact bar
* 15 min/ Impact bar
■ The replacement of aluminium frame by a thick layer of a self-lubricated UHMW allows easy
removal of the T-Bolt.
■ Field testing* showed that replacement time could be cut by half using our bars compared to existing
bars with aluminum frame, which significantly reduce maintenance costs.
* Based on 2 years field testing (primary crusher) in a major Canadian Crushed Stone quarry (16” stone diameter, 1.5 million tons/year).
SOUCY HD IMPACT BARS: RAISE THE BAR
■ Improved seal: The UHMW bottom layer provides a consistent load transfer, is flexible and has
memory so will deflect then snaps back to its original shape, offering improved seal between
conveyor belt and impact bed.
■ Glue and adhesive free: A 2” rubber backing is trapped between two UHMW-PE layers during a
proprietary DCM process. Unlike the majority of competitors bars no adhesives is required to bond
offering a lifetime warranty against delamination.
■ Aluminium, spark and rust Free: UHMW is 15 times stronger and 3 times lighter than aluminium.
Moreover the new bar is sparks and rust free.
■ Quick, convenient and cost effective replacement: the replacement of aluminium frame by a
thick layer of a self-lubricated UHMW allows easy removal of the T-Bolt.
Soucy HD innovative bar construction, consisting of a thick layer of rubber entrapped
between two layers of slick UHMW-PE, cushion the belt and absorb impact.
SOUCY HD IMPACT BAR: INCREASE RELIABILITY, SAVE TIME & MONEY
1. Greater durability: Enhance bars service life by 55%
comparative to the current bars.
2. Easy and quick to replace: Reduce by half down-time
and reduce maintenance costs.
3. Metal-free impact bars: avoid rust and sparks issues
4. Lifetime warranty against delamination
5. More flexibility for bed fixing: customized attachments
6. Fast, On-time Shipping: less than one month
We are raising the bar, taking our exceptional experience in bonding rubber to UHMW-PE and State-of-
the-art technology to offer the most reliable and cost-effective impact bar in the market. 2 years field
testing in a major Canadian Crushed Stone quarry showed that the Soucy HD impact bars:
The end result is longer belt life, reduced spillage and decreased O&M costs
Customized Solutions. Innovative Polymers
YOUR PARTNER FOR SUCCESS
ISLEM YEZZA Business Development Director
Cell. : 819-313-1442 [email protected]
REAL VANDAL Account Manager
Cell. : 614-981-4887 [email protected]