A critical conveyor belt failure brought production at Samarco’s Mariana plant in Brazil to an immediate halt. The operation faced a time-sensitive situation: there was no scheduled shutdown, no contractor on site, and the conventional alternative required vulcanization equipment and securing a replacement belt.

The estimated time for a traditional repair was approximately 48 hours.

For a mining operation on Samarco’s scale, a 48-hour shutdown could have represented potential production losses of US$10 million to US$13 million.

The challenge was not just repairing a damaged conveyor belt. The real objective was to restore operational continuity as soon as possible and avoid a prolonged shutdown of the line.

Emergency repair of 17 meters of belt-edge damage

The project involved restoring approximately 17 meters of edge damage on the conveyor belt using the FLEXSOL® BF-01 Cold Vulcanization System.

The intervention was carried out on July 3, 2015, under real mining operating conditions:

• Ambient temperature: 26 °C
• Low surface moisture
• Total working time: 4 hours and 20 minutes
• Work team: Bertech technician and the Veyance maintenance team

The objective was to demonstrate the ability of FLEXSOL® BF-01 to respond under real emergency conditions, minimizing downtime and enabling a safe, rapid return to service.

Cold repair procedure

The repair was carried out directly in the field through a cold-application process, eliminating the need for heating equipment or vulcanization presses.

Surface preparation

The first step was to bevel the damaged edge and mechanically roughen the surface with a wire brush, preparing the area to ensure proper adhesion.

Area cleaning

FLEXSOL® Cleaning Solvent was then applied to remove dust and surface contaminants. Drying time was approximately one minute.

Primer application

FLEXSOL® Primer was applied to both belt surfaces to optimize adhesion of the repair system. Drying time was approximately two minutes.

Mixing and activation of the compound

The catalyst was added to the FLEXSOL® resin and mixed for one minute until the compound was homogeneous and warm to the touch.

Application

The compound was poured and spread over the damaged area with a spatula. Its self-leveling properties allowed the system to fill irregularities and release air bubbles during application.

Curing and return to service

The material solidified in approximately 30 minutes and reached its full physical properties after one hour.

Operational results

The repair fully restored the integrity of the conveyor belt edge, with strong adhesion and a uniform surface finish.

The project significantly reduced intervention time compared with a conventional repair:

• Repair with FLEXSOL® BF-01: 4 hours and 20 minutes
• Estimated conventional repair: approximately 48 hours

The system returned to safe service within one hour after product application, allowing the plant to resume production the same day.

Operational impact avoided

A conventional repair would have required replacing the damaged section with vulcanized splices, resulting in a prolonged shutdown.

For a mining operation on Samarco’s scale, this could have represented potential production losses of US$10 million to US$13 million.

The FLEXSOL® BF-01 solution allowed the plant to restore operational continuity the same day, significantly reducing the economic and operational impact for the customer.

Follow-up after 8 months in service

After eight months of continuous operation, the repair maintained its integrity and performance, validating the system under real mining conditions.

The case demonstrated that FLEXSOL® BF-01 can support emergency repairs where recovery speed and operational continuity are critical.

Key benefits 

• Designed for unscheduled emergency repairs
• Cold application without vulcanization equipment
• Significant downtime reduction
• High adhesion under real field conditions
• Rapid restoration of operational continuity
• Reduced production losses
• Practical application under real mining conditions

Materials used in the repair

The repair used 65 FLEXSOL® kits for conveyor belt applications, including:

• Resin
• Cleaning solvent
• Primer
• Catalyst
• Application tools

Technical recommendations

For areas with through-damage, FLEXSOL® Non-Stick Laminated Sheets are recommended to contain the compound during application.

Whenever possible, the belt surface should be kept flat to facilitate application and ensure optimal adhesion.