Flexco Flex-Lag Rubber, Flex-Lag Ceramic, Flex-Lag Weld-On Installation, Operation And Maintenance Manual
Flex-Lag® Cold Bond Pulley Lagging
Installation, Operation
and Maintenance Manual
Light-Duty Plain-Pattern
Diamond-Pattern Rubber
Medium Ceramic (39%)
www.flexco.com
www.flexco.com
Diamond-Pattern Ceramic (13%)
Full Ceramic (80%)
Flex-Lag® Cold Bond Pulley Lagging
Purchase Date: ______________________________________________________________
Purchased From: ____________________________________________________________
Installation Date: ____________________________________________________________
This information will be helpful for any future inquiries or questions
about replacement parts, specifications or troubleshooting.
2 Flex-Lag® Cold Bond Pulley Lagging
Table of Contents
Section 1 – Important Information ....................................................................... 2
1.1 General Introduction .......................................................................................... 2
1.2 User Benets ........................................................................................................ 2
1.3 Service Option ..................................................................................................... 2
Section 2 – Safety Considerations and Precautions .............................................. 3
2.1 Stationary Conveyors .......................................................................................... 3
2.2 Operating Conveyors .......................................................................................... 3
Section 3 – Pre-Installation Checks and Options .................................................. 4
3.1 Checklist ............................................................................................................... 4
Section 4 – Installation Instructions...................................................................5-8
Section 5 – Pre-Operation Checklist and Testing.................................................. 9
5.1 Pre-Op Checklist ................................................................................................. 9
5.2 Test Run the Conveyor .......................................................................................9
Section 6 – Maintenance .................................................................................10-12
6.1 New Installation Inspection ............................................................................. 10
6.2 Routine Visual Inspection ................................................................................ 10
6.3 Routine Physical Inspection .............................................................................10
6.4 Maintenance Log ............................................................................................... 11
6.5 Lagging Maintenance Checklist ......................................................................12
Section 7 – Troubleshooting ................................................................................ 13
Section 8 – Specs and CAD Drawings............................................................. 13-21
8.1 Specications ......................................................................................................13
8.2 CAD drawing - Light Duty .............................................................................. 14
8.3 CAD drawing - Plain Rubber...........................................................................15
8.4 CAD drawing - Diamond-Pattern Rubber.....................................................16
8.5 CAD drawing - Diamond Ceramic .................................................................17
8.6 Medium Ceramic, Dimpled Tiles ....................................................................18
8.7 Medium Ceramic, Smooth Tiles ......................................................................19
8.8 Full Ceramic, Dimpled Tiles .......................................................................... 20
8.9 Full Ceramic, Smooth Tiles .............................................................................. 21
Section 9 – Lagging Adhesives/Toolbox .............................................................. 22
Section 10 – Other Flexco Conveyor Products .................................................... 25
1
Section 1 – Important Information
1.1 General Introduction
We at Flexco are very pleased that you have selected Flex-Lag® Pulley Lagging for your conveyor system.
is manual will help you to understand the operation of this product and assist you in making it work up to
its maximum eciency over its lifetime of service.
It is essential for safe and ecient operation that the information and guidelines presented be properly
understood and implemented. is manual will provide safety precautions, installation instructions,
maintenance procedures and troubleshooting tips.
If, however, you have any questions or problems that are not covered, please contact your eld representative
or our Customer Service Department:
Customer Service: 1-800-541-8028
Visit www.exco.com for other Flexco locations and products.
Please read this manual thoroughly and pass it on to any others who will be directly responsible for
installation, operation and maintenance of this pulley lagging. While we have tried to make the installation
and service tasks as easy and simple as possible, it does however require correct installation and regular
inspections to maintain top working condition.
1.2 User Benets
Correct installation and regular maintenance will provide the following benets for your operation:
• Eliminate belt slippage
• Reduced conveyor downtime
• Reduced man-hour labor
• Lower maintenance budget costs
• Increased service life for the lagging and pulley
1.3 Service Option
Flex-Lag® Pulley Lagging is designed to be easily installed and serviced by your on-site personnel. However, if
you would prefer complete turn-key factory service, please contact your local Flexco Field Representative.
2 Flex-Lag® Cold Bond Pulley Lagging
Section 2 – Safety Considerations and Precautions
Before installing and operating Flex-Lag® Pulley Lagging, it is important to review and understand the following safety
information.
There are set-up, maintenance and operational activities involving both stationary and operating conveyors. Each case
has a safety protocol.
2.1 Stationary Conveyors
The following activities are performed on stationary conveyors:
• Installation
• Cleaning
!
DANGER
It is imperative that OSHA/MSHA Lockout/Tagout
(LOTO) regulations, 29 CFR 1910.147, be followed before
undertaking the preceding activities. Failure to use LOTO
exposes workers to uncontrolled behavior of the products
caused by movement of the conveyor belt. Severe injury or
death can result.
Before working:
• Lockout/Tagout the conveyor power source
• Disengage any takeups
• Clear the conveyor belt or clamp securely in place
!
WARNING
Use Personal Protective Equipment (PPE):
• Safety eyewear (splash goggles optional)
• NIOSH-approved air respirator with organic
vapor cartridge (if ventilation is not available as
recommended in enclosed Safety Data Sheets)
• Hardhat • Long-sleeve shirt
• Safety footwear • Apron (optional)
• Nitrile gloves
Close quarters and heavy components create a worksite
that compromises a worker’s eyes, feet and skull.
PPE must be worn to control the foreseeable hazards
associated with conveyor lagging. Serious injuries can
be avoided.
2.2 Operating Conveyors
There are two routine tasks that must be performed while the conveyor is running:
• Inspection of performance
• Dynamic troubleshooting
!
DANGER
Every belt pulley is an in-running nip hazard. Never
touch or prod an operating pulley. Pulley hazards cause
instantaneous amputation and entrapment.
!
WARNING
Pulleys can become projectile hazards. Stay as far from the
pulley as practical and use safety eyewear and headgear.
Missiles can inflict serious injury.
!
WARNING
Never adjust anything on an operating pulley.
Unforseeable belt projections and tears can cause
violent movements. Flailing hardware can cause
serious injury or death.
3
Section 3 – Pre-installation Checks and Options
3.1 Checklist
• Check that the lagging size is correct for the pulley width
• Check that the correct amount of lagging strips are available to lag the
pulley (see Page 6).
• Check that the correct amount of primer, adhesive and activator are
available to lag the pulley (see Page 6).
• Check the carton and make sure all the parts are included
• Review the “Tools Needed” list on the top of the installation instructions
• Check the conveyor site:
· Will the lagging be installed in a chute
· Is the install on an open head pulley
Flex-Lag Primer, Adhesive and Activator ONLY for use with
cold-bond rubber-to-rubber or rubber-to-metal adhesion.
4 Flex-Lag® Cold Bond Pulley Lagging
Section 4 – Installation Instructions
If using non-Flexco adhesives, please follow that company’s instructions for usage, mixing, application and safety
procedures.
Flex-Lag® Pulley Lagging can be used with Flex-Lag Adhesives. Flex-Lag Adhesives consist of a Primer, Adhesive
and Activator. Before using, the Primer should be thoroughly mixed. Before using, one Adhesive and one Activator
should be thoroughly mixed and used within three hours. Reference the Adhesive Usage Charts on Page 6 for
quantity of each material required based on Pulley Diameter and Face Width.
ese materials are meant for use at room temperature. e ambient temperature and temperature of the lagging
and pulley must be between 41˚F113˚F (5˚C 45˚C), and the relative humidity should not exceed 80% during the
lagging procedure. ese should be checked prior to starting and occasionally during the lagging process to ensure
proper bonding.
Proper protective equipment should be used during the lagging process. Wear safety glasses with side shields.
Wear chemical splash goggles if the possibility exists for eye contact with splashing liquid. Avoid skin contact by
wearing chemically-resistant gloves (nitrile) and long sleeved shirt. An apron may be appropriate if splashing can
occur. Respiratory protection may be required to avoid overexposure when handling this product. If general room
ventilation is not available or sucient use a NIOSH-approved air purifying respirator with organic vapor cartridge.
Please reference the Safety Data Sheets for Adhesive, Activator and Primer to see detailed requirements. Also, please
follow any local or state guidelines for use of this product.
Fig. 1
Fig. 2
Physically lock out and tag the conveyor at the power source
before you begin pulley lagging installation.
Tools Needed:
• Grinder (low RPM recommended)
• 24 Grit Flap Disc
• Bench Brush
• Coarse Dish Wheel
• Paint Brushes
1. Prepare the pulley by removing the old lagging, paint and primer.
Sand blast the entire pulley or use a grinder with 24 grit flap disc or
paper disc. Use bench brush and non-oil-based metal solvent to clean
remaining particles from the pulley surface. Paint the pulley surface,
including the edges, with Flex-Lag Primer. Allow to dry completely –
a minimum of 30 minutes.
2. Use a grinder with coarse dish wheel to buff the edges and bottom
of the lagging. Be careful not to smoke the rubber. Wipe with non-
oil-based solvent to clean surface of any particles.
• Heavy Duty Knife
• Chalk Line
• Dead Blow Rubber Hammer
• Lagging Stitchers/Rollers
• Oscillating Tool (for cutting rubber)
5
Section 4 – Installation Instructions (cont.)
3. Use the Strip Selection Chart at right to
calculate the number of strips required for
your pulley diameter. Using a heavy duty
knife, cut lagging strips 4" (100mm) longer
than the pulley face width. Medium and Full
Ceramic lagging come in pre-specified strip
lengths. Note: Do not allow ceramic tiles to
sit at, or over, the edge of the pulley face.
PULLEY DIAMETER
in. mm in. mm
12.6-15.0 320-381 6 42.6-45.0 1083-1145 18
15.1-17.5 382-445 7 45.1-47.5 1146-1210 19
17.6-20.0 446-510 8 47.6-50.1 1211-1273 20
20.1-22.5 511-573 9 50.2-52.6 1274-1336 21
22.6-25.0 574-636 10 52.7-55.1 1337-1400 22
25.1-27.5 637-700 11 55.2-57.6 1403-1463 23
27.6-30.0 701-764 12 57.7-60.1 1466-1527 24
30.1-32.5 765-827 13 60.2-62.6 1529-1590 25
32.6-35.0 828-891 14 62.7-65.1 1593-1654 26
35.1-37.5 892-955 15 65.2-67.6 1656-1717 27
37.6-40.0 956-1018 16 67.7-70.1 1720-1781 28
40.1-42.5 1019-1082 17 70.2-72.6 1783-1844 29
Fig. 3
Adhesive, Activator and Primer Usage Charts
FLEX-LAG® ADHESIVE 0.8L / ACTIVATOR 40g (1:1 mix ratio)
Face Width
In. 10 14 18 22 26 30 34 38 42 46 50 54 58 62 66 70 74 78 82 86 90
Pulley Diameter
FLEX-LAG
Face Width
Pulley Diameter
mm 254 356 457 559 660 762 864 965 1067 1168 1270 1372 1473 1575 1676 1778 1880 1981 2083 2184 2286
8 203 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3
12 305 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 3 4 4 4
16 406 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 5
20 508 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6
24 610 1 2 2 2 2 3 3 3 4 4 4 5 5 5 5 6 6 6 7 7 7
28 711 1 2 2 2 3 3 3 4 4 5 5 5 6 6 6 7 7 7 8 8 8
32 813 2 2 2 3 3 4 4 4 5 5 6 6 6 7 7 8 8 8 9 9 10
36 914 2 2 3 3 3 4 4 5 5 6 6 7 7 8 8 8 9 9 10 10 11
40 1016 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12
44 1118 2 2 3 4 4 5 5 6 6 7 7 8 9 9 10 10 11 11 12 12 13
48 1219 2 3 3 4 4 5 6 6 7 7 8 9 9 10 10 11 12 12 13 13 14
52 1321 2 3 3 4 5 5 6 7 7 8 9 9 10 11 11 12 13 13 14 15 15
56 1422 2 3 4 4 5 6 6 7 8 9 9 10 11 11 12 13 14 14 15 16 16
60 1524 2 3 4 5 5 6 7 8 8 9 10 11 11 12 13 14 14 15 16 17 17
®
PRIMER .75L
In. 10 14 18 22 26 30 34 38 42 46 50 54 58 62 66 70 74 78 82 86 90
mm 254 356 457 559 660 762 864 965 1067 1168 1270 1372 1473 1575 1676 1778 1880 1981 2083 2184 2286
8 203 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
12 305 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
16 406 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
20 508 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
24 610 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
28 711 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
32 813 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
36 914 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2
40 1016 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2
44 1118 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2
48 1219 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2
52 1321 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2
56 1422 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2
60 1524 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2
Strip Selection
STRIPS
REQUIRED
PULLEY DIAMETER
STRIPS
REQUIRED
6 Flex-Lag® Cold Bond Pulley Lagging
Section 4 – Installation Instructions (cont.)
Fig. 4a Fig. 4b
4. Apply first coat of adhesive. Thoroughly mix one can of adhesive and one activator at a time, immediately applying it
to the pulley and strips of lagging. Be sure to apply adhesive to the edges of the lagging as well. This process should use
half of the adhesive/activator required in the chart on Page 6. Note: Allow 4 hours for the first coat to properly cure.
Temperature and humidity will affect dry time.
Fig. 5
6. Apply second coat of adhesive to the pulley. Thoroughly mix one can of
adhesive and activator at a time. From the perpendicular line, apply the
second coat of adhesive to an area slightly greater than one strip of lagging.
Fig. 7
5. After the first coat of adhesive has dried completely, mark a line across the
pulley face using a chalk line or scriber, ensuring the line is parallel to the
shaft’s centerline and square to the edge of the pulley.
7. Apply a second coat of adhesive to one strip of lagging. Be sure to apply
adhesive to the edges of the lagging as well.
Fig. 6
8. After the second coat has reached the appropriate tackiness (approximately
2-5 minutes, touch with back of hand – feels tacky and leaves no adhesive on
hand) install one strip of lagging, using the perpendicular line to assure the
strip is square to the pulley. Working out from the center of the strip, use a
dead blow rubber hammer for tamping to remove the air gaps, ensuring all
surface area receives one hammer blow. Repeat this process with Lagging
Stitchers/Rollers to remove air gaps from drainage grooves. Be sure to check
edges to verify seal.
Fig. 8
7
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