Pulley Lagging Options
ASC Supplied Conveyor Pulley Lagging Options
Looking for conveyor pulley lagging options for your pulley design?
All State Conveyors lagging specialists are able to fabricate reliable rubber and ceramic lagging to meet your pulley design needs.
We offer numerous rubber cover compounds and firmness options (durometers) to choose from, with Plain or Grooved Rubber Lagging and Rubber Backed Ceramic Tile Lagging options, utilising Full Sheet Wrap method or Replaceable Strip Lagging which is bonded to flat and crowned surfaces with cold bonding or autoclave hot vulcanising methods and equipment. Our fast turnaround services ensure quick delivery.
ASC Lagging, Delivers to Your Design Specifications
All State Conveyors are able to provide Drive Pulley (head) and Non Drive Pulley (tail, snub & take-up) lagging solutions for the use in all light to heavy-duty operations. Lagging can be directly bonded to customers steel work by using either cold bonding or hot vulcanising techniques with our in-house fully programmable autoclave. Drum lagging also assists the conveyor belt when it is has a tendency to aqua plane in wet weather or in adverse tracking situations.
All State Conveyors provide primarily 2 lagging options:
- Plain Rubber and Grooved Rubber Lagging
- Rubber Backed Ceramic Tile Lagging
Read below for the full details of our lagging options and recommendations for drive and non-drive pulley lagging.
#1. Plain Rubber and Grooved Rubber Lagging
Rubber lagging is a versatile application. It is essential if you want to contain wear and achieve better traction between your pulley and belt on your conveyor belt system. Rubber is a relatively ‘soft’ flexible material, ideal for use in lagging situations with hardness ranging from 38~80 durometer Shore A.
It is important to understand that with rubber lagging, the operational life is limited to the conditions it works in and must be monitored so that it can be replaced routinely. This process needs to be repeated as the lagging protects the pulley and the belt, and is subjected to continuous operational wear. ASC suggests scheduling re-lagging when doing routine maintenance or shutdown works.
Note: Belt slippage may occur even though rubber lagging increases friction to the conveyor belt.
Do You Choose Plain Rubber or Grooved Rubber Lagging?
There a variety of grooved lagging solutions available that are designed to be ‘Fit for Purpose’. Plain rubber lagging is typically used for non drive pulley’s like the snub pulley, where start up and drive traction is not critical. Plain lagging offers good lateral traction to maintain the friction between the belt and pulley, without excessively increasing friction that could cause the belt to wear faster.
Grooved rubber lagging not only improves the co-efficient of friction and in turn the traction between the belt and the pulley but also assists to operate the belt more effectively, even when there is a residue build up. The Diamond Grooved Lagging quickly dispels any dirt and liquids embedded on the pulley surface whilst in operation. ASC highly recommends grooved lagging to be used where material deposits, heavy rain or water cannot be totally avoided.
Grooved rubber lagging is a more flexible option in comparison to Plain Rubber, which is due to the gaps in the rubber that allows the lagging extra room to flex and move with the conveyor belt. This added flexibility also allows the rubber to keep in contact with the same section of the conveyor belt and helps reduce belt slippage.
ASC offers a number of ‘Fit for Purpose’ groove lagging as well as plain lagging options for pulley surfaces as shown below.
Plain / Bare Lagging
Why Choose Plain Lagging? Plain lagging has a non-grooved flat surface, it is generally used on non-drive pulleys and is suitable for situations where water doesn’t need to be removed as readily from the conveyor belt system such as snub and bend pulleys.
Rubber Type: Grade AS-M or similar
Rubber Hardness: 60 (± 5) duro Shore A
Suitable Pulley Type: Drive and Non Drive pulley such as Tail, Take-Up, Snub and bend pulleys
Pulley Size Capability: Applicable for standard sizes from 30mm~1500mm in diameter for hot vulcanising and the pulley size can be larger for cold vulcanising.
Durability: Low / Medium / High
Application / Bonding Process: Secured with cold adhesives or hot vulcanising
Stocked As: Standard Grade AS-M floor stock
Tips: When considering plain lagging, it is helpful to understand it is very similar to the Patten Grooved and can be used as is (without any groove style) but will not have all the other benefits. Plain and grooved lagging utilises the same bonding techniques.
Diamond Groove Lagging Profile
Why Choose a Diamond Groove Pattern? This grooved pattern is mostly used for reversing conveyor drive pulleys but can also be utilised for bi-direction circulation. Diamond grooved rubber lagging is ideal when more friction to the conveyor belt is required in wet or damp conditions. This profile pattern is excellent for water and dirt shedding.
Rubber type: Rubber: 60 Duro, Grade AS-M or similar
Rubber Hardness: 60 (± 5) duro Shore A
Suitable Pulley Type: Drive and Non Drive pulleys such as Tail Pulley, Take-Up Pulley, Snub Pulley and Bend Pulley
Size of Pulley: Applicable for standard sizes from 30mm~1500mm in diameter for hot vulcanising and the pulley size can be larger for cold vulcanising.
Durability: Low / Medium / High
Application / Bonding Process: Secured with cold adhesives or hot vulcanising
Stocked As: Standard Grade AS-M floor stock
Tips: Allowing a build up of debris in the grooves will greatly affect the friction between the pulley and the belt and cause the belt to eventually malfunction. This profile is a popular standard pattern for lagged conveyor pulleys at All State Conveyors and is readily available. Add image / Specifications
Chevron Lagging Profile
Why Choose a Chevron Pattern? This profile is designed for one directional drive pulleys and is also excellent at dispersing liquids and other sticky substances. It is more flexible when compared to the plain rubber option due to gaps in the rubber, which allows the lagging extra room to bend and move with the conveyor belt. The added flexibility also allows the rubber to keep in contact with the same section of conveyor belt and helps reduce overall belt slippage.
Rubber type: Rubber: 60 Duro, Grade AS-M or similar
Rubber Hardness: 60 (± 5) duro Shore A
Suitable Pulley Type: Drive and Non Drive pulley such as Tail Pulley, Take-Up Pulley, Snub Pulley and Bend Pulley
Size of Pulley: Applicable for standard sizes from 30mm~1500mm in diameter for hot vulcanising and the pulley size can be larger for cold vulcanising.
Durability: Low / Medium / High
Application / Bonding Process: Secured with cold adhesives or hot vulcanising
Stocked As: Standard Grade AS-M floor stock
Tips: The points of the groove should meet in Chevron styled lagging. As the drive drum pulley is one directional, it is important that the lagging is bonded in the precise way by lagging specialists.
Herringbone Lagging Profile
Why Choose a Herringbone Pattern? The Herringbone lagging profile is designed for only forward action pulleys for the easy elimination of liquids and dirt from the pulley and the belt. It is more flexible when compared to the plain rubber option due to the gaps in the rubber, which allow the lagging extra room to bend and move with the conveyor belt. The added flexibility also allows the rubber to keep in contact with the same section of conveyor belt and helps reduce belt slippage.
Rubber Type: Rubber: 60 Duro, Grade AS-M or similar
Rubber Hardness: 60 (± 5) duro Shore A
Suitable Pulley Type: Drive and Non Drive pulley such as Tail Pulley, Take-Up Pulley, Snub Pulley and Bend Pulley
Size of Pulley: Applicable for standard sizes from 30mm~1500mm in diameter for hot vulcanising and the pulley size can be larger for cold vulcanising.
Durability: Low / Medium / High
Application / Bonding Process: Secured with cold adhesives or hot vulcanising
Stocked As: Standard Grade AS-M floor stock
Tips: It’s important to understand that the Herringbone Lagging profile should have the grooves pointing in the direction of the rotation of the pulley. This action not only benefits the pulley but the supports the belt’s forward action as well. This particular grooving is also designed to have exceptional traction.
#2. Ceramic Tiles Lagging (Rubber Backed)
Why Ceramic Tile Lagging?
Ceramic Tile Lagging is an ideal answer if you wish to considerably improve on your coefficient of friction in wet slurry, abrasive and extreme situations for long haulage when steep or heavy start up conditions apply. For instance, mineral-processing equipment associated with open mining and quarry sites are subjected to not only harsh environments with rain and dry conditions but the bulk material carried on the conveyors over longer than normal distances or they are subjected to high tonnage and steeper inclines than most other systems, particularly when feeding to a large high surge pile or considered to be an over-land conveyor system. This ceramic lagging should be considered as fit for purpose.
Ceramic Tile Lagging Provides Better Traction and Positive Drive
Ceramic Tile Lagging provides greater grip, is great for slippage reduction and sheds water and dirt, which is ideal to combat wet slurry and harsh environments. The tiles are extremely abrasion resistant and naturally improve traction between your componentry. The tiles have better surface contact with the conveyor belt and allow the belt to operate under a lower belt tension and provision for less take up weight.
These positive attributes also sustain your equipment and increase their service life. However when utilising these tiles you must ensure that they are ‘fit for purpose’ otherwise they will do more harm than good.
Ceramic lagging is typically profiled with dimple ceramic tiles, which are embedded/molded into a durable rubber backing strip. These strips are then trimmed into lengths for cold bonding or hot vulcanising applications with the appropriate methods and adhesives. Budget wise, ceramic lagging is dearer but has a greater service life and reduces lagging wear in comparison to Rubber Lagging types.
Note: It is important to ensure that the ceramic tile lagging is appropriately positioned on your system or it may not perform as it should. Furthermore, conveyor design, transition distances and drive traction should all be carefully considered when selecting ceramic lagging.
Challenges with Ceramic Tiles Lagging
There are a few issues with ceramic lagging. Problems mainly arise when solid debris positions itself between the pulley and the belt, which may crack the surface of the tiles. This will result in weakening the ceramic, which may eventually chip, and free tiles from the pulley face surface. The dislodged damaged lagging will negatively impact the belt and drive functionality.
Rubber type: FRAS and M Grade uncured strip ceramic lagging
Profile Specialty: Hard wearing in abrasive conditions, assists with belt tracking and slippage, water shed Suitable
Pulley Type: Dimple ceramic lagging for Head or Drive Pulley, Smooth ceramic lagging for Non Drive pulley
Size of pulley: Applicable for standard sizes from 30mm~1500mm in diameter for hot vulcanising and the pulley size can be larger for cold vulcanising.
Durability: Low / Medium / High Application
Bonding Process: Secured with cold adhesives or hot vulcanising
Stocked as: Standard Grade AS-M floor stock
In circumstances where the belt might be isolated or housed independently for vertical applications, such as bucket elevators, the debris becomes abrasive and can cause constant abrasion to the belt and the pulley itself. This results in the tiles effectiveness being minimised and ASC would suggest seeking another lagging option as the wear rate will be too high. This is particularly so, for the recycling and primary manufacturing industries.
All State Conveyors offer customised ceramic surface lagging for your components. Based on your application, this treatment is used to increase or decrease friction and grip or increase wear resistance depending on your needs and budget.
ASC Lagging Methods
All State are able to offer on-site quick change outs with replaceable rubber ‘strip’ and in-house lagging fabrications or re-lagging by our experienced and highly skilled technicians and delivery to your work site for installation, depending on your situation.
All State Conveyors drive and non-drive pulleys can be lagged to meet your design requirements. There is a choice of cold bonded and autoclave hot vulcanising with a Sheet Wrap method or Replaceable Rubber Strip method, both of which is secured with cold or hot bonding methods to the face of the pulley.
The Replaceable Rubber Strip lagging method is a quick on-site installation option to repair or replace damaged parts without removing belts and drum pulleys from the equipment (when ever it is safe to do so) and to minimise system shut down times.
ASC Integrated Lagging Servicing
All State Conveyors provide a complete service for the lagging of your drums and pulleys. We are able to remove worn lagging and repair your pulley to increase adhesion to the pulley shell. We also perform pulley reconditioning and maintenance with re-lagging, grinding, flat and crowned rubber lagging, trimming and painting if required.
