Rubber Lining Services
ABEAR Industrial operates a dedicated rubber lining facility offering four distinct rubber lining processes, each with its own advantages to suit different applications.
Our facility has a 12-ton handling capacity and adheres to stringent quality control standards at every stage of production. Each step is verified and approved before the job proceeds to the next phase, ensuring consistency, reliability, and traceability throughout.
Below are the details of the rubber lining processes we offer.
ABEAR Rubber Lining Services
HV Pre-Moulded Lining
This process is unique to ABEAR Industrial, developed through extensive research and development. It is primarily used for pulley lagging and rubber-ceramic composite linings, but is also preferred for pipe and tank linings due to its superior performance and consistency.
The process involves press-curing the lining material before hot vulcanising it to the metal substrate. Our proprietary HV process produces exceptional mechanical properties, comparable to cold-bonded systems, through a combination of higher pressures, lower temperatures, and industry-leading adhesives. This process results in the most consistent and highest
bond strength achievable to the metal substrate.
For components that include intricate surfaces or geometries, this HV Lining process can be combined with Steam-Cured Lining, allowing uncured rubber to conform perfectly around complex shapes while maintaining overall quality and bond integrity.
Cold Bonded Lining
Extensive research and development into our ABEAR CN Bonding Layer has resulted in what we believe to be the industry-leading cold-bonding system. The process involves press-curing the lining material before cold-bonding it to the metal substrate, ensuring exceptional bond strength and consistency.
Like our HV Pre-Moulded Lining, this method is ideal for intricate rubber patterns and rubber-ceramic composite linings. It is particularly suited to on-site installations, or for components that are too large for an autoclave, or where autoclave curing could cause damage, such as assembled pulleys with bearings.
Our cold-bonded lining systems have consistently outperformed conventional steam-cured linings, delivering superior bond strength and longer service life.
Steam Cured Rubber Lining
Steam curing is the conventional rubber lining method. At ABEAR Industrial, we have refined this process by using compressed air in combination with steam during autoclave curing. The higher pressure relative to temperature improves compound consolidation and significantly reduces trapped air; minimising voids to as little as 10% of their original size and improving overall rubber quality.
This process is particularly well-suited to complex or irregular metal substrates, and is often the preferred solution for one-off components such as spiral mills, flanges, and vented plates.
Chemical Cure Rubber Lining
Chemical-cure rubber lining is used for complex or irregular metal substrates, or for components that are too large for an autoclave or would be damaged by heat, pressure or steam during autoclave curing.
However, chemical-cure linings generally offer lower mechanical performance and reduced bond strength compared to hot-vulcanised or cold-bonded systems. As such, this method is best regarded as a last-resort solution, and should only be used in applications where the lining will not be exposed to significant mechanical load or dynamic stress.
ABEAR Rubber Lining Quality Assurance
ABEAR Industrial adheres to stringent quality control standards. We maintain full batch and serial-number tracking across all our product ranges and services, ensuring complete end-to-end traceability.
We also supply fully compiled Manufacturing Databooks that document every critical stage of production. These databooks include all relevant material certifications, test reports, and quality-verification records: providing clear evidence of material integrity and confirming that every step has been tested, validated, and recorded.
Below are just a few examples of our standard process, procedures and documentation.
Substrate Cleaning and Blasting
We grit blast metal substrates to SA 2.5 or better. We use steel grit that is automatically recycled, filtered and washed-out, ensuring a consistent surface finish and cleanliness.
Primer and Adhesives Application
All coating processes are carried out in accordance with the adhesive manufacturer’s specifications and have been validated through rigorous internal testing. For example: primer thickness is controlled to ensure proper anchoring relative to the prepared surface roughness.
Cure Graph
Our autoclave cure cycles are fully automated and produce a cure graph for each job, allowing us to verify that the process has been completed exactly to specification.
Peel Test
Bond strength is verified using a 90° peel test in accordance with ISO 813. This forms part of our final quality verification before a lined component is released. We aim for 100% rubber tear, and/or a bond strength above 20N/mm. The below example is above 35N/mm from our HV Pre-Moulded Process.
