Conveyor Belt Repairs - CoBond

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www.cobond.com.auConveyor Belt RepairsPg 1

Faster, Stronger,Cheaper Repairs

Conveyor Belt RepairsAbout CoBond Material Solutions:Challenging the way things are done, we are delivering cost effective products and solutions to overcome excessive wear whilereducing downtime and increasing productivity.Some of our innovative products include: fast curing conveyor belt repair kits, proprietary bonded high density ceramic wear plateliners, advanced light weight composite structures, specialist adhesives and sealants, protective coatings and polyurethane castings.A little bit about our conveyor belt repair kits:CoBond’s conveyor belt repair kits really do provide a simple, quick and cost-effective solution for anyone to repair and greatlyextend the life of a damaged or torn conveyor belt.Our repair kits are a two-part, 100% solids polyurethane compound for the repair of rubber (fabric and steel cord), Nitrile and PVC(solid woven) conveyor belts and linings.Types of repairs:Skirt-line wearSpotHoles / puncturesTears / splitsEdge damage (including shark bite)SpliceQuick and easy application of productSuitable for a variety of repairsFast cure timesCan be reused after use – no wastageSafer – no requirement for complexor heavy equipmentCan be used on a slope or angle– no sagging or slumpingLocal service and supportNo requirement for special permitMechanical fastener protectionand concealingAll products are manufactured in Australia.Benefits:No hand mixing requiredPg 1

Conveyor Belt RepairsQik FixRapid RepairFRAS RepairCure Time30 minutes2 Hours30 minutesWorkable Time10 – 12 minutes15 minutes10 – 12 minutesKit Size1050g(37oz)600g and 1.5kg(21oz and 53oz)1050g(37oz)Shore Hardness80 – 85A60 – 65A80 – 85AApplicatorPneumatic Caulking Gun/ Hand Held Caulking GunPneumatic Caulking Gun/ Hand Held Caulking GunPneumatic Caulking Gun/ Hand Held Caulking GunPrimerPrimer No.6 / 11 (Rubber)Primer No.6 / 11 (Rubber)Primer No.6 / 11 (Rubber)Skirtline DamagePPPHole/Puncture RepairPPPSplit RepairPPPPPEdge RepairSplice RepairPPPMechanical FastenerPPPPg 2

www.cobond.com.auConveyor Repair ProductsQik Fix Conveyor Belt Repair Kit (1050g)Qik Fix is a fast curing, 30-minute, two-part 100% solids polyurethane conveyor belt repair kit whichis used for the repair of fabric, steel cord and PVC conveyor belts.Qik Fix has been specifically engineered to be a high performance conveyor belt repair product,offering superior adhesion strength and excellent abrasion and tear resistance.Qik Fix is applied with either a manual or pneumatic caulking gun and self-mixing nozzle, ensuring theproduct is thoroughly mixed at the correct ratio (there is no need for hand mixing).Once applied to the conveyor belt, it has a working time of 10-12 minutes (at 24 C). The highviscosity of Qik Fix allows it to be applied on a belt on an incline or conveyor troughs of up to 50 without sagging or slumping.Completing a repair with Qik Fix provides an engineering grade bond to the substrate, thus increasingthe life of the belt with minimal downtime.Colour: BlackHardness: 80 - 85AShrinkage: 1%Shelf life: 12 months @ 22 C (72 F)Working time: 10 - 12 mins at 24 CReturn belt to service: after 4 hrs @ 24 C (75 F)Rapid Repair Conveyor Belt Repair Kit (600g / 1.5kg)Rapid repair is a 2-hour curing, two-part 100% solids polyurethane conveyor belt repair kit that isused for the repair of fabric, steel cord and PVC conveyor belts.Rapid Repair has been specifically engineered to be a high performance conveyor belt repair productthat matches the hardness of the rubber belt.Rapid Repair is applied with either a manual or pneumatic caulking gun and self-mixing nozzle,ensuring the product is thoroughly mixed at the correct ratio (there is no need for hand mixing).Once applied to the conveyor belt, it has a working time of 15 minutes (at 24 C). The high viscosity ofRapid Repair allows it to be applied on a belt on an incline or conveyor troughs of up to 50 withoutsagging or slumping.Completing a repair with Rapid Repair provides an engineering grade bond to the substrate, thusincreasing the life of the belt with minimal downtime.Colour: BlackHardness: 60 - 65AShrinkage: 1%Shelf life: 12 months @ 22 C (72 F)Working time: 15 min at 24 CReturn belt to service: after 6 hrs @ 24 C (75 F)FRAS Belt Repair Kit (1050g)FRAS repair is a new fast curing, 30 minute, two-part 100% solids polyurethane conveyor belt repairkit that is used for the underground repair of fabric, steel cord and PVC conveyor belts.This fire retardant and anti static (FRAS) repair kit has been specifically engineered and is compliantwith the requirements of MDG 3608 for use in underground mines.FRAS Repair is applied with either a manual or pneumatic caulking gun and self-mixing nozzle,ensuring the product is thoroughly mixed at the correct ratio (there is no need for hand mixing).Once applied to the conveyor belt, it has a working time of 10-12 minutes (at 24 C). The highviscosity of FRAS Repair allows it to be applied on a belt on an incline or conveyor troughs of up to50 without sagging or slumping.Completing a repair with FRAS Repair provides an engineering grade bond to the substrate, thusincreasing the life of the belt with minimal downtime.Colour: Grey / BlackHardness: 80-85AShrinkage: 1%Shelf life: 12 months @ 22 C (72 F)Working time: 10-12 min at 24 CReturn belt to service: after 4 hrs @ 24 C (75 F)Pg 3

Conveyor Belt RepairsPrimer No.3 (polyurethane)Primer No.3 is a two-part polyurethane primer used for bonding CoBond’s Qik Fix Conveyor BeltRepair Kit to an already fully cured repairColour: HoneyNumber of Coats: 1 coatDrying Time: 60 minutesShelf life: 12 months @ 22 C (72 F)Primer No.6 (rubber)Primer No. 6 is a two-part rubber primer used for bonding CoBond’s Qik Fix Conveyor Belt Repair Kitto natural and certain synthetic rubbers.Colour: Dark GreyNumber of Coats: 2 coatsDrying Time: 45 minutesShelf life: 12 months @ 22 C (72 F)Primer No.11 (rubber)Primer No. 11 is a single part rubber primer used for bonding CoBond’s Qik Fix Conveyor Belt RepairKit to natural and certain synthetic rubbers.Colour: ClearNumber of Coats: 1 coatDrying Time: 45 minutesShelf life: 12 months @ 22 C (72 F)AccessoriesManual Caulking GunThis heavy-duty manual caulking gun is used to dispense CoBond’s Conveyor Belt Repair Kit.Ideally suited for small repairs.Pneumatic Caulking GunThis durable pneumatic caulking gun is used to easily dispense CoBond’s Conveyor Belt RepairKits. Ideally suited for large repairs.ApplicatorsCoBond’s range of scraper blades are ideal for applying CoBond’s Conveyor Belt Repair Kit toachieve a smooth and even finish to a repair.Pg 4

www.cobond.com.auRepair StepsStep 1Prepare surface – clean and grind out the repair area with a wire brush/wheel.Ensure a profile in the rubber is produced.Step 2Clean the surface – use Acetone, Perchloroethylene (PERT) or MEK solution with a cleanplain white rag to thoroughly clean the surface.Step 3Prime the surface – thoroughy mix and brush on 2 separate coats of CoBondPrimer No.6 – allow 20 – 45 minutes drying time on the 1st coat and thenapply a second coat.Step 4Repair the surface – once the second coat of the Primer No.6 is tacky, fill therepair area using CoBond’s conveyor repair kit.Step 5Finish the surface – use a scraper blade to smooth out the material to the repairarea and feather out the edges (no need to buff once completed).Pg 5

Conveyor Belt RepairsTypes of RepairsSkirt-line Damage RepairStep 1 – Prepare Surface – clean and buff the repair area with a wire brush/wheel.Ensure a profile in the rubber is produced and a rounded profile with no sharp edges orcorners as per figure 1.Step 2 – Clean the surface – using a clean plain white rag, use Acetone,Perchloroethylene (PERT) or MEK solvent to thoroughly clean the area for repair.Step 3 – Prime the surface – thoroughly mix and brush on 2 separate coats ofCoBond’s Primer No.6. Depending on the ambient temperature, allow 20 - 45 minutesdrying time on the 1st coat before then applying a second coat.Buff corner to a curved profileStep 4 – Repair the surface – once the second coat of CoBond’s Primer No.6 istacky, fill the repair area using CoBond’s conveyor belt repair kit.Note: Ensure part A of the kit has the appropriate viscosity (i.e. the bubble in part Amoves freely when tilted back and forth at a 45 degree angle).Step 5 – Finish the repair – use a scraper blade to smooth out the material to therepair area (as per figure 2) and feather out the edges (there is no need to buff the repaironce completed).Fig. 1Fig. 2Finished repairPuncture or Hole RepairStep 1 – Cut the top and bottom jagged edge of the puncture or hole with a knife asper figure 3.Step 2 – Prepare Surface - clean and buff the repair area with a wire brush/wheel.Ensure a profile in the rubber is produced and a rounded profile with no sharp edgesor corners as per figure 4.Jagged edgeof split beltStep 3 – Clean the surface – using a clean plain white rag, use Acetone,Perchloroethylene (PERT) or MEK solvent to thoroughly clean the area for repair.Step 4 – Prime the surface – thoroughly mix and brush on 2 separate coats ofCoBond’s Primer No.6. Depending on the ambient temperature, allow 20 - 45 minutesdrying time on the 1st coat before then applying a second coat.Fig. 3Step 5 – apply and secure backing or base plate of melamine, aluminum under repairas per figure 4.Fig. 4Backing plateFig. 5Finished repairNote: Ensure the melamine or aluminum is either waxed or has been covered inpacking tape. This will ensure the release of the plate.Step 6 – Repair the surface – once the second coat of CoBond’s Primer No.6 istacky, fill the repair area using CoBond’s conveyor belt repair kit, ensuring to inject it into the underneath edge of the repair.Note: Ensure part A of the kit has the appropriate viscosity (i.e. the bubble in part Amoves freely when tilted back and forth at a 45 degree angle).Step 7 – Finish the repair – use a scraper blade to smooth out the material to therepair area (as per figure 5) and feather out the edges (there is no need to buff therepair once completed). Once cured, remove the backing plate.Pg 6Cut jagged edge backBuff corner to acurved profile

www.cobond.com.auSplit RepairStep 1 – Cut the top and bottom jagged edge of split with a knife as per figure 6.Step 2 – Prepare Surface – clean and buff the repair area with a wire brush/wheel.Ensure a profile in the rubber is produced and a rounded profile with no sharp edges orcorners as per figure 7.Jagged edgeof split beltStep 3 – Clean the surface – using a clean plain white rag, use Acetone,Perchloroethylene (PERT) or MEK solvent to thoroughly clean the area for repair.Step 4 – Prime the surface – thoroughly mix and brush on 2 separate coats ofCoBond’s Primer No.6. Depending on the ambient temperature, allow 20 - 45 minutesdrying time on the 1st coat before then applying a second coat.Step 5 – apply and secure backing or base plate of melamine, aluminum under repairas per figure 7.Step 6 – Repair the surface – once the second coat of CoBond’s Primer No.6 istacky, fill the repair area using CoBond’s conveyor belt repair kit, ensuring to inject it into the underneath edge of the repair.Fig. 6Cut jagged edge backBuff corner to acurved profileFig. 7Backing plateFinished repairFig. 8Note: Ensure part A of the kit has the appropriate viscosity (i.e. the bubble in part Amoves freely when tilted back and forth at a 45 degree angle).Step 7 – Finish the repair – use a scraper blade to smooth out the material to therepair area (as per figure 8) and feather out the edges (there is no need to buff the repaironce completed). Once cured, remove the backing plate.Edge RepairStep 1 – Cut the top and bottom jagged edge of the belt with a knife as per figure 9.Step 2 – Prepare Surface - clean and buff the repair area with a wire brush/wheel.Ensure a profile in the rubber is produced and a rounded profile with no sharp edges orcorners as per figure 10.Jagged edgeof split beltStep 3 – Clean the surface – using a clean plain white rag, use Acetone,Perchloroethylene (PERT) or MEK solvent to thoroughly clean the area for repair.Step 4 – Prime the surface – thoroughly mix and brush on 2 separate coats ofCoBond’s Primer No.6. Depending on the ambient temperature, allow 20 - 45 minutesdrying time on the 1st coat before then applying a second coat.Fig. 9Step 5 – apply and secure the aluminum mould under repair as per figure 11.Fig. 10Note: Ensure the aluminum mould is either waxed or has been covered in packing tape.This will ensure the release of the plate.Step 6 – Repair the surface – once the second coat of CoBond’s Primer No.6 istacky, fill the repair area using CoBond’s conveyor belt repair kit, ensuring to inject it into the underneath edge of the repair.Cut jagged edge backBuff corner to acurved profileFig. 11Clamp angle to beltNote: Ensure part A of the kit has the appropriate viscosity (i.e. the bubble in part Amoves freely when tilted back and forth at a 45 degree angle).Step 7 – Finish the repair – use a scraper blade to smooth out the material to therepair area (as per figure 11) and feather out the edges (there is no need to buff therepair once completed). Once cured, remove the mould.Pg 7

Conveyor Belt RepairsMechanical Fastener ProtectionStep 1 – Prepare Surface – cut the belt and skive top cover down to the first layerof ply as per figure 12. Buff the skived area with a wire brush/wheel. Ensure a profile inthe rubber is produced and a rounded profile with no sharp edges or corners as perfigure 13.Skive top cover awaydown to first plyStep 2 – Install the fastener / clip as per manufactures instructions.Step 3 – Clean the surface – using a clean plain white rag, use Acetone,Perchloroethylene (PERT) or MEK solvent to thoroughly clean the area for repair.Step 4 – Prime the surface – thoroughly mix and brush on 2 separate coats ofCoBond’s Primer No.6, this can be used on the steel fastener / clip. Depending on theambient temperature, allow 20 - 45 minutes drying time on the 1st coat before thenapplying a second coat.Step 5 – Repair the surface – once the second coat of CoBond’s Primer No.6 istacky, fill the repair area using CoBond’s conveyor belt repair kit.Note: Ensure part A of the kit has the appropriate viscosity (i.e. the bubble in part Amoves freely when tilted back and forth at a 45 degree angle).Fig. 12Fig. 13Buff corners down toa round profileInsert fatner clipFill with CoBondFig. 14Step 6 – Finish the repair – use a scraper blade to smooth out the material to therepair area (as per figure 14) and feather out the edges (there is no need to buff therepair once completed).Skirt-line Damage RepairStep 1 – Prepare Surface – clean and buff the repair area with a wire brush/wheel.Ensure a profile in the rubber is produced and a rounded profile with no sharp edges orcorners as per figure 1.Step 2 – Clean the surface – using a clean plain white rag, use Acetone,Perchloroethylene (PERT) or MEK solvent to thoroughly clean the area for repair.Step 3 – Prime the surface – thoroughly mix and brush on 2 separate coats ofCoBond’s Primer No.6. Depending on the ambient temperature, allow 20 - 45 minutesdrying time on the 1st coat before then applying a second coat.Step 4 – Repair the surface – once the second coat of CoBond’s Primer No.6 istacky, fill the repair area using CoBond’s conveyor belt repair kit.Buff corner to a curved profileFig. 1Note: Ensure part A of the kit has the appropriate viscosity (i.e. the bubble in part Amoves freely when tilted back and forth at a 45 degree angle).Step 5 – Finish the repair – use a scraper blade to smooth out the material to therepair area (as per figure 2) and feather out the edges (there is no need to buff the repaironce completed).Pg 8Fig. 2Finished repair

www.cobond.com.auCASE STUDIESREPAIR:146 metre skirt-line damage conveyor belt repairPRODUCT: CoBond Qik Fix / Primer No.6 / Primer No.3LOCATION: New South WalesMATERIAL: CoalSITUATION: A large rock was lodged between the hard skirt and the beltfor a period of time. As a result, this wore a 100mm (W) x12mm (D) grove along the entire length of the belt down tothe steel cables.RESULT:Estimate cost to replace the steel cable belt - 270,000Cost to repair the belt - 35,000Saving - 235,000Importantly, the repairs were performed during plannedmaintenance windows, allowing the belt to remain in servicewithout any issues for a further 16 months until the normalreplacement date.REPAIR:Spot / puncture repairPRODUCT: CoBond Rapid Repair / Primer No.6LOCATION: New South WalesMATERIAL: CoalSITUATION: A material loading facility had 40 spot / puncture repairs tothe boom conveyor as a result of material being caught inbetween the pulley and the conveyor belt.RESULT:Cost to repair the belt - 4,500The repairs were performed during a planned maintenancewindow, allowing the belt to remain in service withoutany issues.REPAIR:60 metre skirt-line damage conveyor belt repairPRODUCT: CoBond Qik Fix / Primer No.6 / Primer No.3LOCATION: Western AustraliaMATERIAL: Iron OreSITUATION: A hard skirt had damaged the belt. As a result, this worea 180mm (W) x 10mm (D) grove along the entire length ofthe belt.RESULT:Estimate cost to replace the steel cable belt - 350,000Cost to repair the belt - 58,000Saving - 292,000Importantly, the repairs were performed during a plannedmaintenance window. The repair enabled the belt to remain inservice for a further 12 months.Pg 9

www.cobond.com.auFor more information on any of ourproducts please contact us on:T: 61 400 386 239E: sales@cobond.com.auwww.cobond.com.au

Rapid Repair Conveyor Belt Repair Kit (600g / 1.5kg) Rapid repair is a 2-hour curing, two-part 100% solids polyurethane conveyor belt repair kit that is used for the repair of fabric, steel cord and PVC conveyor belts. Rapid Repair has been speci!cally engineered to be a high performance conveyor belt repair product

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