Rubber coating Viscogrip is supplied with raw rubber on one side for cold vulcanization by means of a specific solution which confers exceptional rubber-to-metal adhesion.
Installation works are to be done at the ambient temperature not below 10°С.
The room in where you work must be equipped with forced ventilation and fire extinguishing means, should be heated, without dust, dirt, too high moisture, with handling equipment.
For longer storage the coating, glue and other necessary chemical materials should be placed in a dark, cool place.
COATING FOR DRIVING DRUMS OF CORRUGATOR MACHINES
Estimation is for 2 drums with dimensions Ø 800-900 mm, width 2300-2600 mm.
Tools | Quantity | Notes |
---|---|---|
Perforator | 2 pcs | |
Chisel for perforator, 4-5cm wide | 2 pcs | Angle of sharpening is to one of the flat surfaces of the chise |
Grinder, angular or straight | 3-4 pcs | |
Grinding wheels with a large grain size | 20 pcs | |
Metal brushes for the grinder, with bristles of medium hardness | 2-5 pcs | or |
Building knife with replaceable blades | 2-3 pcs |
Materials and tools | Quantity | Notes |
---|---|---|
Glue SC 2000 (green) (1 kg), with hardener UTR 20 (40 g) from REMA TIP TOP | 20 pcs/1kg + 20 pcs/40g | Consumption of glue and hardener:
|
Primer for metal PR- 300 (red) from REMA TIP TOP | 3 kg | Applying primer PR 300 on the metal surface of the drum – ca. 170 g/m2(one layer is enough). |
Cleaning Solvent from REMA TIP TOP | 10 pcs/800 ml. | Cleaning agent, primer and glue should be from one supplier, because cleaning agent can serve as a solvent. |
Paint brush, 80-100 mm wide | 10 pcs | |
Tanks for primer and glue | 3 pcs 2-3 l | It is not recommended to use tanks more than 5l as it is inconvenient due to small amount of glue solution. Glue should be prepared in small quantity taking into consideration that action time of the glue with hardener is not more than 2 hours. |
Rags | 5-10 kg | |
Rubber hammer | 2 pcs | |
Marker | 20 pcs/1kg + 20 pcs/40g | It is important to use a spirit marker. It is forbidden to use markers with fat-containing substances. |
Glue SC 2000 (green) (1 kg), with hardener UTR 20 (40 g) from REMA TIP TOP | 1 | |
Tape measure, 5 m | 1 | |
Building knife with long blade | 1 | |
Triangle with 500 mm ruler | 1 |
Maintenance team: 4-5 people.
Working time: 12 – 16 hours.
Stage 1. Removal of the belts from the driving drums.
Remove the belts from the driving drums.
Stage 2. Preparing working area.
All the works with the drums will take place in the following sequence:
TOP – BOTTOM – BOTTOM – TOP
Stage 3. Removal of the main layer of the old coating.
Top drum.
Step 1
Carefully cut the coating along the drum, down to the metal, using the building knife. Then, using perforator with chisel head, take away the coating from the whole width of the drum. One person uses perforator to tear apart the coating, another person is pulling the coating thus making it easier and faster to work.
Step 2
After the main coating is removed, there will be a layer of old glue on the drum – 1,5-2mm thick. Use again perforator with chisel head to remove this layer.
Remove the glue layer around the
circumference of the drum.
Step 3
Clean the drum by angle or straight grinder. Remove all traces of glue, old rubber, dirt and corrosion.
Metal brush of medium hardness can be used for rough treatment of the drum surface. Just
remove the glue.
Step 4
You can start step 4 skipping Step 3, if remnants of glue on the drum surface are insignificant.
Grinding wheels will get clogged with glue, thus losing their properties.
Make the grinding until the metallic luster is achieved, removing thoroughly the old primer from
the drum surface. Make even grinding of the whole surface.
Dismantle guiding unit between the drying table and rotary cutter in order to provide access to the bottom drum. Repeat actions described above in Steps 1 – 4.
Maintenance team: 4-5 people.
Working time: 3 hours considering the time of the primer drying.
Step 1
Wash the metal surface with the cleaning solution by a rug.
Make it sure that there no traces of grease or any other dirt. The surface should be clean and dry.
Step 2
Primer increases adhesion to metal. Stir thoroughly primer PR 300 before using. If necessary
dissolve the primer. Use solvent and primer from the same manufacturer!
Apply by a brush evenly one layer of the primer PR 300 for metal for each drum.
You can apply the primer simultaneously on both drums. It should take not less than 2 hours for the primer to dry. Do not apply too thick layer.
Maintenance team: 4-5 people.
Working time: 8 hours considering the time of the primer drying.
Step 1
Degrease surface of the drum.
Step 2
Put marking for the first strip in the following way:
Measure from the edge of the drum a distance that will be on 1cm less than width of the applied strip. Put marking around the circumference of the drum.
E.g.: first strip of the coating will be 400mm wide, so marking should be 390mm wide.
Step 3
While the primer PR 300 applied on the drum is getting dry, prepare the rubber coating in the following way:
Note:
If coating was delivered in strips of necessary length, check that each strip has perpendicular cut. If necessary, make correction of the cut.
You should check and correct only one side of the strip, the one that will be first glued to the drum. The strips are supplied with surplus considering the length of the drum circumference.
The other side of a strip will be cut as necessary at the moment of gluing. The coating has a protective film on the side that will be glued to the drum. DO NOT REMOVE
THE FILM BEFORE A CERTAIN MOMENT!
Note:
Step 5
It is IMPORTANT to prepare glue in small quantities, i.e. to use 1kg for the coating and 1kg for the drum. This precaution is necessary because glue is influenced by hardener and in 2-3 hours loses its gluing properties. Prepared glue should be used within 1 hour to use its properties at maximum.
Prepare the glue in the following way:
In the same way prepare one more portion of glue in another tank. Thus you will apply glue solution simultaneously on the strip and on the drum.
Note: 1 kg of the solution is enough for 2 strips of coating or for drum surface where 2 strip of coating can be glued.
Step 6
SIMULTANEOUSLY apply with the pain brush the glue solution on one strip of coating and on the drum on surface where one strip will be applied. Glue should be applied evenly. The layer should not be too thick or too thin.
Glue the strip coating immediately after the glue solution was applied both on the strip and on the drum.
It is IMPORTANT to glue the first strip strictly in accordance with the marking. Glue the strip while slowly rotating the drum.
Press with the help of the rubber hammer and make it sure that coating is pressed gradually and evenly, excluding creation of air pockets.
Excess length should be cut with the sharp knife. Cutting should be very accurate, excluding any slot or bubble in the place where 2 ends of the strip meat. Then SWIFTLY press the strip on the whole surface again using the rubber hammers. Pay attention to the edges and joints.
Step 7
After the first strip is applies, rotate the drum on 180° and repeat the Steps 4-6. Carefully follow recommendation described above applying each strip. Try to avoid gaps between the strips and between the ends of each strip. Rotate the drum on 180° after applying each strip.
Step 8
When all the strips are applied, leave the drum for about 2 hours to rest and then, if there is excess coating protruding on the edge of the drum, cut it using the knife with long blade.
Top drum
Follow recommendations described above in the Steps 1-8 for the bottom drum.
Wait for 2 hours after the rubber coating is installed. Cut excess coating protruding on the edges of the drum using knife with long blade. Now proceed to installation of the belt.
After the coating is installed, wait for 4-6 hours to allow the glue to harden properly. Then heat up the machine and start production.