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Belzona® Insitu Shaft Repair Solution Saves Days Of Lost Production



Mining and Quarrying (MINQ)



Mechanical Power Transmission (MPT)


Customer Location:

Lime stone quarry, SW England


Application Date:

August 2013


Application Situation:

Main drive roller on conveyor loading finished product to trains.



Bearing Failure had caused severe damage to the shaft stopping the loading of trains and the ability to meet customer deadlines potentially costing the quarry hundreds of thousands of pounds in lost revenue. Traditional repair method of complete drum replacement would require the removal of the building’s roof and some of the structural frame which houses the conveyor, hire of a crane & manufacture of a new roller and rubber lagging which could take over five days to complete, this was no acceptable to the quarry or their customers.



Belzona 1111 (Super Metal)





Application Method:

The repair was carried out in accordance with Belzona System Leaflet  MPT-2 For rebuilding damaged shafts using forming techniques


Belzona Facts:

The application was carried out and the conveyor back into service the following day ensuring that they made their customers deadline. Cost of conveyor being out of sevice £10,000.00 per hour Traditional repair method materials costs - Crane hire and rubber lagged new drum £3,000.00  Traditional repair method lost time - five days of lost conveyor based on 12 hour shifts = £600,000.00   Total projected cost to quarry £603,000.00 Belzona repair method costs - Belzona material and manufacture of former £560.00 Belzona Repair method lost time - two days of lost conveyor based on 12 hour shifts = £240,000.00 Total cost to Quarry £240,560.00 BELZONA SOLUTION TOTAL SAVING £362,440.00


Photographs Description

Severe damage to conveyor roller drive shaft View of the tight application area Former fabricated on site to create new bearing mounting surface Shaft repair being carried out insitu without the need to remove anything from the conveyor

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