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.
HDPE infill spacer
Direct bond adhesive
Ceramic proven tile design
High performance Elastotec ceramic tiles
Ceramic Specifications
| 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 |
Tile edge flat on surface and perpendicular to applied load.
Applied load
Two 100x25mm tiles (one either side of 12mm steel plate)
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 |
DIRECT BOND CERAMIC LAGGING EXTREME - NON-DRIVE
Dimensions: Non-Drive pads 302x1155mm Tiles 100x25x6mm
| PRODUCT | CODE | TILE SIZE | TILE SEPARATION | TILES/PAD | PADS/CARTON | PAD WIDTH | PAD LENGTH | SQM/CARTON | WEIGHT/sqm |
|---|---|---|---|---|---|---|---|---|---|
| Direct Bond Non-drive 10.5mm Tiles | ELA-DBCL-ND-1160-86-10.5 | 20x20x10.5 mm body+1.5mm dimple. Dimples facing down | 2.5mm | 22x22 Total 484 | 4 | 500mm | 500mm | 1 | 25Kg |
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