Devcon R-Flex Outperforms in Copper Mine Conveyor Belt Repair

Introduction: A Critical Conveyor Belt Challenge

In the high-demand environment of copper production, equipment reliability is paramount. One world-leading copper producer faced significant disruptions due to damage in its conveyor belt system—an essential component in ore transport. Traditionally, the maintenance team relied on metal clips to repair belting. While functional, this method introduced new complications: the clips routinely damaged scrapers and often caused further deterioration of the belt itself over time.

Seeking a more sustainable solution, the maintenance team trialed a rubber coating product from a competing brand. Unfortunately, it proved inefficient, requiring more than double the application time, and the conveyor’s return to service was significantly delayed. Worse still, the product lacked durability—it cracked and failed where it contacted metal components. Faced with growing safety concerns, extended downtimes, and subpar results, the team began the search for a better alternative.

The Devcon R-Flex Solution

After reviewing several repair options, the customer chose Devcon® R-Flex, a liquid urethane compound engineered for flexible, high-wear industrial environments. Known for its fast cure time, outstanding adhesion, and durability under stress, R-Flex presented a clear upgrade over previous repair methods.

The repair began with a thorough cleaning of the belt surface using a soft brush and acetone, focusing on a 10 cm radius around the damaged area and metal clips. Next, an abrasive disc was used to roughen both the rubber and metal surfaces to ensure optimal adhesion. A final cleaning pass with acetone removed all loose debris and residual rubber.

To prepare for the urethane pour, Devcon® Flexane® FL-10 Primer was applied to all metal surfaces, while Devcon R-Flex Surface Conditioner treated the rubber areas. Because the repair area was located on an incline, protective tape was used strategically to control the flow of the liquid compound.

Once the surface was ready, the Devcon R-Flex was poured directly onto the belt and metal clips. A plastic applicator was used to spread the material evenly and create feathered edges, ensuring a smooth transition between the repair and the original belt surface.

Even though the ambient temperature was relatively low (59°F / 15°C), the repair was not delayed. A portable heater was used to accelerate the cure time, demonstrating the flexibility of Devcon R-Flex under less-than-ideal field conditions.

Results: Faster Repairs, Longer Performance

The outcome far exceeded expectations. Devcon R-Flex completed the repair within just 90 minutes, even with the incline and cooler temperature. Production resumed quickly—minimizing costly downtime.

More importantly, the repaired belt showed no signs of separation, cracking, or wear even under continued heavy-duty use. The customer reported that the belt operated as if it were new, and the repair’s integrity held up far better than the competitor’s product.

Durability That Outperforms the Competition

Unlike the previous rubber coating that failed shortly after application, Devcon R-Flex proved itself in real-world, high-stress conditions. Its high peel resistance and exceptional adhesion to SBR belts make it one of the most reliable belt repair solutions in the market. The ability to withstand abrasive conditions and high tension environments is a significant advantage, especially in mining and heavy industry.

Conclusion: A Smarter Belt Repair System

By choosing Devcon R-Flex, the copper producer achieved:

• Rapid repair time (90 minutes vs. several hours)
• Reduced downtime and increased productivity
• Improved safety through a simplified, controlled application process
• Longer-lasting repairs that hold up to operational demands

Devcon R-Flex’s user-friendly application, fast cure, and industry-leading performance made it the clear winner. This case study reinforces why R-Flex is the preferred choice for professionals seeking a cost-effective, durable, and efficient solution to conveyor belt repairs in demanding industrial environments