Restoring Conveyor Belt with Belzona Polymeric Coatings
Conveyor belts play a crucial role in various industries, ensuring the efficient movement of materials and products. The failure of these conveyor belts can lead to production halts and jeopardize product quality. In response to an inquiry from a leading cement manufacturer in India, our team undertook the challenge of repairing a damaged conveyor belt without resorting to the traditional vulcanization method. This innovative approach not only saved substantial costs but also prevented a protracted shutdown, ensuring minimal disruption to the client’s operations.
The Problem:
A prominent cement plant in India approached us with a damaged conveyor belt, which had suffered from excessive wear due to the harsh materials it transported and the friction generated by rough sliding and impacts of hard substances. The jagged and sharp edges of these materials had penetrated the rubber belt, leading to severe tearing and splitting. The traditional vulcanization method, while effective, required significant time, a specialized crew, and equipment to be brought to the site, leading to extended downtime that the client wished to avoid.
Belzona Solution:
We chose to employ Belzona Polymeric Coatings, a proven solution for repairing ripped and damaged conveyor belts. The repair process, which did not necessitate the disassembly of the belt, involved the following steps:
Inspection: Our service engineer thoroughly inspected the conveyor belt to assess the extent of the damage and the specific repair requirements.
Tear Termination: The first step in the repair process was to terminate the tear. This was achieved by drilling holes at each end of the tear, preventing its further propagation.
Rubber Removal: The top layer of the damaged area was removed by undercutting to prepare the surface for the application of the Belzona Polymeric Coating.
Surface Preparation: The substrate under the tear was abraded until it achieved a wooly finish. This ensured optimal adhesion of the Belzona product to the substrate.
Coating Application: Belzona 2211, a high-performance epoxy repair material, was thoroughly mixed and applied over the tear. Care was taken to ensure a firm bond with the substrate, creating a seamless repair.
Reinforcement: A pre-cut piece of Belzona 9341 Reinforcement Tape was embedded over the repair area and encapsulated with the remaining mixed material. This reinforcement ensured the longevity and durability of the repair.
Curing: Once the repair was completed, the belt was allowed to cure, adhering to the manufacturer’s guidelines for curing times and conditions.
Return to Service: After the curing process, the conveyor belt was put back into service, ensuring minimal downtime and a swift return to full production capacity.
Results:
The successful repair using Belzona Polymeric Coatings prevented the need for a costly conveyor belt replacement and avoided protracted shutdown, ensuring the uninterrupted operation of the cement manufacturing facility. The repaired belt proved to be durable, resilient, and capable of withstanding the challenging conditions of the cement industry.
Follow-up Inspection:
After one year of continuous operation, the repaired conveyor belt was subjected to a comprehensive inspection. It was found to be in perfect running condition, demonstrating the effectiveness and durability of the Belzona repair. The client was pleased with the long-lasting results and the substantial cost savings achieved by choosing this innovative repair approach.
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