Wear Indicator Rubber Lagging

Wear Indicator
Rubber Lagging

Products > Rubber Lagging > Wear Indicator Rubber Lagging

Wear Indicator
Rubber Lagging

Wear Indicator Rubber Lagging is popular having a visual indication on when the lagging needs to be scheduled for replacement.

Elastotec Wear Indicator Rubber Lagging has been developed to provide mining companies with a long life lagging that will provide a visual indication when the abrasion resistant lagging has been worn away and the lagging should be scheduled for replacement.

The coloured wear indicator layer is designed to indicate when the lagging replacement is required and to also provide protection for the pulley shell while lagging replacement is scheduled.

Download Brochure

Request a Quote

Name

This field is for validation purposes and should be left unchanged.

Name(Required)

First Last

Job Title

Company(Required)

Email(Required)

Phone(Required)

Site

Country(Required)

Country

Message

Key Features and Benefits

Built-in Visual Wear Indicator

A coloured sublayer (blue for SBR, red for FRAS) becomes visible when the abrasion layer is worn, alerting for replacement.

Shell Protection Margin

Helps avoid catastrophic pulley shell wear by providing warning before metal is exposed.

High Abrasion Resistance

Uses a robust synthetic elastomer top layer for long service life in demanding conditions.

Low Temperature Flexibility

Compound retains flexibility down to –50 °C, suitable for cold environments.

Strong Bonding System

Proven bonding between the abrasion layer and coloured backing ensures integrity under load.

Flexible Thickness Options

Supplied in 15, 20, and 25 mm thicknesses to suit different pulley designs and anticipated wear depth.

Wide Operating Temperature Range

Rated for –40 °C to +70 °C for reliable performance in diverse climates.

Trust Elastotec Hot Vulcanised Ceramic Lagging

Minimise Risk, Maximise Production and Reduce Downtime.

We don’t just manufacture lagging – we engineer performance. Here’s How:

The Elastotec Autoclave

Precision-controlled vulcanization for superior bond strength.

Investing in Excellence: The Elastotec Autoclave

For over a decade, Elastotec has set the industry benchmark in Hot Vulcanised Ceramic Lagging (HVCL). Our ongoing commitment to our clients has been the same from Day 1: Deliver lagging that is engineered to outlast the mechanical components of the pulley – minimising the risk to their operations, whilst helping maximise productivity and performance.

In 2012, Elastotec invested in our own autoclave – allowing for precise controls over the critical bonding and curing conditions as part of a highly robust testing process. Very few manufacturers have the commitment, the equipment and the expertise to perform this process in-house.

Unlike conventional methods, our HV process ensures that heat and pressure – essential for vulcanisation – do not degrade rubber properties or weaken the ceramic-to-rubber bond.

The result? Years of rigorous testing (over 1000 tests) have confirmed that Elastotec HVCL delivers a 100% rubber tear bond between all lagging components, with less than 5% change in ceramic to rubber adhesion strength after autoclave curing.

This is extremely difficult to achieve.

The Elastotec “HV” coloured logo is your stamp of assurance. That’s why Elastotec is the only HVCL that is Engineered to Perform: Minimise risk. Maximise production. Reduce downtime.

In-House Product Design & Manufacturing

Innovation-driven solutions for maximum longevity.

Inhouse Product Design & Manufacturing

When unplanned downtime costs hundreds of thousands of dollars, reliability isn’t just a goal – it’s a necessity. At Elastotec, we don’t take shortcuts. Instead of relying on third-party components, we design, develop and manufacture everything in-house to eliminate risks and guarantee performance.

Ever wondered why our Hot Vulcanised Ceramic Lagging (HVCL) consistently outperforms all alternatives? By maintaining full control over every variable, we can guarantee every outcome:

· We formulate our own rubber compounds in-house – specifically designed for conveyor applications
· We select and test our ceramic tiles to exact specifications
· Our ceramic-to-rubber bond system was specifically designed to cope with the hot vulcanising process, ensuring zero tile debonding (from the rubber) post autoclaving and whilst in service
· We design, test and refine our bonding systems with our own purpose-built equipment
· We manufacture in controlled conditions, in our own facility that is 100% dedicated to pulley lagging

With over a decade of continuous improvement, we’ve achieved a ‘unified’ approach to manufacturing – from compound formulation to final lagging application.

While others assemble, we engineer – ensuring our lagging outlasts the mechanical components of the pulley itself.

The Elastotec “HV” coloured logo is your stamp of assurance.  That’s why Elastotec is the only HVCL that is Engineered to Perform:  Minimise risk.  Maximise production. Reduce downtime. 

Approved Applicator Program

Rigorous training and certification to ensure flawless application.

Approved Applicator Program

No matter how exceptional Elastotec Hot Vulcanised Ceramic Lagging (HVCL) is, improper installation compromises performance. A world-class product means nothing if it’s not applied correctly – that’s why we’ve taken quality control beyond manufacturing and into application.

We created the Elastotec Approved Applicator Program to guarantee every installation meets the same high standards as our manufacturing process:

– Exclusive Application Rights – Only trained, certified applicators can install Elastotec HVCL, ensuring strict quality control.
– Comprehensive Training
– A rigorous certification process, backed by a 38-page application manual refined over 10+ years.
– Equipment Validation – We verify that all application equipment is compatible with Elastotec HVCL, eliminating variables that can lead to installation failures.
– Standardised Processes – Surface preparation, adhesive selection, and application techniques follow our strict, standard procedures.
– Mandatory Testing – Every pulley undergoes adhesion testing before leaving the workshop, guaranteeing bond strength.
– Shared Warranty Responsibility – Elastotec and our Approved Applicators jointly back both the product and installation – a rare industry commitment.

By controlling both product quality and application, we eliminate common lagging failures such as debonding, edge lifting, and joint separation. The result? A superior, long-lasting system -engineered, applied, and tested for maximum reliability.

The Elastotec “HV” coloured logo is your stamp of assurance.  That’s why Elastotec is the only HVCL that is Engineered to Perform:  Minimise risk.  Maximise production. Reduce downtime. 

Advanced Laboratory Testing

Every batch is tested for uncompromising quality and durability.

Advanced Laboratory Testing

Inside Elastotec’s Testing Laboratory: Where Science Drives Performance When your operation depends on reliable conveyor performance, the difference is in the detail – and that’s where Elastotec delivers.

Our Testing Philosophy: Verify Every Aspect For over a decade, Elastotec has led the way in Hot Vulcanised Ceramic Lagging (HVCL) through a relentless commitment to rigorous testing and continuous innovation. We don’t just test quality – we engineer it into every product.

The Elastotec Testing Laboratory rigorously tests across three key areas:

– Rubber Compound Performance – From abrasion resistance to tensile strength, rheology to chemical resistance we validateproperties that affect your operations.
– Ceramic Quality & Durability – Our ceramic testing protocols ensure optimal performance and wear characteristics.
– Bond Integrity Systems – We test every connection point: ceramic-to-rubber, rubber-to-steel, and more, ensuring the unified performance that defines Elastotec quality.

Testing Across Real-World Conditions Elastotec has invested in specialised environmental chambers to replicate the harshest conditions, from 40°C up to +150°C. While our in-house Autoclave tests both before and after vulcanisation – an often overlooked but critical step in quality assurance.

We work with leading external labs like TUNRA and the Australian Ceramics Institute to ensure our systems perform even in the most demanding environments. At Elastotec, testing isn’t a checkbox – it’s the foundation of performance.

The Elastotec “HV” coloured logo is your stamp of assurance. That’s why Elastotec is the only HVCL that is Engineered to Perform: Minimise risk. Maximise production. Reduce downtime.

Proven Track Record

Over 5,000 successful applications worldwide.

Proven Track Record

Over 10,000 Proven Applications Worldwide Since its development in 2012, Elastotec Hot Vulcanised Ceramic Lagging (HVCL) has been installed on more than 10,000 pulleys across the world’s most demanding mining operations.

This widespread adoption reflects the consistent performance and reliability of a properly engineered solution:

– Proven in Iron Ore – From Western Australia’s operations to Brazil’s mining networks, Elastotec HVCL has become the specified solution for companies who cannot afford pulley failures.

– Trusted in Copper – Major copper mines across Chile, Peru, Indonesia, and Mongolia rely on our lagging for their critical conveyor systems.

– Performing on the World’s Largest Conveyors – Elastotec Hot Vulcanised Ceramic Lagging is successfully performing in the biggest conveyors in the world, including Gearless Drive Conveyors powered by 6 MW motors.

– Adopted Industry-Wide – From Australian coal operations to mining sites throughout North America, our global footprint continues to expand based on documented performance.

The technical advantage comes from a combination of toughness and flexibility. Our solution prevents debonding from pulley shells and eliminates tile separation from rubber backing, even in punishing environments. Yet at the same time, due to its engineered flexibility, it is kind to the belt and splices – protecting these costly components from premature wear and fatigue.

Elastotec hot vulcanised ceramic lagging has extended pulley service life to the point where the lagging outlasts the mechanical components of the pulley. This means conveyors no longer need to be stopped due to lagging failures – a fundamental shift in maintenance planning and operational reliability.

The Elastotec “HV” coloured logo is your stamp of assurance. That’s why Elastotec is the only HVCL that is Engineered to Perform: Minimise risk. Maximise production. Reduce downtime.

Lagging Select – Your Online Resource

The ultimate platform for selecting the right lagging solution.

Lagging Select

Lagging Select – Engineering Excellence Behind Elastotec Hot Vulcanised Ceramic Lagging

Pulley lagging isn’t guesswork – it’s engineering. And at Elastotec, we don’t just offer a product. We deliver a system designed for precision, performance, and reliability.

Our Hot Vulcanised Ceramic Lagging is engineered to outperform because it’s selected using Lagging Select – our proprietary analysis tool that ensures every application is tailored to your conveyor’s unique demands.

What sets us apart?
– Lagging Selection. Tailored to system specs & performance goals
– Root Cause Analysis. Identify why failures happen — and fix them for good
– Performance Assessment. Quantify gains before making the switch

Whether you’re selecting lagging for a new pulley, solving premature failures, or looking to extend belt life – we back every recommendation with data-driven engineering.

The Complete Elastotec System includes:
– Autoclave bonding
– In-house R&D and manufacturing
– Certified applicators
– Advanced lab testing
– 10,000+ global applications
– Backed by Lagging Select engineering analysis

Why settle for trial and error when you can choose with confidence? It’s not just about having the best lagging – it’s about having the best lagging for YOUR application.

More Information

Pulley Lagging Case Studies

How lagging select can de-risk an entire mining operation

Download

Hot Vulcanised Ceramic Lagging Extends Pulley Life at an Iron Ore Mine

Download

Increased Service Life of Pulleys With Elastotec Hvcl

Download

Talk to Our Lagging Team

Request a Quote

This field is for validation purposes and should be left unchanged.

Name(Required)

First Last

Job Title

Company(Required)

Email(Required)

Phone(Required)

Site

Country(Required)

Country

Message

Mariana Ballestrin

Key Account Manager

David Morley

Key Account Manager

Caroline Oliveira

Key Account Manager

Greg Fogo

Key Account Manager

Request a Quote

Facebook

This field is for validation purposes and should be left unchanged.

Name(Required)

First Last

Job Title

Company(Required)

Email(Required)

Phone(Required)

Site

Country(Required)

Country

Message