In industrial operations where conveyor belts play a critical role in operational continuity, repair time and solution reliability can directly affect productivity, costs, and plant availability.
At CSN Cimentos in Volta Redonda, Brazil, sidewall and cleat repairs on conveyor belts were traditionally performed using SC-2000 adhesive cement or similar adhesive systems. Although widely used in the industry, these methods presented two major issues: long curing times and low durability in service.
The conventional process required surface preparation, multiple adhesive layers, and up to 24 hours of waiting time before the belt could return to service.
Beyond the extended downtime, the results were not satisfactory: the sidewalls and cleats detached in less than one month, causing new shutdowns, rework, and loss of operational continuity.
Operational challenge
The operation needed a solution that could:
- Drastically reduce downtime.
- Eliminate recurring detachment issues.
- Carry out the repair directly in the field.
- Avoid complex vulcanization processes or long curing times.
- Ensure reliable adhesion under real industrial operating conditions.
The intervention was carried out on August 26, 2015, under the following conditions:
- Ambient temperature: 19 °C
- Low surface moisture
- Total intervention time: 3 hours and 30 minutes
- Work team: Bertech technician, CSN maintenance technician, and six Vulmax mechanics
The solution: cold repair with FLEXSOL® BF-01
To solve the problem, the Bertech Brazil team utilized FLEXSOL® BF-01, a cold vulcanization system designed for rapid repairs and critical conveyor belt applications.
The solution eliminated the long curing times associated with traditional adhesives and significantly reduced total intervention time.
Repair procedure
Surface preparation
The damaged surface was prepared with a bevel cut and mechanical roughening using a wire brush.
Cleaning
FLEXSOL® Cleaning Solvent was then applied to remove dust and surface contaminants.
Primer application
FLEXSOL® Primer was applied to both belt surfaces to optimize system adhesion.
Mixing and activation
The catalyst was added to the FLEXSOL® resin and mixed until the compound was homogeneous.
Compound application
The material was spread over the repair area with a spatula, allowing self-leveling and uniform filling of irregularities.
Curing
The system solidified in approximately 30 minutes and reached full physical properties after one hour.
Results
The intervention reduced total repair time from approximately 24 hours to just 3 hours and 30 minutes.
The belt returned to service approximately one hour after product application.
The main results included:
- Drastic reduction in operational downtime.
- Elimination of recurring detachment issues.
- Excellent mechanical performance and superior adhesion.
- Repair completed entirely in the field.
- Rapid restoration of operational continuity.
FLEXSOL® BF-01 achieved adhesion to rubber of 22.5 N/mm², approximately five times the typical standard used in conveyor belt manufacturing.
After eight months of monitoring, the repair still showed no detachment or failures.
Operational impact avoided
A conventional repair using traditional adhesives would have required up to 24 hours of operational downtime, with potential losses estimated at US$250,000 to US$750,000, in addition to the risk of rework due to premature adhesion failure.
The FLEXSOL® BF-01 solution allowed the plant to restore operational continuity the same day and eliminate recurring detachment issues.
Key benefits of FLEXSOL® BF-01 for conveyor belts
- Rapid on-site repairs.
- Cold application without vulcanization equipment.
- Significant downtime reduction.
- High adhesion under real operating conditions.
- Designed for operational emergencies.
- Reduced production losses.
- Greater reliability compared with traditional adhesives.
A solution designed for operational continuity
In mining and heavy industry, a repair must do more than solve the immediate damage: it must do so rapidly, minimize downtime, and ensure long-term operational reliability.
The case at CSN Cimentos demonstrates how a cold repair system can transform a slow, recurring problem into a rapid, durable, and operationally efficient solution.