Direct Bond Lagging

As a specialist pulley lagging manufacturer Elastotec has developed the Direct Bond Ceramic Lagging and method of application.

The method of application has been designed to ensure consistent and reliable results under a variety of application conditions. In addition, a network of Approved Applicators has been trained to use the Elastotec Direct Bond Ceramic Lagging (DBCL) application method. This ensures that only trained operators using OEM materials apply the Elastotec DBCL. The result:

Consistent application to OEM speciﬁcations.
Reliable result.
Long life trouble free lagging performance.

Category:Elastotec Direct Bond Lagging Tags:Direct Bond, Lagging

Description

Description

Application

Elastotec Direct Bond Ceramic Lagging (DBCL) is designed for use on drive and non-drive conveyor pulleys. This lagging provides a maintenance free wear resistant surface that will provide increased traction for drive pulleys and a smooth surface for bend and tail pulleys.

Key features and benefits

Increase friction coefﬁcient on drive pulleys, grouted tiles decrease the risk of ingress and corrosion, longer service life, superior bonding strength, proven application.
It is a maintenance-free, wear resistant cover applied to pulley shells that contributes to reduced downtime and lower operating costs by improving traction in drive pulleys and providing hard wearing surface on non-drive pulleys.
The high co-efﬁcient of the studded tiles ensures there is no movement between the ceramic-lined drive pulley surface and the conveyor belt surface. Drive Pulleys have dewatering grooves that dissipate water can be hosed down without losing traction and studs with rounded edges that present a less severe interface with the belt bottom cover.
Non-Drive Pulleys the smooth tile surface provides a low maintenance surface with proven long service life under a variety of conditions.
For drive pulleys with Elastotec Direct Bond Ceramic Lagging consideration must be given to ensuring the conveyor design does not create slippage between the conveyor belt and the Direct Bond Ceramic Lagging as this can cause belt cover wear. This is most likely on medium and high tension belting applications. Elastotec can assist conveyor users with computer modelling using the “Lagging Analyst” software to determine if slippage is likely to occur for speciﬁc conveyor pulley applications.
Australian developed product.
Australian owned company.
Innovative application method.
Reduced application time, lead time & cost.

Design

Our unique Direct Bond Ceramic Lagging (DBCL) system was developed to provide a lagging for use on both drive and non-drive pulleys that provides exceptional levels of service life.

Ceramic Specifications

Typical values

Property	Non-drive	Drive
Aluminium oxide	92%	95%
Specific gravity g/cm3	3.6	3.7
Vickers hardness (HV10)	1000	1200
Flexural strength (Mpa)	270	300
Compressive strength (Mpa)	1600	1800
Fracture Toughness (Mpa m1/2)	3-4	3-4

Technical Advantages

1. Tiles

High performance 95% aluminium oxide ceramic for increased abrasion and crack resistance to provide longer service life than the 92% aluminium oxide tiles used by other suppliers.

Drive tiles designed with 1mm dimples on back surface to ensure consistent tile position and low Total Indicator Runout (TIR) – see photo below. Also the Elastotec ceramic tiles are based on a high performance 95% aluminium oxide that is dry injection pressed and sintered under tightly controlled conditions. This produces a small particle size ceramic with outstanding physical properties, abrasion and ﬂex crack resistance.

2. Adhesion System

High strength bonding system to provide adhesion of the ceramic tiles to the pulley shell >20MPa. Metal primer for application to the steel pulley shell immediately after sandblasting to prevent oxidation and ensure consistency and control – removes chance of operator error.

DIRECT BOND CERAMIC LAGGING METAL PRIMER

Application of DBLC can take 3-4 days to complete during which tile the blasted ﬁnish on the pulley shell can start to oxidise / corrode. To eliminate the risk of variable adhesion due to pulley shell corrosion after blasting, Elastotec has developed a primer system that when applied immediately after the blasting of the pulley shell seals the pulley surface and prevents surface corrosion. Photo #1 shows surface corrosion on a pulley shell after only 16 hours from the time the shell was sand blasted. The primer has no adverse effect on adhesion values of the tiles and the steel shell but it does provide a minimum of 4 weeks protection from corrosion for the shell.

DIRECT BOND CERAMIC ADHESIVE

The Elastotec DBA adhesive has been formulated to combine excellent adhesion to the steel pulley shell and the aluminium oxide tiles with robust processing characteristics. This adhesive has proven performance for outdoor service exposed to UV, water, dust, dirt, etc. The adhesive has good properties at both low and elevated temperatures and can operate in pulley lagging applications from -20°C to +70°C.

Bond strengths as tested

1	2
Bond strength	31.2 Mpa

3. Application Process

Elastotec developed an application procedure to ensure maximum service life. Elastotec trained operators with checklist / Record for each pulley.

As a specialist pulley lagging manufacturer Elastotec has developed the DBCL and the method of application has been designed to ensure consistent and reliable results under a variety of application conditions. In addition a network of approved applicators have been trained to use the Elastotec DBCL application method. This ensures that only trained operators using OEM materials apply the Elastotec DBCL. The result:

Consistent application to OEM speciﬁcations.
Reliable result
Long life
Trouble free lagging performance.

Lagging specifications – Direct Bond Ceramic Lagging

DIRECT BOND CERAMIC LAGGING - DRIVE

Dimensions: Drive pads 1155x41mm Tiles 20x20x6mm

PRODUCT	CODE	TILE SIZE	TILE SEPARATION	TILES/PAD	PADS/CARTON	PAD WIDTH	PAD LENGTH	SQM/CARTON	WEIGHT/sqm
Direct Bond Drive 6mm Tiles	ELA-DBCL-D-1155-41	20x20x6mm +1mm dimples top + 1mm dimples bottom	1mm	2x57 Total 114	21	41mm	1155mm	1	22.5Kg

DIRECT BOND CERAMIC LAGGING EXTREME - DRIVE

Dimensions: Drive pads 1160x86mm Tiles 20x20x10.5mm

PRODUCT	CODE	TILE SIZE	TILE SEPARATION	TILES/PAD	PADS/CARTON	PAD WIDTH	PAD LENGTH	SQM/CARTON	WEIGHT/sqm
Direct Bond Drive 10.5mm Tiles	ELA-DBCL-D-1160-86	20x20x10.5 mm body +1.5mm dimple	2.5mm	4x57 Total 228	6	86mm	1160mm	0.6	25.0Kg

DIRECT BOND CERAMIC LAGGING - NON-DRIVE

Dimensions: Non-drive pads 500x500mm Tiles 20x20x6mm

PRODUCT	CODE	TILE SIZE	TILE SEPARATION	TILES/PAD	PADS/CARTON	PAD WIDTH	PAD LENGTH	SQM/CARTON	WEIGHT/sqm
Direct Bond Non-drive 6mm Tiles	ELA-DBCL-ND-500-500-06	20x20x6mm body	1mm	23x23 Total 529	4	500mm	500mm	1	21Kg