Built to Last: Devcon® R-Flex® Delivers Long-Term Belt Protection

When it comes to conveyor belt repairs, the key questions are:

• How long will the repair take?
• What method ensures the best performance?
• How long will a temporary fix last before it fails?

In mining and heavy industrial operations, any delay in belt repair can result in significant productivity loss. Shutting down to reroute material to another line is costly and inefficient. That’s why fast, reliable, and long-lasting repair solutions are essential.

The Challenge: Repeated Damage to a Critical Conveyor Belt

At a copper mining facility, a long SBR (Styrene-Butadiene Rubber) conveyor belt was used to move ore from the raw material processing area to the refinery. This belt is critical to plant operations and handles high volumes of abrasive ore daily.

Over time, the belt developed significant grooves and tears due to continuous exposure to sharp, heavy materials. Previous repair materials failed prematurely, forcing frequent maintenance stops and reducing overall productivity. The mine needed a durable, long-lasting belt repair solution capable of withstanding harsh environmental conditions and minimizing downtime.

The Solution: Devcon® R-Flex® for Long-Lasting Abrasive Protection

To restore functionality and extend the life of the belt, the maintenance team used Devcon R-Flex, a proven rubber repair compound designed for high-abrasion environments.

Repair Process:

1. Belt Preparation: All ore material was cleared from the belt to expose the damaged area.
2. Surface Abrasion: The area surrounding the damage was abraded using a disc pad to ensure maximum adhesion.
3. Surface Conditioning: A surface conditioner was applied to remove contaminants and improve bonding.
4. R-Flex Application: Devcon R-Flex was mixed and applied to the grooves at a thickness of ⅛ inch.
5. Curing Time: The compound cured in just 90 minutes, restoring the belt quickly and effectively.

The Results: High Performance in a Demanding Environment

Reduced Downtime

The belt was back in service within two hours, minimizing disruption to plant operations and restoring full material flow.

Superior Durability

After switching from a competitor product that failed after one cycle, the mine conducted monthly inspections of the Devcon repair. After three operating cycles, the Devcon® R-Flex® repair showed no signs of wear — delivering 3X the performance of the previous solution.

Reliable Application in Harsh Conditions

Despite the hot and humid conditions of the copper mine, Devcon® R-Flex® was unaffected by the environment. The repair was completed smoothly, using just a few simple steps.

Conclusion: A Smarter Belt Repair Solution

Devcon® R-Flex® offers a fast, simple, and durable solution for conveyor belt repairs in tough industrial environments. For operations where uptime is critical and repairs must endure extreme wear and tear, R-Flex® delivers proven results — lasting 3 times longer than competing products and restoring performance in a fraction of the time.

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FAQs – Devcon® R-Flex® Conveyor Belt Repair Solution

Q1: What is Devcon® R-Flex®, and what makes it suitable for conveyor belt repair?
A: Devcon® R-Flex® is a two-part, flexible rubber repair compound specifically engineered for abrasion resistance and flexibility. It is ideal for repairing worn or damaged rubber components like SBR conveyor belts exposed to harsh, high-wear environments such as mining, aggregates, and heavy industry.

Q2: How long does it take to repair a conveyor belt using R-Flex®?
A: The complete repair process—including surface prep, application, and cure—can be completed in as little as two hours, with full curing in just 90 minutes. This fast turnaround helps minimize operational downtime and gets critical equipment back in service quickly.

Q3: What kind of surface preparation is required before applying R-Flex®?
A: Proper surface preparation is essential for a successful repair:

Remove all loose material and clean the damaged area

Abrade the surface with a disc pad to create a rough texture for better bonding

Apply a Devcon surface conditioner to eliminate contaminants and enhance adhesion

Q4: How does R-Flex® compare to competitor repair products?
A: In the case study at a copper mine:

A competitor product failed after one operating cycle. Devcon® R-Flex® lasted three cycles with no signs of wear, providing 3X the durability, this demonstrated significant improvement in both performance and service life.

Q5: Can R-Flex® be used in hot and humid conditions?
A: Yes. R-Flex® is designed for tough field conditions and performs well in hot, humid, and dusty environments, making it ideal for remote mining and industrial locations where environmental control is limited.

Q6: Is this repair considered temporary or permanent?
A: R-Flex® provides a semi-permanent repair—it can last through multiple operating cycles and is much more durable than traditional patch solutions. While it’s not a replacement for full belt replacement when needed, it offers long-term performance for most operational requirements.

Q7: What thickness should R-Flex® be applied at?
A: In the case application, R-Flex® was applied at a thickness of ⅛ inch (approximately 3 mm) to fill grooves and tears in the belt. The appropriate thickness may vary depending on the extent of damage and application.

Q8: What types of conveyor belts can R-Flex® repair?
A: R-Flex® is suitable for most rubber-based conveyor belts, including SBR, natural rubber, and EPDM belts commonly used in mining, aggregates, and processing plants.

Q9: Can the repaired section be reconditioned or re-applied if needed?
A: Yes. R-Flex® repairs can be inspected and reconditioned during regular maintenance if necessary. Reapplication can be performed easily by repeating the same surface preparation and application process.

Q10: Does Devcon® offer technical support or training for R-Flex® applications?
A: Yes. Devcon® offers technical data sheets (TDS), application guides, and field support to ensure proper usage. On-site training or consultation can also be arranged through authorized distributors or Devcon representatives.