Reliability from load to discharge

Transcription

1 Trellex Wear Protection Solutions Reliability from load to discharge Trellex Wear Protection Solutions EN

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3 Contents Reliability from load to discharge Reliable material transport 2 Material flow throughout the process 3 RES Our approach 4 Wear theory The choice of material 6 The work environment an important factor 7 Products Trellex Wear Protection 8 Trellex Conveyor Accessories 28 Trellex Belt Scrapers 36 Trellex Pulley Lagging 48 Trellex Slurry & Bulk Hose System 54 Conversion Table 63 1

4 Reliability from load to discharge Reliable and efficient solutions throughout the entire material flow For many years, our products have been used as successful problem solvers. We have solved such problems as wear and abrasion, high noise levels and dust propagation, and we have helped reduce heavy maintenance costs, all with the aim of optimising material flows and constantly improving availability. We concentrate on: Wear and tear Caking Dust Noise Material spillage We concentrate on mines, mineral processing, sand and gravel, construction, civil engineering and recycling, but our products are used successfully in all industries which deal with various kinds of wearing materials. Our aim is to create cost-effective solutions throughout the entire materials flow to enable customers to produce more and maintain less. From experience we know that it is often not enough just to improve a single aspect of the production line. We must also know how intervention affects the rest of the material flow. Knowledge of our customers processes and how the various parts fit together has enabled us to develop a complete range for creating reliable flows, from input and loading, through the materials transport chain, ending with unloading and shipping. We have developed a holistic concept: a message associated with high quality and reliable functioning, which we wish to be representative of Trellex Wear Protection Solutions - Reliability from load to discharge. 2

5 Primary Processing Material handling Material flow throughout the process Trellex Wear Protection Solutions has a range which suits most applications. To illustrate this we utilise a schematic image of an industry. We divide flow into three distinct areas: primary, process and materials handling. Primary The primary link in the flow consists of raw material handling. In this area we cover such applications as Truck Loading Platforms, Primary Hoppers, Chutes, Conveyors, Screens and Feeders. Typical products used are PP Wear Plates, SQ Module System, Poly-Cer, Flexback, Rubber Sheeting, Belt Scrapers, Belt Conductors, Sealing Systems, Pulley Lagging and Loading Systems. Processing Within processing we have the fine calibration of material flows, and it is here that actual production or refinement is performed. Equipment such as Mills, Magnetic Separators, Flotation Equipment, Agitators, Transfer Chutes and Channels, Conveyors etc all require wear protection of some kind. Sometimes the material is in liquid form and is conveyed in pipes or hoses. Typical products available in this field are Hoses, Bends, Reducers, Branch Pipes, PP elements, SQ plates, Poly-Cer, Flexback, Rubber Sheeting, Belt Scrapers, Belt Conductors, Sealing Systems, Pulley Lagging and Loading Systems. Material handling The final product must be handled, stored and transported in a manner suited to the material. Here we find conveyors, transfer chutes, hoppers and silos, all of which need wear protection of one kind or another. Products PP elements, SQ plates, Poly-Cer, Flexback, Rubber Sheeting, Belt Scrapers, Belt Conductors, Sealing Systems, Pulley Lagging and Loading Systems are normally used. 3

6 RES Our approach RES stands for Reliability, Environment and Safety. With the help of our products we focus on operating reliability, improved work environment and secure and safe applications. In the final analysis, the customer benefits from a more efficient facility. Reliability Unscheduled stoppages and disruptions are not acceptable in these times of intense competition. Instead, good results depend on continuous production and high levels of availability. We strive to be a close and long-term partner, and therefore for many years we have been developing a range of highly reliable, long-lived products with the consequent low overall cost. Trellex products create costeffective solutions throughout the entire material flow - everything to help our customers produce more and maintain less. The environment Dust is harmful to health, gets into various parts of machinery and leads to abnormally rapid wear. Noise causes damage to hearing and impairs normal counications. Failing to hear warning signals is a safety risk which must be taken seriously. Similarly, poorly maintained equipment with copious material spills leads to a problematic work environment with many health hazards. Using equipment which reduce noise and holds materials in place leads to improved process utilisation, less wastage and fewer repairs. In addition, facilities are cleaner and the work environment more satisfying for the staff. Safety All companies are subject to internal rules and regulations and those issued by various official authorities. Safety regulations are among them. We prioritise safety features, so our equipment can be used in as safe a manner as possible. 4

7 Wear theory Rubber as a material Materials are defined as elastic if they are of high elasticity, i.e. they can be stretched out to at least twice their original length and then return to their original shape when the load is removed. Rubber is an elastomer in which the elastic properties are achieved by vulcanization. Rubber materials are viscoelastic. This means they act both as a spring and an absorber at the same time. Their deformation properties vary with temperature and speed of deformation. At low temperatures and high deformation rates, the rubber becomes more rigid and below a critical temperature (brittle point) they become hard and brittle. The brittle point varies depending on the type of rubber material, and corresponds to the minimum temperature at which the material can be used. SBR, styrene-butadiene rubber Styrene rubber is the most widely produced synthetic rubber and is used extensively in tires and wear rubber. The raw material is petroleum. This rubber must be reinforced with a filler and thus is most used in medium hard rubber materials. NR, natural rubber Natural rubber is the product extracted from the rubber tree. It has excellent mechanical properties and since it requires no reinforcing filler, rubber blends can be made softer than the corresponding SBR blends. NR blends are normally more elastic than SBR blends. Natural rubber performs well in the cold, but tends to crystallise at very low temperatures (below -40 C). 5

8 The choice of material Product wear is found in all industries, but wear is of the greatest financial significance in the mineral-related industries. Wear and corrosion have an extremely significant impact on maintenance costs, availability and equipment life. Wear Rubber can be used alone or in combination with metals, ceramics, plastics and textiles. The material or combination of materials which gives the best results from all operating standpoints must be assessed on a case to case basis. Operating conditions must always be analysed and all factors associated with the choice of wear material must be taken into account. Initial costs are very often an important factor in the choice of wear protection, but if the lowest possible overall cost is the aim, it is also important to include such parameters as availability, productivity and lower service and maintenance costs, to name the most important ones. Various types of wear The choice of wear material greatly depends on the type of wear which is involved. Three main types of wear may be distinguished: sliding, cutting and crushing. Sliding wear arises when grains of moving materials raise the surface or plough off fine particles. This type of wear is coon in e.g. spouts, flotation equipment and shaking tables. Cutting wear is caused by high impact particles when sharp material edges cut up or make holes in the surface. This may be found, for instance, in mills, chutes and material hoppers. Crushing wear occurs when the wear surface is exposed to pressure. This type of wear may be found, for instance, when loading truck boxes, on primary feeders, primary screens and barges. Hard or elastic? Materials which fall onto a hard wear surface such as steel may cause plastic deformations in the surface. By contrast, rubber surfaces are able to absorb the kinetic energy without any resulting deformation. The elasticity of the rubber absorbs the kinetic energy and after impacts, the surface reassumes its original shape. One should never compromise when it comes to quality and thickness if one is to utilise the properties of the rubber correctly. The thickness and rubber quality must be related to the material element size and drop height. If the drop height is too great and/or element size is too large compared with the thickness of the rubber, the kinetic energy will be great enough to penetrate to a depth where the rubber is compressed, stretched or torn. This type of crushing damage is normally referred to as penetration damage. Thus the thickness must be calculated allowing for the relevant impact energy based on material element sizes and drop height. 6

9 The work environment an important factor The higher noise levels are and the longer personnel are exposed to noise, the greater the risk of injury. 40% of staff employed in the manufacturing and mining industries are exposed to considerable levels of noise during more than half of their working hours. The corresponding figure in the building and construction industry is 35%. In 2003, the European Parliament and Council passed directive 2003/10/EU on minimum requirements for employees health and safety through exposure to hazards relating to physical agents (noise) at work. Article 5.1 of the directive states: Taking account of technical progress and of the availability of measures to control the risk at source, the risks arising from exposure to noise shall be eliminated at their source or reduced to a minimum. One might say that the work environment in our customer segments is brutal. Heavy, wearing and sharp-edged materials are dropped onto trucks and feeders, bounce and slide down chutes on their way between crushers, screens and transfer chutes. If the wear protecting material is made of steel, there is an ear shattering noise as the material strikes and slides against the steel surfaces and makes the work environment unacceptable. Because of the increased influence of environmental legislation and greater consideration for the health and welfare of employees and peripheral personnel, traditionally noisy industries must seriously reconsider their noise levels. Rubber subdues noise levels The two foremost properties of rubber are its elasticity and its resistance to wear. The elastic properties of rubber allow it to yield and stretch when force is applied without causing permanent deformation. The wear resistance of rubber partly stems from this property, i.e. from its ability to yield and give way, and is in many cases superior to that of other materials, including steel. Besides the ability of rubber to absorb impacts and blows, it also has environmental benefits. When steel is replaced by rubber, it muffles noise and vibrations. By using rubber instead of steel, noise levels may be drastically reduced and the work environment considerably improved. db , Hz Above the curves for noise levels for rubber-lined and steel-lined truck boxes. A rubber lining reduces the decibel level by 10 db (A), which personnel perceive as a 50% reduction. Trellex Wear Rubber Steel Accepted noise level 7

10 8 TRELLEX WEAR PROTECTION SOLUTIONS Slitskydd

11 Trellex Wear Protection Wear Protection Trellex Wear Protection is an overall term for a large variety of products with a broad area of application, especially where wear, both impact and sliding, is a fact of life, but also for use in reducing noise and minimising corrosion. Unscheduled stoppages in production and remedial maintenance caused by material spillage are significant problems and can result in major annual costs, especially for industries which handle wearing materials. It is entirely possible to reap annual savings by taking preventive action. Using wear protection materials whose service life and wear patterns can be predicted can also reduce overall costs. The versatility is manifest since Trellex Wear Protection can be installed in a wide variety of places within Mining, Construction and Civil Engineering, the Cement Industry, the Fertilizer Industry, the Paper and Pulp Industry etc. The reason for Trellex Wear Protection s versatility is precisely this wide area of use. Rubber has advantages such as protection against various types of wear, both chemical and mechanical, long service life, lower overall costs than for equivalent wear protection in steel, it is easier to install, easier to handle and assemble, and thus stoppage times are shorter. Yet another advantage of rubber is its noise reducing properties. Rubber efficiently reduces noise, makes less noise than other lining materials and has excellent wear properties. Thus, by choosing the right rubber lining one can solve one s wear problems and reduce the causes of noise, i.e. contact between solid materials and metal. Quarry trucks, mine trucks, primary chutes, feeders, skips, cone crushers The transport of ore, stone and other highly abrasive materials puts great strain on truck surfaces, especially during loading when they often have to withstand the impact of blocks of up to a cubic metre in size. The Trellex 60 wear resistant rubber element is an almost ideal solution to this wear problem and has greatly contributed to improving operating finances for these heavy load vehicles. The truck lining is exposed to impacts during loading and pressure during transport and sliding abrasion during unloading is tipped out. Products which may be used to great benefit in quarry trucks, mine trucks, primary chutes, feeders, skips, cone crushers etc are: PP50 - PP150 SP75 SP125 PT75 PT 125 9

12 Spouts, chutes, hoppers, transfer points The production processes in the mining, stone and cement industries involve comprehensive conveying activities between various stages of processing, when the often highly abrasive materials expose the equipment to major wear impact of various types. Trellex Wear Protection may to great advantage be installed in chutes, spouts, hoppers and transfer points to minimise wear and reduce noise, while prolonging service life. The choice of rubber material, thickness and type is based on the handled material s unit sizes, shape, drop height, volume, angle of impact and material type. Trellex wear rubber elements satisfy highly varying requirements relating to loads and other operating conditions. Serrated elements are used in structures with impact angles which are unfavourable to rubber surfaces. Products which may be used to great benefit in chutes, spouts, hoppers, transfer points etc are: PP13 - PP55 SP50 SP75 SB40 - SB75 SQ30 - SQ50 Poly-Cer LF Low-Fric Feeders, screen chutes Feeders and screen chutes are intended to supply e.g. the crusher or the screen with a flow of material which is in reasonable proportion to the quantities the equipment is designed to process. It is important to try to avoid this flow stopping. Flow problems such as the caking and backing up of materials, high wear which results in the need for frequent repair stoppages or high levels of noise which have a negative impact on audibility are things that can be drastically reduced using Trellex products. When choosing which products to use for each application, material type, hardness, drop height and angle of impact are all factors that must be taken into account. Products which may be used to great benefit for feeders and screen chutes are: SQ30 SQ50 PP13 - PP55 Poly-Cer LF low-fric Poly-Cer During the transfer, sorting and transport of crushed rock there are always problems with wear and abrasion. High material movement speeds, narrow impact angles to the wear surface and large material flows all increase the wear problem. Frequent wear liner changes also result in costly operating stoppages. Traditionally, rubber, white iron alloys and various types of wear steel have been used for wear protection and to deal with the stresses arising. The Trellex Poly-Cer product can be more than 10 times more wear resistant than steel. Poly-Cer is a rubber element with a ceramic material wear surface. There are unique advantages to this combination of materials. The hard ceramic surfaces provide unsurpassable wear resistance and the elasticity of the rubber absorbs the impact of the blows. Poly-Cer is used in many applications within the mining and quarrying industries. It is particularly suitable for applications where abrasion is great and the angle of impact of materials against the plates is small. Typical installations include transfer and loading stations, screen chutes, feeders etc. The product range is wide and consists of: Trellex Poly-Cer Range Poly-Cer Sheeting Poly-Cer Slim 20 Poly-Cer Classic 35 Poly-Cer HD 64 Poly-Cer HD 95 10

13 Trellex PP Trellex PP Wear Plates are manufactured from T-60 Wear Rubber and with hot vulcanised steel back plates. Medium heavy rock and gravel industry. Demanding mining and industrial applications. Excellent wear resistance in applications with both impact and sliding wear. The steel backing reduces the possibility of small particles getting in under the lining and guarantees secure fixing. Wear Plates reduce noise and vibrations, and are lighter compared to conventional steel lining. Trellex PP Wear Plates provide first class wear protection in such tough applications as truck beds, primary chutes, etc. and for secondary applications such as chutes, feeders, channels, silos and other applications that are subject to wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of fixing methods. PP standard range Art. No Designation/ Thickness () Width x Length () Weight kg/ea PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x PP x Fixing methods Through bolt Stud welded bolt Plug welded Self-tapping screw Steel plate T-60 Wear Rubber 11

14 Trellex PP-XL Trellex PP-XL Wear Plate is made of T-60 Wear Rubber with hot vulcanized steel back plates. Area of use Medium heavy stone and gravel quarrying industry. Demanding mining and industrial applications. Excellent resistance to wear in applications with both impact and sliding wear. The steel backing reduces possibilities for small particles to penetrate under the lining and guarantees securer fastening. The wear plate reduces noise and vibrations and is lower in weight than conventional steel linings. The Trellex PP-XL Wear Plate is an excellent wear protection for bins, chutes, feeders,, silos and other applications exposed to wear and noise. Can manage all ph values and water types and resists most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to constant heat in excess of 70 C. Installation Quickly and simply installed with our flexible program of secure fastening methods. PP-XL standard range Art. no Tot. thickness (rubber + steel) Width x Length () Weight kg/ea PP-XL 13 (10+3) 1500 x PP-XL 15 (12+3) 1500 x PP-XL 18 (15+3) 1500 x PP-XL 20 (15+5) 1500 x PP-XL 20 (17+3) 1500 x PP-XL 23 (20+3) 1500 x PP-XL 25 (20+5) 1500 x PP-XL 25 (22+3) 1500 x PP-XL 30 (25+5) 1500 x PP-XL 30 (27+3) 1500 x PP-XL 40 (35+5) 1500 x PP-XL 55 (50+5) 1500 x Fixing methods Through bolt Stud welded bolt Plug welded Self tapping screw T-60 Rubber Steel plate 12

15 Trellex PT Trellex PT Wear Plates are manufactured from T-60 Wear Rubber and with hot vulcanised aluminium fixing profiles. Medium heavy rock and gravel industry. Demanding mining and industrial applications. Excellent wear resistance in applications with both impact and sliding wear. The vulcanised aluminium profiles allow for fewer fixing points than steel-reinforced wear plates. Wear Plates reduce noise and vibrations, and are lighter compared to conventional steel lining. PT Wear Plates provide excellent wear protection for feeders, primary bins, chutes, silos and other applications that are subject to wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Trellex PT standard range Art. no Designation/ Thickness Width x Length () Weigth kg/ea PT x PT x PT x PT x PT x PT x PT x PT x PT x Installation Easily, quickly and securely installed using the Trellex T-bolt system. Fixing method Plate width c/c T-bolt fixing system C/C 13

16 Trellex SB Trellex SB Wear Plates are manufactured from T-60 Wear Rubber with moulded holes for fixing. The holes are reinforced with fixed hot vulcanised internal steel washers. Medium heavy rock and gravel industry. Demanding mining and industrial applications. Excellent wear resistance in applications with both impact and sliding wear. The wear plates are bendable and easy to cut. They reduce noise and vibrations, and are lighter compared to conventional steel lining. Trellex SB Wear Plates provide excellent wear protection for feeders, bins, chutes, silos and other applications that are subject to wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of secure fixing methods. Trellex SB standard range Art. no Thickness () Width x Length () Weight kg/ea SB x SB x SB x SB x SB x SB x SB x SB x SB x SB x Fixing methods Through bolt Stud welded bolt

17 Trellex SP Trellex SP Wear Plates are manufactured from T-60 Wear Rubber with a serrated surface and with fixed hot vulcanised steel back plates. Medium heavy rock and gravel industry. Demanding mining and industrial applications. Excellent wear resistance in applications with both impact and sliding wear. The steel backing guarantees secure fixing so that the wear plates remain together even if the lining is exposed to extremely abrasive and sharp particles. Wear Plates reduce noise and vibrations, and are lighter compared to conventional steel lining. Trellex SP Wear Plates provide excellent wear protection for bins, chutes, silos and other applications that are subject to wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. The serrated surface has been designed to provide optimal life for material with impact angles between 15 and 50. Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of fixing methods. Trellex SP standard range Art. no Thickness () Width x Length () Weight kg/ea SP x SP x SP x SP x SP x SP x SP x SP x SP x SP x SP x SP x SP x Fixing methods T-60 Wear Rubber Through bolt Stud welded bolt Steel backing 15

18 Trellex WB Trellex WB Wear Bars are manufactured from T-60 Wear Rubber and with hot vulcanised aluminium fixing profiles. Medium heavy rock and gravel industry. Demanding mining and industrial applications. Excellent wear resistance in applications with both impact and sliding wear. The vulcanised aluminium profile allow for fewer fixing points than steel-reinforced wear plates. Wear Bars reduce noise and vibrations, and are lighter compared to conventional steel shrouding. Trellex WB Wear Bars provide excellent wear protection for bins, chutes, silos and other applications that are subject to wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Installation Easily, quickly and securely installed using the Trellex T-bolt system. Trellex WB standard range Art. no Width () Height () Weight kg/ea WB WB WB WB WB WB WB WB WB WB WB WB WB WB WB All lengths 1500 Fixing method Designation Recoended T-bolt WB 50 M12 TF 35/25 WB 75 M16 TF 35/55 (M12 TF 35/25) WB 100 M20 TF 55 (M16 TF 35/55) WB 125 M20 TF 55 WB 150 M20 TF 55 T-bolt fixing system 16

19 Trellex SQ 300 The Trellex SQ 300 Module System is manufactured in three different types of material: Rubber, Polyurethane (PU) and a combination of PU/ceramic. Medium heavy rock and gravel industry. Demanding mining and industrial applications. Excellent wear resistance in applications with both impact and sliding wear. The modular system is very flexible and adaptable. The various types of material can be combined and thereby offer a very wide range of areas where they can be used. The modular system reduces noise and vibrations, and is lighter compared to conventional steel lining. The SQ 300 Module System provides excellent wear protection for feeders, bins, chutes, silos and other applications that are subject to wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Patented. Trellex SQ 300 standard range Designation/ Thickness () All modules are 300x300 Material Fixing SQ RU 50 Rubber T-60 Spindle & PU-plug SQ RU 40 Rubber T-60 Spindle & PU-plug SQ RU 30 Rubber T-60 All in one, spindle & plug SQ PU 50 PU 80 Spindle & PU-plug SQ PU 40 PU 80 Spindle & PU-plug SQ PU 30 PU 70 All in one, spindle & plug SQ CE 40 Ceramic & PU 2-part spindle & CE-plug Art. no Designation Weight SQ 300 Box CE SQ 300 Box PU SQ 300 Box PU SQ 300 Box RU SQ 300 Box RU SQ 300 Box RU SQ Box contains 66 pcs of wear elements, plugs, spiders Installation Simple, quick and secure installation with our flexible range of spindles and plugs. Fixing methods Rubber/PU 40 and 50 Rubber/PU 40 and 50 Ceramic CE 40 Rubber/PU 30 17

20 Trellex Poly-Cer Trellex Poly-Cer are manufactured from T-60 Wear Rubber with built-in ceramics and with fixed hot vulcanised steel back plates. Medium heavy rock and gravel industry, with secondary and lighter applications. Excellent wear resistance in applications with sliding wear and high material speeds. Excellent wear characteristics where the material has only a slight impact angle. The steel backing guarantees secure fixing. Poly-Cer to reduce noise and vibration. Poly-Cer provide excellent wear protection for feeders, bins, transfer chutes, silos, transfer points and other applications that are subject to excessive wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of secure fixing methods. Trellex Poly-Cer standard program Art. no Designation Thickness x Width x Length () Weight kg/ea Poly-Cer Slim 20 x 500 x Poly-Cer Slim 20 x 500 x Poly-Cer Classic 35 x 500 x Poly-Cer Classic 35 x 500 x Poly-Cer Classic 35 x 500 x Poly-Cer Classic 35 x 500 x Poly-Cer HD x 244 x Poly-Cer HD x 262 x Poly-Cer HD x 302 x Poly-Cer HD x 500 x Poly-Cer HD x 250 x Poly-Cer HD x 500 x Ceramics Fixing methods T-60 Wear Rubber Steel backing Stud welded bolt Self-tapping screw

21 Trellex Poly-Cer Sheeting Trellex Poly-Cer Sheeting are manufactured from T-60 Wear Rubber with built-in ceramics and contact layer prepared for easy glueing. Medium light mining, rock and gravel industry, with secondary and lighter applications. Excellent wear resistance in applications with sliding impact and high material speeds. Poly-Cer sheeting reduces noise and vibration. Trellex ceramic sheeting provides excellent wear protection for feeders, chutes, channels and other applications that are subject to a lot of wear and noise. Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Trellex Poly-Cer Sheeting standard dimensions Dimensions () Article no 8 x 500 x 500 (ceramic tiles 10 x 10 x 4) x 500 x 500 (ceramic tiles 20 x 20 x 4) Installation Cold vulcanization, glueing. 19

22 Trellex Flexback Trellex Flexback rubber is manufactured from T-60 Wear Rubber and is hot vulcanised with embedded, perforated steel plate, t = 0.7. Medium heavy rock and gravel industry, with secondary and lighter applications. Excellent wear resistance in applications with both impact and sliding wear. The reinforcement makes it possible to construct self-supporting channels and chutes with simple supports of angle iron and flat iron. Flexback reduce noise and vibrations, and are lighter compared to conventional steel lining. Flexback rubber provides excellent wear protection for chutes, channels, bins and other applications that are subject to wear and noise. Trellex Flexback standard range Art. no Designation/ Thickness Width x Length () Weight kg/ea FB x FB x FB x FB x FB x Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of secure fixing methods. Fixing methods Hilti nails Self-tapping screw Drill & Self-tapping screw Vagon bolt 20

23 Trellex Flexback PU Trellex Flexback PU is manufactured from polyurethane and with embedded cast-in, perforated steel plate, t = 0.7. Medium heavy rock and gravel industry, with secondary and lighter applications. Excellent wear resistance in applications with both impact and sliding wear. The reinforcement makes it possible to construct self-supporting channels and chutes with simple supports of angle iron and flat iron. Flexback reduce noise and vibrations, and are lighter compared to conventional steel lining. Flexback PU provides excellent wear protection for chutes, channels, bins and other applications that are subject to wear and noise. Trellex Flexback PU standard range Art. no Designation/ Thickness Width x Length () Weight kg/ea FBU x FBU x FBU x Other thickness and hardness on request Resists all PH values but is not designed for underwater applications. Resists attack from most oils and chemicals and is especially good for environments exposed to ozone. Supplied with a standard hardness of 78 sh(a) (yellow). Also available as alternatives in hardnesses of 70 sh(a) (blue) and 90 sh(a) (green). Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of secure fixing methods. Fixing methods Hilti nail Self-tapping screw Drill & Self-tapping screw Vagon bolt 21

24 Trellex Flexback Serrated Trellex Flexback Serrated is manufactured from T-60 Wear Rubber and is hot vulcanised with embedded, perforated steel plate, t = 0.7. Medium heavy rock and gravel industry, with secondary and lighter applications. Excellent wear resistance in applications with impact wear. The reinforcement makes it possible to construct self-supporting channels and chutes with simple supports of angle iron and flat iron. Flexback reduce noise and vibrations, and are lighter compared to conventional steel lining. Trellex Flexback Serrated standard range Art. no Designation/ Thickness () Width x Length () Weight kg/ea FBS x Trellex Flexback Serrated provides excellent wear protection for chutes, bins and other applications that are subject to wear and noise Resists all PH values and water types, also most oils and chemicals in moderate/small concentrations. The serrated surface has been designed to provide optimal life for material with impact angles between 15 and 50. Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of secure fixing methods. Fixing methods Hilti nails Self-tapping screw Drill & Self-tapping screw Vagon bolt 22

25 Trellex PPU Trellex PPU Wear Plates are manufactured from polyurethane, backed by cast-in steel plate. Medium heavy rock and gravel industry. Demanding mining and industrial applications. Excellent wear resistance in applications with sliding wear. The steel backing reduces the possibility of small particles getting in under the lining. The steel backing also guarantees secure fixing so that the wear plates remain together even if the lining is exposed to extremely abrasive and sharp particles. Wear Plates reduce noise and vibrations, and are lighter compared to conventional steel lining. PPU Wear Plates provide excellent wear protection for chutes, channels, bins and other applications that are subject to wear and noise. Trellex PPU standard range Art. no Designation/ Thickness Other dimensions on request Width x Length () Weight kg/ea PPU x PPU x PPU x Resists all PH values but is not designed for underwater applications. Resists attack from most oils and chemicals and is especially good for environments exposed to ozone. Supplied with a standard hardness of 78 sh(a) (yellow). Also available as alternatives in hardnesses of 70 sh(a) (blue) and 90 sh(a) (green). Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of secure fixing methods. Fixing methods Polyurethane Steel backing 3 Through bolt Stud welded bolt Plug welded Self-tapping screw 23

26 Trellex LF Trellex LF Plates are manufactured from ultra high molecular weight polyethylene (PE-UHMV). Light duty applications with clogging problems and sticky materials. Excellent for applications that require extremely low friction. Trellex LF Plates provide excellent solution for bins, chutes, silos and other low wear applications having problems with sticky materials. Resists all PH values and water types, also most chemicals in moderate concentrations. There are three grades of LF Plates: Pure PE-UHMW (white), Anti-static (black), Reclaim (mixed). Other information Must not be exposed to continuous heat in excess of 70 C. Installation Simple and quick installation with our flexible range of secure fixing methods. Trellex LF standard range Art. no Designation Thickness x Width x Length () Other dimensions and quality on request Weight kg/ea Trellex LF R3 10 x 1250 x Trellex LF R3 12 x 1250 x Trellex LF R3 15 x 1250 x Trellex LF R3 20 x 1250 x Trellex LF R3 25 x 1250 x Trellex LF R3 40 x 1250 x Trellex LF R3 6 x 1000 x Trellex LF S9 10 x 1250 x Trellex LF S9 12 x 1250 x Trellex LF S9 15 x 1250 x Trellex LF S9 20 x 1250 x Trellex LF S9 25 x 1250 x Trellex LF S9 40 x 1250 x Trellex LF S9 6 x 1000 x Trellex LF X9 10 x 1250 x Trellex LF X9 12 x 1250 x Trellex LF X9 15 x 1250 x Trellex LF X9 20 x 1250 x Trellex LF X9 25 x 1250 x Trellex LF X9 40 x 1250 x Trellex LF X9 6 x 1000 x Recoended fixing pattern Fixing methods W L 400 Through bolt Rivet Welded bolt Hilti nail Screw with plug 24

27 Trellex Granuflex Trellex Granuflex is made of two special Wear Rubber materials with hot vulcanized textile weave reinforcement. Within the fertilizer industry and certain mining industries of the pellet plant type. Both lateral and longitudinal textile weave reinforcement provides a strong and stably shaped lining. Minimises material back-ups and provides a more even end product quality. Trellex Granuflex is an excellent wear protection for granulating drums and pellet drums exposed to wear and caking problems. Can manage all ph values and water types and resists most oils and chemicals in moderate/small concentrations. Is resistant to all chemicals normally used in the production of fertilizer. Other information Must not be exposed to constant heat in excess of 70 C or 120 C, depending on quality. Installation Quickly, securely and easily installed with a specially adapted fastening method. Trellex Granuflex standard dimensions Name () Thickness () Width (max ) GS GS GS GS 70 must not be exposed to constant temperatures in excess of 70 C. GS 120 must not be exposed to constant temperatures in excess of 120 C. Fastening method 25

28 Trellex Wear Rubber Sheeting T-60 Black SBR, used for crushing and cutting abrasion. It is the high tear resistance, together with a high tensile strength and a moderate to high rate of elongation that makes T-60 extremely resistant to the wear and tear of impacting and abrasive rocks. T-40 Black NR, used for sliding abrasion of small particles. It is the high rate of elongation that makes T-40 particular well suited as protection against small, sharp, and hard particles eroding the surface. TR-60 Black SBR, used for less severe crushing and cutting abrasion. Good tear resistance, yet high tensile strength and a moderate to high elongation makes this grade an excellent, price-worthy choice when softer rocks and smaller impact forces are involved. 26 T-60 T-40 TR-60 Hardness Shore A 60 ±5 40 ±5 60 ±5 Tensile strength MPa Ultimate stretch load % Tearing strength kn/m Density mg/m Temperature range C -30 till till till +80 Resistance to oil, petrol small small small Resistance to chemicals moderate moderate moderate Identification line yellow green red Dimensions Thickness () Width () Length 4 (m) Smooth Rubber Sheeting yes T-60 T-40 TR-60 Tear off Layer 2 Contact Length 4 Layer 3 (m) Smooth Rubber Sheeting Tear off Layer 2 Contact Length 4 Layer 3 (m) yes yes yes 10 yes yes yes 10 yes yes 10 yes Smooth Rubber Sheeting yes yes yes 10 yes yes 10 yes yes yes yes 6 yes 6 yes yes yes yes 6 yes yes 6 yes yes yes yes 5 yes yes yes 3 yes 5 5 yes yes yes 3 yes 5 5 yes yes yes 3 yes 5 5 yes yes yes yes yes 1) Serrated - available in dimensions 1350 x 3000 with serrated surface. 2) Tear Off Layer one side is fitted with a tear-off fabric. Removing the fabric leaves a rough surface free of contaminants and suitable for gluing. 3) Contact Layer one side is coated with a special contact layer with tear-off film. Tearing off the foil leaves a surface free of contaminants. The special contact surface provides a strong adhesive joint and reduces the need for roughening. 4) Roll length 25 and 50 m on request. 5) Width Contact Layer 3

29 27

30 28 TRELLEX WEAR PROTECTION SOLUTIONS

31 Trellex Conveyor Accessories A dirty environment often results in poor finances. Maintenance is neglected, bearings and the life of other components is impaired. The number of operating stoppages and disturbances has a negative impact on production. Unscheduled conveyor stoppages may be costly, as the belt acts as a process artery. The main whys and wherefores of conveyor material spillages lie with loading and unloading of materials. Spillage is caused during unloading as a result of some materials being left on the belt after the turn. This material sticks to the belt and is released onto the return rollers along the whole length of the conveyor belt. When loading, troubles are mostly the result of the kinetic energy of the material after unloading and the drop height. The kinetic energy of dropping materials must be absorbed in order to avoid mistracking and leakage through the sealing system. Belt stoppages are in many cases caused by spillage-related problems. Trellex Wear Protection Solutions has a range of products which are suited to solving the coonest problems affecting conveyors. Loading Normally, loading is the most critical point on the conveyor at which damage can occur. The material drop height, unit size, speed and direction are all factors which contribute to and cause damage to belts, conveyors and traditional support rollers alike. This is where the material flow changes direction, the kinetic energy must be absorbed, the material is retarded and then accelerated again and is controlled until the turbulence of transfer has stopped, all of which are problems that are virtually eliminated using the Trellex loading system. It replaces traditional roller cradles and efficiently absorbs the kinetic energy from falling stones, and also supports the belt edge. The conveyor belt is protected against penetration and the risk of belt misalignment is reduced. The Trellex loading system has no moving parts, thus avoiding problems with worn bearings and stationary rollers. While removing the need for the demanding work of replacing broken-down rollers, operating reliability is increased. The combination of energy-absorbing non-moving elements and efficient sealing prevents material spillage and reduces cleaning costs. Sealing with wear liner Trellex Glide Bars and Impact Bars are used for the sealing system. They are used on the troughed sides when transporting materials. It supports the belt edge thereby preventing sag between the conveyor rollers, which provides an even surface for the sealing system to seal against. In combination with the Trellex Sealing System this effectively prevents dust and material spillage. The sealing system uses material with a slightly lower wear resistance than the belt. In this way you can confine wear to the sealing strip thus extending the working life of the significantly more expensive belt. If the loaded material is allowed to press against the sealing strip it will eventually work its way under it. By fitting a Trellex Wear Liner in the lower section of the loading zone, the material is kept away from the side seal. This substantially reduces the risk of spillage and wedging which would otherwise lead to increased wear or damage to the belt. Belt guiding system Wear and poor adjustment can incapacitate a conveyor belt prematurely. Loading point misalignment, side winds, rain/snow and uneven absorption of heat from the sun can interfere with the operation of conveyors. This is where our Belt Conductor enters the scene. This belt guiding system can prolong the life of a conveyor and thus improve reliability. With active control and guiding of the belts, maintenance costs can be cut considerably. The belt guiding system protects vital parts of the conveyor frame from damage. Less wear on the belt increases life and reduces costs. A misaligned belt causes point loading of rollers. A frozen roller can slice a belt in minutes. A centred belt causes less wear and fewer break-downs. Trellex belt conductor minimize the risk of costly, unscheduled repair stoppages and increases availability, thereby keeping cleaning costs to a minimum. 29

32 Trellex Impact Bar The Trellex Impact bar is of sandwich layer design consisting of polyethylene and rubber with a vulcanised aluminium profile for easy fastening with T bolts. The Trellex Impact Bar is designed to absorb impacts and to create a sealed surface against the conveyor belt in such areas as loading zones beneath a conveyor belt, thereby preventing damage to the conveyor belt and its equipment. Top coating of ultra high molecular weight polyethylene provides high wear resistance and low friction. Rubber material of high energy absorption capacity. Protects belts and conveyors when loading. No moving parts provides a maintenance-free loading station. Fastening system using T-bolts for placing anywhere along the bar as required. Medium heavy stone and gravel quarrying industry. Demanding mining work and industrial applications. Ultra high molecular weight polyethylene, rubber, aluminium. Other information For best results Trellex Impact Bars should be installed into Trellex Impact Cradles. Installation Drop height: max 2 m Material size Max 400 Measure Width Belt width Height Side/centra/side Length Available roll lengths Art.No T-bolt fixing system Dimensions Art.No T-bolt TF35/25 M12x40/ Nuts Nyloc M Washers BRB 13x24 HB200 FZB Recoended number of Energy absorbing elements Maximum 10 gap between centre section and sides 30

33 Trellex Glidebar Trellex Glidebar is a sandwich construction of polyethylene and rubber with a vulcanised aluminium profile for easy fixing with T-bolts. Trellex Glidebar is designed to absorb impacts and to create a sealed surface against the conveyor belt in such areas as loading zones beneath a conveyor belt, thereby preventing damage to the conveyor belt and its equipment. Top layer of ultra high molecular weight polyethylene provides high wear strength and low friction. Rubber material with the ability to absorb large amounts of energy. Protects conveyor belt and equipment against heavy loads. There are no moving parts in Trellex energy absorbing elements, which means that they provide a maintenance-free loading station. Fixing system with T-bolts for individual location anywhere along the absorber unit. Trellex Glidebar standard range Product Range Dimensions () Art. No Glidebar x 200 x Glidebar x 300 x T-bolt system incl nut and TF35/25 M 12 x 40/35 washer, 4 T-bolts/glidebar Medium heavy rock and gravel industry. Demanding mining and industrial applications. Ultra high molecular weight polyethylene (PE-UHMW), rubber, aluminium Other information For best results Trellex Glidebar should be installed into Trellex Impact Cradles. Installation Drop height: max. 0,5 m Material size Max

34 Trellex Impact Cradle Strong steel mounting cradle for the installation of Trellex Impact Bars. An Impact Cradle, replacing the current conveyor roller stand, is placed in the conveyor loading zone as a support and to ensure that the belt has a stable profile, and also that a proper seal is achieved during loading. Strong steel design that can withstand heavy loads. The side angles are adjustable to obtain the best sealing and accessibility. C/L Medium heavy rock and gravel industry. Demanding mining and industrial applications. Construction material Steel, S235JRG2 Surface treatment Powder-coated BLUE RAL 5005 W L Other information A questionnaire from Metso Minerals must be completed to obtain the correct design. For best results, the Impact Cradles should be installed together with Trellex Impact Bars. Side angles that are not standard can be made on request. Installation Drop height: max. 2 m Material size Max. 400 Belt width L Angle X1 or X and and and and and and and and and Width W The width depends on the type of conveyor 32

35 Trellex Snap-On Sealing System Trellex Snap-On Sealing System for sealing conveyor belts in loading zones. The Trellex Snap-On is an effective system that is suitable for sealing at loading zones alternatively along the whole conveyor belt. The extruded rubber sealings can be obtained in long lengths, which reduces the number of joints and the risk of spillage. Snap-on elements are easy and quick to install. Adjustment of the rubber sealing against the conveyor belt is done by slackening the wedge bolts that secure them. When these are slackened, the strips automatically slide down on to the belt. The wedge bolts are then tightened again. Maintenance is simplified and spillage reduced. Trellex wear liners should be mounted on the inside of the chute walls. This prevents loaded material from pressing directly on to the sealing strips and helps to centre the bed of material on the belt. Wear liners consist of bent 15 thick wear rubber elements that have the rear sides reinforced by steel plate. Loading zones in the medium heavy rock and gravel industry. Demanding mining and industrial applications. Complete system Article no. Description Trellex Snap-On Sealing, complete Standard length Remarks 2400 Both sides Spare parts Article no. Width Trellex Snap-On sealing profile L= Trellex Snap-On guide plate L= Wedge bolt Square washer 33

36 Trellex Clamp-On Sealing System Trellex Clamp-On Sealing System for sealing conveyor belts in loading zones. The Trellex Clamp-On is an efficient system for sealing conveyor belts in loading zones. External sealing uses polyurethane blocks, which are locked into place by fast-operating locking bars for quick and easy installation. This can reduce the cost of service and maintenance. The block material provides a long life while being gentle to the belt. Trellex wear liners should be mounted on the inside of the chute walls. This prevents loaded material from pressing directly on to the sealing strips and helps to centre the bed of material on the belt. Wear liners consist of bent 15 thick wear rubber elements that have the rear sides reinforced by steel plate. Loading zones in the medium heavy rock and gravel industry. Demanding mining and industrial applications. Complete system Article no. Description Trellex Clamp-On Sealing, complete Trellex Clamp-On Sealing, complete Standard length Sealing block length Spare parts Article no. Width Trellex Quick release clamp Trellex Clamp-On locking bar L= Trellex Sealing PU-blocks L= Trellex Sealing PU-blocks L= Trellex Clamp-On guide plate L= Trellex Wear liner L=

37 Trellex Belt Conductor The Trellex Belt Conductor centres the conveyor belt. Trellex Belt Conductor is mounted on the return part of the belt and actively controls and continuously conductor the belt. Trellex Belt Conductor SBC & HD-SBC The edge rollers of the belt guide sense belt mistracking and make the conductor roller centre the belt. Increases availability and minimises the risk of unscheduled stoppages. Belt conveyors Optional extras Conductor roller with Trellex roller lagging Edge roller cartridges of polyurethane material, ESA 78 Lubrication kit. Construction material: Steel, S235JRG2 Surface treatment: Powder-coated BLUE RAL 5005 Trellex Belt Conductor RBC Standard SBC Heavy Duty HDBC Reversibel RBC Light applications x x Heavy applications x x Belt speeds <3,5 m/s >3,5 m/s <3,5 m/s The pictures show the Trellex Belt Conductor in action 35

38 36 TRELLEX WEAR PROTECTION SOLUTIONS

39 Trellex Belt Scrapers Belt cleaning is not just a question of aesthetics, it is also an important determining factor if efficient, safe and profitable conveying is to be achieved. In the Trellex belt cleaning product range known as ABC Absolute Belt Cleaning we have focused on finding technical solutions for our customers equipment that provide high efficiency, long wear life and a minimal maintenance needs. High efficiency ensures minimum spillage The parameters that affect efficiency include the scrapers contact angle to the belt, the contact area and the contact pressure per surface unit. On the ABC scrapers these values are kept as close to the ideal as possible throughout the wear life of the blades. As a result, these scrapers show constant and extremely high cleaning efficiency from installation and throughout their wear life. To further increase the efficiency of the scraper, the blades are divided into segments, which can move independently of each other. Reduced spillage leads to less wear on the conveyor and its components and bring clean-up cost savings. Long wear life for lowest operating costs The life expectancy of a scraper closely depends upon its efficiency. The more material that passes between the scraper and the belt, the higher the wear rate becomes. Thanks to the high and constant cleaning efficiency of our scrapers the amount of material still adhering to the belt after the scraper can be reduced to a minimum. Consequently its wear life is extended and the cost per ton low. Minimal maintenance needs for trouble free operation Since the blade to belt contact pressure remains almost constant throughout the entire wear life of the scraper blade, there is no need to re-tension the spring and the need for maintenance is reduced to an absolute minimum. The belt cleaning system is designed to operate in a dirty and demanding environment, and the blades are shaped in such a way that the build-up of material on the blades is minimized. ABC scrapers are made of Trellex s own polyurethane material, which has outstanding wear properties. Using polyurethane means that an aggressive scraping angle can be used without any risk of damaging the belt. The special design of the blades means no reinforcing metal parts are needed. The base of the blade is securely held in place in a specially designed aluminium cassette. 37

40 Trellex ABC Silverline Pre-Cleaner The Trellex ABC Silverline Pre-Cleaner, (complete with blade, shaft and type S spring tensioner) Conveyor belt cleaning. The Pre-Cleaner is placed against the conveyor belt drive drum, just below the material flow. Individual blades free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are made from two different materials, high grade Polyurethane and Polycarbonate. The blades are mounted in an aluminium cassette, which makes installation and changing blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Material causing wear in areas such as mining, smelting plants and gravel pits. Wet applications Other information The ABC Silverline is fully compatible with other Trellex Pre-Cleaners such as the ABC90 and ABC95, which means that no mechanical alterations are necessary if changing to a different blade type. Patent pending. Blades Material: Polyurethane/Polycarbonate Colour: Silver Density: 1.19 Mg/m 3 Hardness: 70 Shore A Temperature in dry air: -30 C to +70 C Tensioner/cassette: Steel / aluminium Installation Belt speed: < 3.5 m/s Drive drum Dia: Ø Tensioner: BB single type S, BB double type S Article no. Complete set Belt width A No. of blades Cleaning width B Aluminium profile length C Shaft length (max.) D

41 Trellex ABC 70 Pre-Cleaner The Trellex ABC 70 Pre-Cleaner, (complete with blade, shaft and type S spring tensioner) Conveyor belt cleaning. The Pre-Cleaner is placed against the conveyor belt drive drum, just below the material flow. Individual, entirely high grade polyurethane, blades free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Medium heavy rock and gravel industry. Less demanding mining and industrial applications. Other information The ABC 70 is fully compatible with other Trellex Pre-Cleaner such as the Silverline and ABC95, which means that no mechanical alterations are necessary if changing to a different blade type. Blades Material: Polyurethane Colour: Yellow / Blue Density: 1.19 Mg/m 3 Hardness: 70 Shore A Temperature in dry air: -30 C to +80 C Tensioner/cassette: Steel / aluminium Installation Belt speed: < 3.5 m/s Drive drum Dia: Ø Tensioner: BB single type S, BB double type S Article no. Complete set Belt width A No. of blades Cleaning width B Aluminium profile length C Shaft length (max.) D

42 Trellex ABC 90 Pre-Cleaner The Trellex ABC 90 Pre-Cleaner, (complete with blade, shaft and type S spring tensioner). Conveyor belt cleaning. The Pre-Cleaner is placed against the conveyor belt drive drum, just below the material flow. Individual, entirely high grade polyurethane, blades free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Medium heavy rock and gravel industry. Less demanding mining and industrial applications. Other information The ABC 90 is fully compatible with other Trellex Pre-Cleaners, such as the Silverline and ABC 95, which means that no mechanical alterations are necessary if changing to a different blade type. Blades Material: Polyurethane Colour: Yellow Density: 1.19 Mg/m 3 Hardness: 90 Shore A Temperature in dry air: -30 C to +70 C Tensioner/cassette: Steel / aluminium Installation Belt speed: < 3.5 m/s Drive drum Dia: Ø Tensioner: BB single type S, BB double type S Article no. Complete set Belt width A No. of blades Cleaning width B Aluminium profile length C Shaft length (max.) D

43 Trellex ABC 95 Pre-Cleaner The Trellex ABC 95 Pre-Cleaner, (complete with blade, shaft and type S spring tensioner). Conveyor belt cleaning. The Pre-Cleaner is placed against the conveyor belt drive drum, just below the material flow. Individual, entirely high grade polyurethane, blades free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Timber and paper industries, and sawmills. Other non-wearing organic material. Other information The ABC 95 is fully compatible with other Trellex Pre-Cleaners such as the Silverline and ABC90, which means that no mechan-ical alterations are necessary if changing to a different blade type. Blades Material: Polyurethane Colour: Red Density: 1.19 Mg/m 3 Hardness: 95 Shore A Temperature in dry air: -30 C to +70 C Tensioner/cassette: Steel / aluminium Installation Belt speed: < 3.5 m/s Drive drum Dia: Ø Tensioner: BB single type S, BB double type S Article no. Complete set Belt width A No. of blades Cleaning width B Aluminium profile length C Shaft length (max.) D

44 Trellex ABC 70-HD Pre-Cleaner The Trellex ABC 70-HD Pre-Cleaner, (complete with blade, shaft and type S spring tensioner). Conveyor belt cleaning. The Pre-Cleaner is placed against the conveyor belt drive drum, just below the material flow. Individual, entirely high grade polyurethane, blades free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Medium heavy and heavy rock and gravel industry, mining and other heavy industrial applications. Other information The ABC70-HD is fully compatible with other Trellex Pre-Cleaners such as the ABC90-HD, which means that no mechanical alterations are necessary if changing to a different blade type. : Blades Material: Polyurethane Colour: Yellow/Blue Density: 1.19 Mg/m 3 Hardness: 70 Shore A/65 Shore D Temperature in dry air: -30 C to +70 C Tensioner/cassette: Steel /aluminium Installation Belt speed: m/s Drive drum Dia: Ø Tensioner: BB single type S, BB double type S Article no. Complete set Belt width A No. of blades Cleaning width B Aluminium profile length C Shaft length (max.) D

45 Trellex ABC 90-HD Pre-Cleaner The Trellex ABC 90-HD Pre-Cleaner, (complete with blade, shaft and type S spring tensioner). Conveyor belt cleaning. The Pre-Cleaner is placed against the conveyor belt drive drum, just below the material flow. Individual, entirely high grade polyurethane, blades free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Medium heavy and heavy rock and gravel industry, mining and other heavy industrial applications. Other information The ABC90-HD is fully compatible with other Trellex Pre- Cleaners such as the ABC70-HD, which means that no mechanical alterations are necessary if changing to a different blade type. : Blades Material: Polyurethane Colour: Yellow Density: 1.19 Mg/m 3 Hardness: 90 Shore A Temperature in dry air: -30 C to +70 C Tensioner/cassette: Steel / aluminium Installation: Belt speed: m/s Drive drum Dia: Ø Tensioner: BB single type S, BB double type S Article no. Complete set Belt width A No. of blades Cleaning width B Aluminium profile length C Shaft length (max.) D

46 Trellex ABC HMS & HMS-XL Pre-Cleaner The Trellex HMS & HMS-XL Pre-Cleaner, (complete with blade, shaft and type S spring tensioner). Conveyor belt cleaning. The Pre-Cleaner is placed against the conveyor belt drive drum, just below the material flow. Individual blades, with a high grade polyurethane base and a tungsten carbide edge, free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Used where abrasive and wearing material is to be handled, such as reclaimed glass, crushed flint and quartz. Medium heavy rock and gravel industry, and other industrial applications. Blades Material: Polyurethane Colour: Red Density: 1.19 Mg/m 3 Hardness: 90 Shore A Temperature in dry air: -30 C to +70 C Tensioner/cassette: Steel /aluminium Installation Belt speed: < 3.5 m/s Drive drum Dia: Ø Tensioner: BB single type S, BB double type S Other information The ABC HMS is fully compatible with other Trellex Pre-Cleaners such as the ABC70 and ABC90, which means that no mechanical alterations are necessary if changing to a different blade type. The HMS-XL has a larger wear section of tungsten carbide than the HMS blade. Article no. Complete sets HMS / HMS XL Belt width A No. of blades Cleaning width B Aluminium profile length C Shaft length (max.) D / / / / / / / / /

47 Trellex HMS and HMS-PU T-Cleaner The Trellex ABC HMS & HMS-PU T-Cleaner, (complete with blade, shaft and type NT spring tensioner). Conveyor belt cleaning. The best place for a T-Cleaner is just behind the point where the belt leaves the drive drum. Individual blades, with a high grade polyurethane or rubber base and a tungsten carbide edge, free to move independently of each other for maximum cleaning flexibility and providing excellent belt cleaning without damaging the belt. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. Used where abrasive and wearing material is to be handled, such as reclaimed glass, crushed flint and quartz. Medium heavy rock and gravel industry, and other industrial applications. Blades Material: Polyurethane or rubber with a tungsten carbide edge PU/Rubber colour: Yellow/Black PU/Rubber density: PU 1.19 Mg/m3, Rubber 1.12 Mg/m 3 PU/Rubber hardness: 90/60 Shore A Temperature in dry air: PU: -30 C till +70 C Rubber: -30 C till +80 C Tensioner/cassette: Steel / aluminium Installation Belt speed: Drive drum Dia: Tensioner: < 3.5 m/s Ø BB single type NT, BB double type NT-HD Other information The ABC HMS is fully compatible with other Trellex T-Cleaners, which means that no mechanical alterations are necessary if changing to a different blade type. A B C Article no. Complete set Polyurethane blades Article no. Complete set Rubber blades Belt width A No. of blades Cleaning width B Aluminium profile length C

48 Trellex HS and HMS Arm Cleaner The Trellex HMS & HS Arm Cleaner, (complete with blade, shaft and type S spring tensioner) Conveyor belt cleaning. The best place for an Arm Cleaner is just behind the point where the belt leaves the drive drum. Individual blades of tungsten carbide (HMS) or hardened steel (HS). The arms holding the blades are held in rubber mounts. The blades are fitted alternately and are fee to move independently of each other to provide maximum cleaning flexibility. Thos provides efficient belt cleaning without causing damage to it. The individual blades are mounted in an aluminium cassette, which makes installation and changing of worn blades quick and easy. A spring tensioner ensures that the correct pressure is exerted on all the blades, which reduces the need for maintenance. HMS: Medium heavy rock and gravel industry. Less demanding mining and industrial applications. HS: Timber and paper industries, and sawmills. Other nonwearing organic material. Blades Material: Tungsten carbide edges Colour: Black Density: PU 1.19 Mg/m3, Rubber 1.12 Mg/m 3 Hardness: 90/60 Shore A Temperature in dry air: -30 C to +80 C Tensioner/cassette: Steel / aluminium Installation Belt speed: HMS <3.5 m/s, HS <2.5 m/s Drive drum Dia: N/A Tensioner: BB single type S, BB double type S Article no. Complete set HS blades Article no. Complete set HMS blades Belt width A Cleaning width B No. of blades Aluminium profile length C D E Total Short arm Long arm min max

49 Trellex Belt Brush ABC 6-12 Trellex Belt Brush a cost-effective solution for the cleaning of patterned belts An efficient belt brush for dry, fine materials. The belt is kept clean and spillage below the belt is reduced. This results in lower maintenance costs and less down time. Brush tube in modules for maximum flexibility The brush tube consist of 150 long modules which makes it possible to replace only those modules that are worn. One size module fits all belt widths. A lockingring on each side keeps the modules in place. The modules has sawtooth pattern that hook into each other thereby making it possible to replace the all modules from one side. The modules are low weight and can easily be handled by one person. The bristles are placed in a V pattern for best possible cleaning efficiency. The brush tube is corrosion resistant and counteracts the build up of material. High operational security Trellex Modular Belt Brush is powered by a drum motor. Compared to other brushes, the Trellex Belt Brush requires very small space. The hermetic sealing system keeps dirt and dust out of the motor in an effective way, which makes it practically maintenance free. New, simple suspension The simple, strong suspension demands very little space. It comes pre-assembled from the factory, which makes the installation fast and simple. Recoended for applications within the limits below Belt speed: <2.5 m/s (<500 fpm) Belt width: (20-72 ) Temperature: -25 up to +40 C (-15 up to +105 F) Applications: Dry and fine materials Avoid: Wet and sticky materials Motor also available in stainless steel for aggresive environments. Many advantages quick and easy installation reduces carry back less clean-up easy adjustment simplified maintenance improved work environment Article no. Belt width No. of brush modules Cleaning width A Motor width B C min. C max. 47

50 48 TRELLEX WEAR PROTECTION SOLUTIONS

51 Trellex Pulley Lagging The job of the drive pulley is to provide the belt with traction force. The drive pulley can be fitted with a suitable friction lagging to increase the coefficient of friction. The lagging on the pulley is also used to reduce wear on the pulley surface and to perform an auto-clean function. Running a conveyor without slippage protection is like driving a car on tires with the tread worn away. The worse the conditions become, the greater the risk of losing grip. Therefore it is important to have slippage protection that ensures operation even under harsh conditions including rain, snow, ice and clay. Trellex Wear Protection Solutions has a wide range of pulley laggings which suit most situations. Trellex Traclag pulley lagging fits most types and sizes of pulleys. It can also be used effectively with turn and breaker pulleys. In addition, Trellex Traclag is suitable for use as pulley lagging on drive pulleys in reversible conveyors. Applied to pulleys using adhesive, its syetrical pattern affords excellent grip between conveyor belts and pulley lagging in both directions. Trellex Griplag Pulley Lagging Trellex Griplag has a special design that provides a number of unique advantages; the rubber element features a metal strip that is vulcanized into the front edge of the rubber. This strip contains several holes for fixing the rubber to the pulley using selftapping screws. This special fixing method, combined with the elasticity of the rubber and the round, conical stubs protruding from the surface of the element, means that Trellex Griplag is able to eliminate practically all wear between belt and lagging caused by the difference in belt elongation on the upper and lower sides of the conveyor. The self-cleaning tread stops aquaplaning and materials backing up on the drive pulley. Griplag is used on the drive pulley which rotates in one direction. Trellex Pulley Bars are constructed with heavy-duty operation in mind and are made from a durable, long lasting rubber compound. An aluminium profile has been vulcanized into the rubber and bars are fixed in position on the pulley with self tapping screws. The design of the bar lends itself to inclined and vertical lift conveyors. Trellex Pulley Bars are syetrical. This means that they are ideally suited for use with reversible operation conveyors. Trellex Pulley Bars have a long operating life, even in heavy-duty applications. Trellex Ceramic pulley lagging Cer-lag is extremely effective in difficult working conditions such as wet and muddy conditions where belt slippage occurs. The hardwearing ceramic inserts produce extremely high wear resistance. 49

52 Trellex Griplag Trellex Griplag, Pulley Lagging. Trellex Griplag is fixed on the drive pulley with special self tapping screws. Decreases the risk of slipping and increases friction between conveyor belts and pulleys. The open pattern of the lagging with its round conical knobs together with the free-suspended design effectively prevents materials caking and backing up on belts and lagging. The free suspended design also helps protect against the formation of ice in damp weather conditions when the temperature is fluctuating below and above zero. The pulley does not have to be removed while installing the lagging. The pattern, the special fixtures and the space between the lagging efficiently remove rain water and prevent aquaplaning. Belt conveyors and elevators. Not for reversible conveyors. Art no Screw: M6SF-TT10x Material: Wear Rubber 60 Sh A with vulcanized in fastening rail S235JRG2 Range Griplag Standard 18 x 300 x * Griplag Mini 18 x 150 x * * complete with screws 6-20 ( ) Standard: 1200 x 300 x 18 A B C/D C/D C/D C/D C/D C/D C/D 400 3/14 4/14 4/14 5/14 6/14 6/14 8/ /14 5/14 5/14 6/14 7/14 8/14 10/ /14 7/14 7/14 9/14 10/14 11/14 14/ /14 8/14 8/14 10/14 11/14 12/14 16/ /14 10/14 10/14 12/14 14/14 15/14 20/ /14 12/14 12/14 14/14 16/14 18/14 24/ /14 15/14 15/14 18/14 20/14 23/14 30/ /14 16/14 16/14 19/14 22/14 24/14 32/14 A = Diameter of drive pulley B = Width of drive pulley C/D = Number of lagging elements/spaces in Mini: 1200 x 150 x 18 A B C/D C/D C/D C/D C/D C/D C/D 200 3/7 4/7 4/7 5/7 6/7 6/7 8/ /7 5/7 5/7 6/7 7/7 8/7 10/ /7 6/7 6/7 7/7 8/7 9/7 12/ /15 6/15 6/15 7/15 8/15 9/15 12/ /7 8/7 8/7 10/7 11/7 12/7 16/ /7 10/7 10/7 12/7 14/7 15/7 20/ /15 12/15 12/15 14/15 16/15 18/15 24/ /7 14/7 14/7 17/7 19/7 21/7 28/ /7 16/7 16/7 19/7 22/7 24/7 32/ /7 20/7 20/7 24/7 27/7 30/7 40/ /7 24/7 24/7 28/7 32/7 36/7 48/ /7 25/7 25/7 30/7 34/7 38/7 50/ /7 30/7 30/7 35/7 40/7 45/7 60/7 50

53 Trellex Pulley Bar Trellex Pulley Bar, Slip protection bars. Trellex Pulley Bar is fixed on the drive pulley with special self tapping screws. Decreases the risk of slipping and increases friction between conveyor belts and pulleys. Because of the mechanical fixture and because pulleys can be left on the conveyor when fitting, it is easy to replace worn lagging. The lagging pattern and the spaces between lagging efficiently remove rain water and prevent aquaplaning. Because of the syetrical design of the lagging it is ideal for use on reversible conveyors. Belt conveyors and elevators. Art no Size: 1365 x 70 x * Screw: M6SF-TTMB x 25 Material: Wear Rubber 60 Sh A with fastening rail vulcanized in aluminium *complete with screws Number of bars Pulley diameter Belt speed <1.5m/s Belt speed >1.5m/s Alt. 1 Alt. 1 Alt Alt ( )

54 Trellex Traclag Trellex Traclag Pulley lagging. Drive pulleys, turn pulleys, breaker pulleys and other pulleys. Decreases the risk of slipping and increases friction between conveyor belts and pulleys. Its syetrical pattern provides good grip between conveyor belt and lagging in both directions. The pattern efficiently removes rain water and prevents aquaplaning. Traclag is glued to the pulley. The contact layer simplifies preparation by eliminating roughing and degreasing. Belt conveyors and elevators. Alternative material Oil/grease resistant materials. Heat resistant materials. Art no Size: 8 x 1500 x 50 m x 1500 x 50 m x 2000 x 50 m x 2000 x 50 m Material: Wear Rubber 60 ± 5 ShA Upper side/wear side: Diamond patterned Rear side: Contact layer Thickness 12 on request Trellex Traclag with diamond pattern Trellex Traclag with diamond pattern 52

55 Trellex Cer-Lag Trellex Cer-Lag Pulley lagging. Drive pulleys, turn pulleys, breaker pulleys and other pulleys. Decreases the risk of slipping and increases friction between conveyor belts and pulleys. Round in-vulcanized ceramic tiles with high friction design. Contoured surface for water drainage and to decrease the risk of aquaplaning. The lagging is easy to handle and pulleys need not be removed from their mountings. The lagging is glued to the pulley. Because of the syetrical design of the lagging it is ideal for use on reversible conveyors. Primarily drive pulleys working under harsh operating conditions, e.g. wet and muddy applications. Art no Size: 10 x 250 x x 250 x Material: Wear Rubber 60 ± 5 Sh A Round ceramic tiles 53

56 54 TRELLEX WEAR PROTECTION SOLUTIONS

57 Trellex Slurry & Bulk Hose System The Trellex System The Trellex Slurry & Bulk Hose System is based on 3 easily exchangeable standard components - the Hose, Coupling and Gasket. The Coupling is fixed mechanically around the smooth Hose. The Hose retains its fullbore cross-section, even at the point where the Coupling is fitted. The Coupling does not come into contact with the material being handled, and is consequently not exposed to or creating any wear. It can be reused when the Hose is replaced. The Coupling does not have to match any particular pattern on the Hose. It can easily be turned around the Hose, until it is accurately aligned with the flange to which it is to be connected. The Trellex Slurry & Bulk Hose System can be connected to flanges drilled in conformity with all major international flange standards. The Hose Available from ID44 to ID610 ( 1.3/4 to 24 Ø). Inner tube of thick black natural rubber, middle layer of reinforcement, and full embedded spiral wound galvanized steel wire. Outer layer of smooth wear & weather resistant rubber cover. Working pressure 5 to 10 bar, safety factor against bursting 3,2 times working pressure, suction 50% to 90% vacuum. The picture (see next page) shows a principal description on how a hose is made. The inner tube is taking care of the internal activities inside the hose and needs to have good resistance against transported material. Then depending on what the hose is designed for, reinforcement and steel helix is added, to handle pressure stress, overpressure and vacuum, but also to give the hose dimensional stability during compressive load. Finally the outer cover is applied for protecting the reinforcement against external stress such as wear and ozone. The Coupling Made of corrosion resistant, high-strength cast aluminium, with burst rating at 3,2 times the working pressure. Elongated holes in the front flange enable the Coupling to be connected to all mayor flange standards. The Coupling consists of identical segments. If one segment is lost, or damaged, it can be replaced with any other segment of the same size. The Couplings are supplied with bolts for the side flanges. To prevent them from turning, these bolts are of square head type, and also provided with stop rings to prevent them from falling out during assembly. The Gasket The Gasket is tapered on the rear end to compensate for irregularities and jags that may occur when the Hose end is tried to exact length. The tapered rear will also center the Gasket perfectly to the inner diameter of the Hose. The front of the Gasket is fluted to ensure leak-proof performance. 55

58 1. Outer Cover 2. Reinforcement 3. Helix 4. Inner tube Product codes In mining, slurry is a mixture of water and mineral particles, pumped between different processing equipments. And with fine particles, transported by hydraulics, a soft, natural rubber will give the best wear performance. The Trellex Slurry Hose will therefore have a wear tube of Trellex 40 rubber. If slurry is wet handling, then bulk is dry handling of materials like cereals, powders, granulates, etc. Dry, pneumatic transport often results in an increase of temperature. A 60 Shore SBR rubber will perform better when higher temperatures are involved and/ or large particles under dry conditions. The Trellex Bulk Hose has a wear tube of Trellex 60 rubber. Our product codes for respective hose are: Trellex Slurry Hose type Trellex Bulk Hose type Our product codes for couplings and gasket are: Trellex Split-Flange Coupling type Trellex Tapered Gasket, type 11101S Our product codes for Bends are: Trellex 3D Bend type (45 ) without flanges Trellex 3D Bend type (90 ) without flanges Iediately after the type code, we state the inside diameter of the particular hose, bend, coupling, gasket or whatever. Example: A coupling will thus match a hose , and a gasket 11101S-204 will fit into this hose. Requests outside the Trellex standard range please contact responsible Product line. 56

59 Trellex Material Handling Hose Trellex Material Handling Hose for hydraulic applications has a wear tube of rubber quality Trellex T40. Pumping of extremely abrasive materials. Thick long-life wear tubes with smooth walls and low flow resistance. Together with Trellex couplings and sealings, these hoses form an extremely reliable system which retains the free flow area without turbulence at the couplings. In the mineral processing industry, coal refinement plants, power plants in the steel and cement industries and other applications where high wear resistance combined with flexibility and vibration reduction is required. The hoses are reinforced with cord and have embedded galvanized steel wire spirals for managing dynamic pressure and underpressure. The safety factor against bursting is 3.2 times the working pressure. Installation Trellex Material Handling Hoses are cut to size on site. Trellex Handling Hose standard program Article no. ID ID inch OD Standard length m Wear tube Working pressure Mpa Min.bend radius Slurry hose kg/m

60 Trellex Couplings Trellex split flange couplings are made of high strength aluminium alloys. The couplings consist of two or four identical segments which are mounted mechanically on the smooth hose. Pumping of extremely abrasive materials. The couplings are reusable after replacing hoses, since they do not come into contact with the transported materials. In the mineral processing industry, coal refinement plants, power plants in the steel and cement industries and other applications where high wear resistance combined with flexibility and vibration reduction is required. E F C B A Trellex couplings comply with most flange standards. Installation The couplings do not need to be suited to any special pattern on the hose cover. It is simply twisted around the hose until it fits into the flange connected. Article no 58 *) ANSI norm only Coupling size A Dimension B C ExF Holes per joint Sections per segment Weight kg Matches flange DIN 2632 PN 10 ANSI B16.1 Class 150 Operating pressure Mpa x x x , x x x , x x x x x x x x x x x * x x * x x x * x x x

61 Trellex 3xD Bend Trellex 3xD Bends are made completely of rubber, cord reinforced and with a fully embedded galvanized steel wire spiral. Trellex 3xD Bends are intended for use in tight spaces where ordinary Trellex hoses cannot be bent enough. For optimum wear economy, the outer bend has a >30% thicker wear tube than the inner bend. It comes in 90 and 45 versions. Thick exceptionally long-life wear tubes with smooth walls and low flow resistance. Feed nozzles to magnetic separators or similar equipment. The safety factor against bursting is 3.2 times the working pressure. Straight sections outside the 3xD bend allow connection with Trellex couplings. r = 3xD C B Installation Quickly and easily installed without special tools. C D A Trellex 3D 90 type Article no ID OD Inner radius Wear tube Outer radius Operating pressure Mpa A x B C r x x x x x x x x x x x x

62 Trellex Reducers Trellex Reducers provide a transition between different diameter pipes or hoses to compensate for changes in flow speed. Pumping of extremely abrasive materials. Trellex Reducers are made entirely of rubber with steel wire cord reinforcement. The thick wear tube with smooth walls is made of T40 rubber. A less than 2 x 8 cone provides smooth flow without turbulence and is available in standard lengths, flanged and ready for quick and easy replacement. The flanges are steel reinforced and drilled to match the coonest flange standards. In the mineral processing industry, coal refinement plants, power plants in the steel and cement industries and other applications where high wear resistance combined with flexibility and vibration reduction is required. The safety factor against bursting is 3.2 times the working pressure. Installation See installation manual Conical transition pipe Reducers ID/id Wear Tube Working Pressure Mpa Length L ID id 63/ / / / L 102/ / / / / / / / / / / / / / /

63 Trellex Branch Pipes Trellex Branch Pipes of steel, clad on the inside with 10 T40 wear rubber. The internal cladding stretches out over the flanges. Pumping of extremely abrasive materials. The branch pipe is long lived thanks to the thick soft coating of Trellex 40. In the mineral processing industry, coal refinement plants, power plants in the steel and cement industries and other applications where high wear resistance combined with flexibility and vibration reduction is required. The branch pipe is treated with anti-rust paint on the outside and provided with flange connections drilled in accordance with DIN 2632 or ANSI B16.1 Other information Other sizes, shapes, branch types, hole drilling etc available upon request. Trellex Branch Pipes A Ø ID A B Ø Hole division. DIN ANSI inch B Ø ID 61

64 Trellex Gaskets The conical Trellex Gasket is designed for use together with Trellex hoses and bends. Together with the Trellex coupling, the gasket ensures completely sealed couplings while retaining full inner diameter. Pumping of extremely abrasive materials. Trellex Gaskets are steel reinforced so as to retain the same inner diameter as the hose when pressed into it. The gaskets allow turbulence free passage and are the same size as the inner diameter of the hose. The conical shape compensates for irregularities in the hose ends. Grooves at the front eliminate the risk of leaks. In the mineral processing industry, coal refinement plants, power plants in the steel and cement industries and other applications where high wear resistance combined with flexibility and vibration reduction is required. Other information Two couplings and two gaskets are required to form a complete link between two hoses. Installation See installation manual For internal hose diameter A B ØA ØB 62

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