Drum & Pulley Lagging
All State Conveyors offer reliable lagging solutions for your drum & pulley design specifications.
All State Conveyors offer Plain and Grooved rubber or Polyurethane and Ceramic Tile lagging solutions to increase the longevity of your pulley and belt life. Lagging is either bonded with our hot autoclave vulcanising method or cold bonded with our ContiTech adhesives. Lagging can be produced with 40~80 duro natural rubber in a variety of rubber compounds.
Our in-house Grinding Service delivers your preferred lagged rubber thickness or crowning dimension to your specifications. We stock a wide range of pulley lagging materials to ensure prompt delivery.
What is Lagging?
The term lagging describes a variety of elastomers used to coat the contact surface of a conveyor pulley. Its primary purpose is to enhance traction by increasing the coefficient of friction between the surfaces. The enhanced friction may also improve belt life by allowing for lower belt tensions and reducing abrasive conditions between the pulley and the belt. Additionally, lagging can protect the drum metal from premature wear and can be more cost effective to replace the lagging than the drum its self.
The type of contact surface chosen for the pulley face will impact a number of application variables within the conveyor system. Unless an alternate surface is desired, pulleys are finished with a plain steel or machined type finish comparable to that of a standard tube or pipe utilised when manufacturing the initial drum. Un-lagged plain steel drum pulleys are best utilised in clean and dry conditions where traction does not need enhancing, and where no foreign matter is present on the return belt.
The most common contact surface modifications are those designed to increase the traction or grip between the drive pulley and the underside (pulley cover) of the conveyor belt. In addition to providing increased traction, an alternate contact surface may be utilised to impact the pulley wear resistance, ease of cleaning, reduce aqua planning and aesthetics. You can read more about benefits delivered by pulley lagging further down the page.
Rubber pulley lagging fabrication is usually specified in terms of its type, hardness, thickness and finish.
Lagging Type and Finish
There are 2 main choices for rubber based lagging, Rubber or Rubber Backed Ceramic Tile Lagging. The rubber finishes can be either smooth and plain or grooved to your specifications. Rubber backed ceramic tiles are ideal for the harshest of conditions particular when the conveyor is operating in extremely wet conditions or long haulage situations. The rubber utilised in lagging has a number of properties, which assists the pulley to gain traction, reduce the wear it is subjected to and to enhance friction with the conveyor belt.
The type of lagging profile to be used is specified on the basis of what it is used for, what it is subjected to and how long you require your pulley to function. For instance, a typical flat or troughed belt conveyor system may require the following as shown:
The type of lagging hardness to be used is also specified on the basis of what it is used for, what it is subjected to and how long you require your pulley to last. Snub pulleys and bend pulleys are usually located on the carrying side (Non Drive) of the belt and are subjected to a lot of debris and dirt. In this case ACS would recommend applying a hardness of 35 to 45 durometers Shore A. The Drive and Take-Up and Tail pulleys require a hardness of between 55 and 65 durometers Shore A to ensure operational consistency.
The variant for rubber lagging thickness is within the standard range of 6mm~12mm. We are able to produce a thicker profile upon request by combining thickness combinations. It is important to acknowledge that the pulley rubber lagging hardness should be less than that of the cover rubber of the running belt. The drive pulleys tend to require a grooved lagging thickness of 10mm~12mm unless non standards are specified, whereas the other pulleys require plain lagging anywhere from between 6mm – 10mm. ASC is able to suggest the appropriate thickness but will also engineer to your specifications.
Engineering to your situationASC Pulley Lagging Fabrication and Services
ASC Drive and Non Drive Drum Pulley Selections
All State Conveyors supply a wide range of high quality Drive and Non Drive Pulleys used for belt conveyors. These head, tail, take-up and snub pulleys are designed for light to heavy duty applications. These pulleys can be supplied with or without cylindrical or crowned shaped lagging to assist with belt tracking. We also stock self-cleaning Winged and Spiral Pulleys, which have the self cleaning capabilities to remove loose materials that may enter the return side of the conveyor system. ASC has the expertise to deliver a variety of shaft configurations and machined surfaces, including live shafts, dead shafts, taper locks, flat crowned, heat stressed, self cleaning and lagged.
Download drum pulley data completion form to request a quotation or to order directly, click here.
Or contact our specialist team for any enquiry for drum pulley.
ASC Reliable Lagging Service to Suit Your Pulley Design
At All State Conveyors, our manufactured or our customers supplied conveyor head, tail and snub drums can be provided with custom and standard lagging, designed and manufactured by our skilled lining and lagging technicians to your specifications. All our technicians are very experienced in understanding the various sources of friction and environmental conditions that may effect the tension of your conveyor belt system and will suggest and design solutions to ensure maximum belt and pulley life for both standard and complex applications.
Types of Rubber and Durometers Used for Lagging Rubber
Our lagged finished materials and styles are comprised of either natural rubber or in a variety of rubber compounds which include specially blended rubbers such as Nitrile, EPDM, Neoprene, FRAS (flame resistant and anti-static) and White Hygienic, and also a choice of embedded rubber with ceramic tiles to give superior traction and wear protection for the toughest of working conditions.
Hot vulcanised lagging for your drum pulley utilises rubber compounds such as, AS-M Grade Rubber, abrasion resistant rubber, coloured neoprene or nitrile blends for the printing and food industries, with the standard shore hardness of 65 (± 5) and other durometers and blends achieved upon request. Note: that coloured rubber compounds are also available upon request.
ASC Lagging Bonding Solutions: Cold or Autoclave Hot Vulcanising
All State Conveyors are able to provide reliable cold bonded drum pulley lagging, with cured rubber to bond to our customers pulley using ContiSecur adhesive. We are also able to utilise our in-house fully programmable autoclave hot vulcanising procedure for ultimate adhesion.
Autoclave Hot Vulcanising: Application of Pressure is the Key Component
All State Conveyors in-house autoclave hot vulcanising provides superior bonding of rubber to metal and rubber to rubber by applying both heat and pressure to conveyor drums and other steel substrates. This process gives one of the best possible adhesion ratings when compared to the cold bonding process which uses rubber based glue. Hot vulcanising is highly recommended for chemical and abrasive slurry handling and long haul, high tonnage applications.
The key component of our industrial autoclave is in the application of pressure; during the heating process the materials are under constant pressure whilst curing during the cooking process. This pressure enables the rubber to gain maximum contact with the metal with uncured rubber primers giving a long lasting working life for your lagged or lined steel component. After the cooking process, the conveyor drum may be grooved with either a diamond or chevron pattern or simply left as a plain flat finish.
Did You Know? Vulcanised lagging recommended for drive pulleys on conveyors operating under high belt tension.
Various Lagging Options (Methods) to Suit Your Specifications
There are a number of lagging options on offer at ASC. These include, Rubber Lagging and Rubber Backed Ceramic Tile Lagging, with the choice off Sheet Wrap methods or Replaceable Strip Lagging, either of these which can be autoclaved with hot vulcanising or cold bonding. Finished Rubber Lagging can be supplied in plain (bare) or patterned with either a diamond, chevron or herringbone styles, which can be applied either on a flat or crowned surface to your engineered specifications.
Integrated Lagging Solutions
ASC offers a complete service which compliments our many lagging options. We have the ability to remove worn lagging and fix damaged lagged surfaces to increase adhesion to the pulley shell. We also perform pulley reconditioning and maintenance with abrasive blasting, re-lagging, grinding, flat and crowned rubber lagging, trimming and painting during pulley change outs. We have the expertise to deliver a variety of shaft configurations and machined surfaces, including live shafts, dead shafts, taper locks, flat crowned, heat stressed, self-cleaning and lagged.
All State Conveyors works with you to understand where your issues are and the complexity of your operation and to quickly rejuvenate your existing drum or introduce a new lagging solution to improve your operations. We look to ensure that our suggested or your instructed lagging is fit for purpose and it has the life span to fit your requirements.
Our conveyor pulleys and metal work can abrasive blasted to meet AS 1627.4-2005 standards – this preparatory work allows our highly skilled lining and lagging technicians to achieve the best possible bond between the rubber compound and the steel substrate.
Not Sure What Type of Pulley Lagging is Best Suited for Your Operation?
You can read more about our in-depth Drum Pulley Lagging Options, click here.
To obtain a quote, email your pulley design or call us on 03 97066339 to speak with one of our technical sales team to discuss your lagging requirement.
ASC Rubber Lagging Complete with Grinding Services
All State Conveyors in-house grinding service is set up to deliver to our customers specifications, especially if you have a preferred lagging rubber thickness, profile of a flat or crowned (tapered) pulley surface and diamond, herringbone or chevron groove styles.
We accommodate industrial rubber rollers and pulleys up to 4 metres in length and 2 metres in diameter (bonding methods apply). We cater for all rubber grinding aspects with rubber hardness from 30~85 duro shore hardness. Rubber grinding can also be applied with specially blended rubbers such as Nitrile, EPDM, Neoprene, FRAS (flame resistant and anti-static) and White Hygienic.
Why Grind a Rubber Lagged Straight Faced and Crowned Pulley?
- To remove depleted rubber or to recover worn lagging rubber
- To solve problems associated with excessive lagging heights which cause misalignment or the belt being overstretched.
- To alter the conveyor belt speed by either increasing or decreasing the thickness of the lagging.
After completing your lagging, our expert technicians at ASC are able to create a crowned finished surface, which will further assist with your conveyor belt tracking. It is advisable when utilising lagged pulleys that you understand the appropriate height that you require for your crown to ensure your belt remains durable and not over tensioned – generally 1.5 mm over the diameter.
ASC offers a crowning service to fashion the correct height for your crowned pulley. Our technicians will firstly lag your pulley and then crown the surface of your pulley to your engineered specifications. Their expertise ensures that they can offer you appropriate lagging options including hot vulcanised and cold bonded techniques.
Email us or call us on 03 97066339 and speak to our sales department about your rubber lagging requirements or to arrange a quote.
Why you need pulley lagging6 Key Benefits Delivered by Pulley Lagging
#1. Wear Resistance and Abrasion Protection
Conveyor belt drums located under pick-up points, transfer points, bins and bunkers are very vulnerable to abrasion. In order to reduce the likelihood of this happening, drum pulley lagging will not only assist with protecting your componentry but assist with belt tracking and alignment.
#2. Better Grip/Traction
Pulley lagging protects your conveyor belt from potential wear and abrasion. If you lag your drive pulley it will result in greater durability because it will assist with the effectiveness of the drive and of the apparent friction between the pulley and the conveyor belt.
#3. Reduce Slippage
Extreme wet weather, wet slurry and muddy conditions increase the likelihood of slippage and aqua planning. Lagging assists in these tough conditions to create greater friction grip and greatly reduces the likelihood of slippage, particularly if the drive pulley is appropriately lagged and grooved. Grooving has an additional benefit as it improves the cleaning action for both the drive and belt.
#4. Self Cleaning
Processed rock materials can carry residue such as water, mud and dirt, therefore your system needs the self cleaning action of the grooved pulley, this helps to prevent the unwanted material sticking and therefore aids to remove this potential hazard. If the conveyors are subjected to extreme weather conditions such as heavy rain or extreme overnight cold temperatures creating ice, then grooved lagging also assists with removing the potential frozen build up and displaces water on the pulleys.
#5. Maximise Service Life
Rugged wet or dry working conditions coupled with extreme weather can be associated with mining and quarrying environments and cause numerous challenges for your conveyor system. Conveyor belt componentry can also cause unnecessary stoppages if not properly maintained with protection such as lagging. Lagging comes in a number of finishes such as duro hardness or lagged with grooved rubber or plain wrapped which increases positive drive in adverse conditions.
#6. Long Term Maintenance Investment
Head, tail and snub drums are subjected to continuous degradation and build up of debris. This is due to the repetitive, fast, high wearing environment and spillage from the conveyor belt. To safeguard your pulleys peak performance and your investment, ASC would recommend shielding your componentry with high-grade rubber performance rubber lagging. Plain and grooved lagging is designed to secure your pulleys working life, dependability and production hours. It is actually cheaper in most cases to re-lag a drum than it is to re-make another one.
Looking for Pulley Lagging Option that is Best Suited for Your Operation?
You can read more about our in-depth Drum Pulley Lagging Options, click here.