Conveyor Belt Repair Options
When your conveyor belt breaks down, there are a number of repair options available to you before you consider replacing the belt. Each have pros and cons and different methods are advisable in different situations. If you have any questions about any of the information below, one of our sales team will be happy to provide more info.
Mechanical Clippings
The most common of these are the Flexco E style clips and they’re generally used for rip repairs that are long in length, or in situations where your belt down time needs to be kept to an absolute minimum. Once they’re on, the plant can start up straight away, but the mechanical clips sit proud of the belt which means that the belt can’t be operated with scrapers. They’re also susceptible to pick up which can tear the belt or tear clips out, further damaging the belt. They can sometimes create excessive noise when the mental clips go round the roller and can also be quite rigid so are not recommended for smaller systems. On the plus side, no hazardous chemicals or solvents are used.
Super Screw (MLT) Fix and Go Kits
These are a relatively new product and work by fixing two pieces of rubber to the belt (one on the return side and one on carry side) and screwing the rubber together. They’re generally used for puncture type issues where a small section of the belt has been damaged. They are very strong because of the reinforcing fastening in them and again there is no down time – the belt can be started as soon as it’s fixed. If you need to use scrapers on your belt, the repair can be recessed into the belt and they are not noisy because of the rubber cover. The repair can be pricey so it’s not advisable for a long tear. They can be fiddly to fit but minimal additional tools are needed, you can do it yourself pretty easily with just a drill.
Repair Band
This is the most versatile of repair options because they can fix a wide range of issues – grooves, puncture points, edge damage or general wear. They come in a variety of different widths and can be reinforced or non-reinforced. Even though chemicals and solvents are used, you don’t need any heat treatment so it’s still one of the quicker repairs but you do need curing time for the glue. They are readily available and relatively inexpensive, however the repair sits proud of belt so scrapers can’t be used and they’re susceptible to pick up points which can pull the repair band off.
Cut Out Cold Options
These are similar to a repair band, but here you recess the repair into the belt cover and dress it off to be the same thickness as the belt, so scrapers can still be used and chances of picking up are a lot lower. It’s cheaper than a hot repair, and still quite flexible so can go round small pulleys. The prepping can be time consuming when cutting out is involved, but they’re generally stronger and more robust than a repair band.
Urethane Repairs
A 2 or 3 part epoxy resin mix is used to activate the glue before the repair is performed. They are very strong and much harder wearing than a rubber compound so will often outlast the belt itself. They’re easy to use as minimal prep work is involved and normally fast setting so down time is limited. They’re versatile and can be used for a range of issues but they can be expensive and are generally limited to wear and gouge issues, not for long repairs. Note that this doesn’t reinforce the belt in any way and you only have a short working time – a few minutes before it starts to set – so it can be fiddly to work with. On the plus side, no special equipment is required.
Hot Repairs / Hot Spot Repairs
The biggest advantage with a hot repair is that you’re removing damaged parts and rebuilding parts of the belt. This makes it the strongest repair you can do, and they generally last the best because you’re using the same material and composite as the belt itself. The repair is time consuming, however, and there can be a bit of work involved to get spot press or vulcanizer to site. You also need power and water available, and the weather can affect the repair, causing it to fail. It doesn’t affect other instruments on the system such as magnets and weightometers, there is no curing time once the press is removed (so the belt can be run straight away) but they can be costly if the tear is big because of the time and materials involved.
Resplice or Insert
A resplice will provide you with a brand-new repair, but you usually lose length in the adjustment, in which case an insert will be required instead. It is a time-consuming option and also bear in mind that every time you cook the belt you age the rubber, which opens you up to more problems down the track because it makes the rubber more brittle and often cracks sooner. You will then need to weight up the benefits of replacing the whole belt instead.