In a manufacturing line, every minute counts. Even brief periods of downtime can disrupt production and affect the bottom line. One often overlooked but crucial component in conveyor systems is pulley lagging. This is a layer of material that covers the conveyor pulley to enhance grip, prevent slippage, and protect the equipment, ultimately extending its operational lifespan.
Yet not all lagging is created equal. The material selected can directly influence conveyor performance and long-term maintenance costs. While traditional rubber is common, polyurethane offers three to five times the service life and markedly better abrasion resistance. Those extra months, or years, of reliable operation often make the difference between smooth production and costly downtime.
Pulley lagging is a protective layer that bonds to the conveyor pulley’s shell. It serves three key purposes:
Pulley lagging involves managing cyclic shear stress that builds up where pulleys meet under different conditions. When belts move over pulleys, the lagging material takes the stress while keeping the needed friction levels. By creating a textured surface, pulley lagging helps ensure consistent contact with the belt, thereby enhancing its performance. This is especially important at high speeds or in challenging environments.
Without proper lagging, belts are more likely to slip, wear out quickly, and lose efficiency. And while some companies view pulley lagging as a part to be replaced when it fails, industry experts understand that lagging failure is one of the most common and costly reasons for conveyor downtime. Here at AMES, we view it as an engineered part of the pulley and should last the lifetime of the Pulley.
Rubber is the most commonly used and cost-effective lagging option. It is available in plain or grooved styles, such as diamond, herringbone, and chevron, to suit different traction needs. Plain rubber is ideal for non-drive pulleys, while grooved rubber helps shed water and improve grip where more friction is needed.
There are two main types of rubber lagging application: cold-bonded and hot-bonded:
Built for harsh environments, ceramic lagging features high-friction ceramic tiles or cylinders embedded in rubber. Dimple ceramic increases mechanical grip, while smooth ceramic provides a balance between friction and wear. Coverage can be customised (typically 13%, 39%, or 80%) to suit specific needs. Although durable, ceramic lagging can be prone to cracking under heavy impact or when hard debris becomes lodged in the system.
Often referred to as plastic lagging, polyurethane is a high-performance alternative, particularly for non-drive pulleys or where material build-up is common. It can be applied as a strip or cast directly onto the pulley. Offering 3–5 times the lifespan of rubber and superior resistance to wear, polyurethane is gaining popularity for operations that prioritise long-term durability and lower maintenance.
Despite its importance, pulley lagging can fail in several ways: it can separate from the shell, the material can wear out, the belt cover can get damaged, and splices don’t last as long. The most common failure points include:
Cold Bonded Rubber Strip Lagging has long been a go-to solution for many conveyor systems due to its speed of application and reduced downtime. However, in heavy-duty industrial environments, its limitations quickly become apparent. As operational demands grow more intense, many businesses are rethinking rubber lagging and exploring more durable alternatives.
Rubber’s inferior abrasion resistance makes it more susceptible to wear in abrasive conditions. In high-speed applications or systems that handle rough materials, rubber simply doesn’t hold up. Stresses during loaded startups or when material spills come into contact with return belts can cause the rubber to deform and break down over time.
These repeated deformations lead to material loss. Sharp particles, frequent impacts, and sliding friction accelerate this deterioration, leading to costly replacements and reducing overall system efficiency.
Despite its intended role in improving grip, rubber lagging often underperforms in wet or dusty environments. Moisture can create a thin film between the rubber surface and the belt, acting as a lubricant that significantly reduces friction. While grooved patterns like diamond or herringbone are designed to channel water away, they introduce a new problem – debris buildup.
In dusty operations, grooves can collect fine particles like sand or dirt. This buildup reduces surface traction and can cause the belt to slip or misalign. Some teams attempt to fix this by adding abrasive materials to increase grip, but this only accelerates wear. It’s a maintenance cycle that’s hard to break.
One of the biggest drawbacks of rubber lagging is its relatively short lifespan, typically lasting only one year in demanding industrial environments. Replacing is inconvenient as it is expensive and time-consuming.
Each re-lagging operation often requires:
In some cases, a full lagging failure can halt production for up to days, even weeks. This kind of downtime is costly, and it disrupts schedules, delays deliveries, and puts added pressure on operations to catch up.
While rubber lagging may be suitable for light-duty or controlled environments, it often falls short when exposed to the harsh realities of industrial operations.
Its wear rate, sensitivity to environmental conditions, and high maintenance demands make it a less-than-ideal choice for long-term reliability. For those looking to improve system performance and reduce downtime, it’s worth considering more robust alternatives like polyurethane lagging.
In recent years, polyurethane lagging has become a material of choice for many operations. It is a highly versatile lagging material, known for its excellent resistance to abrasive wear, chemical exposure, and material buildup, becoming the solution of choice in operations where material buildup between the belt and pulley is an ongoing issue.
While commonly used on non-drive pulleys, polyurethane’s adaptable hardness and surface formulation also allow it to be engineered for high-friction grip, making it suitable for a wide range of applications and environments.
Polyurethane lagging is typically applied in one of two ways:
Polyurethane strip lagging consists of rubber-backed polyurethane sections that are applied in strips rather than as a full sheet or through direct casting. This type of lagging is used in some conveyor applications and allows for individual strip replacement as needed.
However, at Ames Direct, we recommend the hot-cast polyurethane process for its superior bond strength, durability, and long-term performance. We have a purpose-built facility in Goulburn, NSW, specifically equipped to deliver high-quality cast polyurethane lagging tailored to your operational needs.
Cast polyurethane lagging is applied through a hot vulcanisation process, forming a seamless, joint-free bond directly to the pulley surface. This method delivers exceptional adhesion and wear resistance, making it one of the most durable and long-lasting lagging solutions available. It does require complete pulley removal for installation and repair, but its durability and longevity often offset the added effort.
Its high-performance characteristics, like superior load handling, resistance to abrasion, and strong chemical resilience, make it ideal for extreme operating conditions. Cast polyurethane is often the preferred choice in heavy-duty applications where maximum durability and grip are critical, and where other lagging materials may not hold up under pressure.
Polyurethane lagging doesn’t just last longer, it dramatically reduces a system’s downtime and ongoing maintenance expenses. On average, polyurethane lagging provides a service life 3 to 5 times longer than traditional rubber options. In real terms, that’s around five years of performance, compared to just one year for natural rubber.
Selecting the right lagging for your conveyor pulley isn’t a one-size-fits-all decision. The best choice depends on the pulley’s role, the operating environment, and the materials being conveyed. Getting it right can significantly improve system performance, reduce maintenance, and prevent costly downtime.
Not all pulleys serve the same function. Drive pulleys are responsible for generating movement and keeping the belt in motion. Not all pulleys serve the same function. Drive pulleys are responsible for generating movement and keeping the belt in motion. They require high-friction lagging to ensure the belt grips securely and doesn’t slip under load. Polyurethane deliver strong traction and long service life, especially under high-torque conditions..
Non-drive pulleys, on the other hand, guide or support the belt without transferring power. Since grip is less critical, more economical lagging options, such as plain rubber or standard polyurethane, are typically used. These materials provide sufficient wear resistance and support while helping to minimise overall system costs.
Your conveyor system’s working environment plays a major role in determining the most suitable lagging material. When evaluating your options, consider the following:
With conveyor systems becoming faster, more powerful, and more complex, choosing lagging based on price alone can be detrimental to operations. That’s why a professional assessment is essential. At Ames Direct, our team works closely with Maintenance and Production Managers to match the right lagging solution to each unique set of operational demands.
We recommend basing your decision on external testing data, which offers greater reliability than in-house results. These tests typically measure:
Quality control from experienced engineers ensures that only properly tested and approved materials are installed, helping you avoid premature failure and costly production delays.
Ultimately, the right pulley lagging strikes the perfect balance between application needs and environmental demands, delivering long-term efficiency, durability, and peace of mind.
When it comes to pulley lagging, longevity, performance, and reliability matter, and polyurethane continues to outperform traditional rubber in nearly every way.
While rubber lagging may appear budget-friendly upfront, its inability to withstand high-abrasion environments and poor performance in wet or dusty conditions make it a less efficient choice in the long run. Polyurethane, on the other hand, offers exceptional wear resistance and better manages material buildup, making it especially well-suited for non-drive pulley applications.
Need help choosing or installing the right polyurethane lagging? You’re in the right place. As Australia’s trusted manufacturer of high-performance Rubber and Polyurethane Lagged Rollers, Ames Direct offers expert guidance, custom solutions, and durable products built to withstand the harshest industrial environments. Get in touch with our team today to keep your conveyors moving and your downtime to a minimum.
