Technical Papers, Case Studies & News


Hot Vulcanised lagging application involves the chemical cross-linking of five reactive layers during the autoclave curing process. To achieve the desired 100% rubber tear adhesion all five layers must crosslink at the same time. Occasionally conditions can be created in the autoclave that prevent this happening, and result in non-uniform adhesion around the pulley circumference. This bulletin explains how these conditions occur and what needs to be done to eliminate this problem.

Iron Ore Port Facility High Tension Bend Pulley – Elastotec Polyurethane Lagging

In November 2017 a major iron ore port facility in the Pilbara decided to replace the ceramic lagging on a high tension bend pulley – the ceramic lagging had suffered physical damage on one edge that had exposed the pulley shell (Photo#1). With a capacity of around 180 million tonnes/ annum of iron ore the port operates 24/7 year round and so reliability of the conveyor system is critical to achieving the maximum ore through put.

Spare Pulleys – Hot Vulcanised vs Cold Bonded Lagging

Spare pulleys are held so that in the event that an operational pulley requires replacement this can be done quickly and efficiently at the timing dictated by the mine maintenance personnel. The reason for changing a pulley broadly falls into two categories. • Change out during a planned maintenance shut • Emergency change out due to catastrophic pulley failure

Elastotec expands lagging operations

Our dedicated teams in Australia and Vietnam working really hard to understand lagging performance, and to engineer solutions that provide the longest possible lagging service life under all conditions.

Consequences of catastrophic failure with cold bonded lagging for new mining projects

Catastrophic lagging failure due to debonding occurred within two weeks of installation and operation of the pulley, resulting in a shutdown of production, and necessitated a replacement of the pulley. Within only two weeks of service, this ceramic lagging was already experiencing loss of the ceramic tiles.

New Approved Applicator

Early in 2019 Kledkaew Inter Products Co, Ltd. a rubber lining company based in Bangkok Thailand were approached by a representative from a major power station, with a request for a pulley lagging that would significantly extend the lagging service life beyond the 12 months that was typically being achieved with the rubber lagging currently in use.

Ceramic Lagging Tile Loss – Causes and Prevention

Ceramic lagging is chosen for pulleys where a long trouble free service life is required to ensure that the conveyor is operational when required and to avoid unplanned conveyor shutdowns. This is a critical for mining companies where conveyor down time costs run into thousands of dollars per minute.

The importance of good metal preparation to good lagging adhesion

Correct pulley shell surface preparation is essential for good lagging adhesion. Grit blast to a 50-100 um surface roughness and check by measuring at multiple points across the pulley face and around the pulley circumference.

EL.IN Approved Applicator

EL.IN. is an engineering company based in Grevena in northern Greece. For many years EL.IN. has been refurbishing pulleys for the Public Power Corporation (PPC) of Greece. PPC operates seven power stations that are fuelled by Lignite and a number of mines that supply the fuel for these mines. The PPC operations have conveyor systems with over 2,000 pulleys in service with a number of different lagging types in service, including rubber, cold vulcanised ceramic and direct bond ceramic.

Curragh coal mine – improved service life of conveyor pulleys

The Curragh Coal Mine is an open cut coal mine located near Blackwater in Central Queensland, Australia. The mine supplies high quality, low ash coking coal and has reserves of approximately 90 million tonnes which is amongst the largest in the world. Coal from Curragh is shipped via the Blackwater rail system to the Port of Gladstone for export. Curragh Coal mine is owned by the Coronado Coal Group a US based company.

Oyu Tolgoi High Tension Bend Pulleys – Improved Performance

Oyu Tolgoi is a large copper mine that has both open-cut and underground operations and has been operating since 2013. The mine is jointly owned by the Mongolian government and Rio Tinto and is located in the South Gobi Desert. Once fully operational, the mine is expected to produce 450,000 tonnes of copper annually.

How to Maximise Pulley Service Life

For the past five years, Elastotec has collected data from our network of Approved Applicators on the modes of lagging failure that are seen on pulleys sent for refurbishment.

New Technology Extends Service Life of Non Drive Pulleys and Protects the Conveyor Belt

Mining is an industry where reliability is crucial and unplanned down time can result in millions of dollars lost over a single day. Elastotec is focused in making the conveying process more reliable by eliminating unplanned maintenance due to lagging failure.

Martin Sprocket China

Martin Sprocket and Gear (Martin) is an international manufacturer of power transmission, and materials handling equipment including conveyor pulleys and idlers. Martin has 35 plants located throughout the USA, Canada, Mexico, Brazil and China. The company is focused on manufacturing high quality products, maintaining large inventories to ensure superior service to their customers, being contactable 24/7 and providing exceptional field support.

Vale’s Vargem Grande iron ore conveyor lagging problem

Vale-operated Vargem Grande mine site is located in the state of Minas Gerais, Brazil and contains 2.53 billion tonnes of proven and probable iron ore reserves, making it the world’s fourth biggest iron ore mining operation. The Vargem Grande site comprises three open-pits: Tamandua, Capitao do Mato and Aboboras.

White FDA-approved Ceramic Lagging – bulk sugar ship-loading conveyor

Sugar Australia operates a specialised food-grade bulk refined sugar vessel, MV “Pioneer”. Elastotec developed a white ceramic lagging made from FDA materials approved by the U.S. Food and Drug Administration (FDA) for handling sugar on a ship-loading conveyor drive pulley.
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