When support or transport rollers on a pipe rolling line wear out in just a few weeks, downtime and emergency maintenance become chronic issues. Steel and rubber linings crack, chip, and cannot withstand abrasive dust and impact loads. Switching to cast polyurethane fundamentally changes the service life of the unit. This article examines how polyurethane performs in pipe rolling production, which components are worth replacing, and the results enterprises can expect.
Why Polyurethane is Optimal for Roller Lining in Pipe Rolling Production
Polyurethane lining for rollers in pipe rolling workshops provides 10 times higher wear resistance compared to rubber. Thanks to the elastic nature of the material in the range of 80-95 Shore A for abrasive areas, polyurethane absorbs particle impacts and protects the roller from groove cuts, which cannot be achieved with conventional rubber or metal.
In conditions of transporting hot or cold rolled products, pipes, or slabs, polyurethane lining retains its shape even under dynamic and variable loads. The working temperature range of TIMOL polyurethane, from -60 to +100 °C, allows its use in both cold and hot sections of the line without losing properties. This provides versatility for different stages of the rolling process.
In addition to wear resistance, polyurethane does not corrode, is not afraid of moisture, oils, acids, which is crucial for workshop conditions with increased environmental aggressiveness. The elasticity of polyurethane offers another advantage, vibration damping, which reduces the load on bearings and contributes to stable operation of the unit.
Which Components and Parts Should Be Replaced with Polyurethane
In pipe rolling lines, polyurethane is mainly used for lining the working surfaces of support and transport rollers, guides, rollers, bushings, rings, and scrapers. The greatest effect is achieved precisely in those areas where abrasive dust, chips, metal scales act, and there is a risk of impact loads.
Roller lining with polyurethane is performed by the free casting method to the customer’s size. It is important to choose the correct hardness: for abrasive units, in the range of 80-95 Shore A, where the balance between elasticity and abrasion resistance is maintained. For structural elements operating under constant pressure, hardness up to 70 Shore D may be chosen, but for abrasive loads, the elastic Shore A range is optimal.
Components that particularly benefit from polyurethane lining:
- Rollers of transport and conveyor sections
- Support rollers and guides
- Bushings, rings, scrapers for cleaning
- Support elements operating in high-wear zones
Thanks to the versatility of polyurethane, replacement is possible for both new and refurbished rollers. For more details on the types of products manufactured by the factory, see the Polyurethane Products Catalog.
Practical Tip: For maximum roller lining resource in abrasive conditions, choose polyurethane in the range of 80-95 Shore A. The elasticity of this range absorbs particle impacts and provides real protection against abrasion.
Comparison of Polyurethane with Rubber, Steel, and Caprolon (Numerical Data)
The comparative table presents the key properties of TIMOL polyurethane and materials traditionally used for roller lining in pipe rolling workshops.
| Material | Abrasion DIN 53516 (mm³) | Working t (°C) | Density (g/cm³) | Tensile Strength (MPa) | Hardness (Shore) |
|---|---|---|---|---|---|
| Polyurethane (TIMOL) | 20-45 | -60…+100 | 1.05-1.25 | 25-60 | 50A - 70D |
| NBR Rubber | 80-150 | -30…+100 | 1-1.3 | 10-25 | 40A - 90A |
| SBR Rubber | 100-200 | -40…80 | 0.94-1.1 | 8-20 | 40A - 80A |
| Caprolon (PA6/PA66) | 30-90 | -40…+100 | 1.13-1.15 | 60-85 | 75D-85D |
| Steel (St3, St45) | , | -40…+500 | 7.7-7.9 | 370-700 | 120-250 HB |
The abrasion of polyurethane according to DIN 53516 is 20-45 mm³, while for SBR rubber, it is 100-200 mm³, meaning rubber wears out 3-5 times faster. Caprolon shows decent abrasion resistance (30-90 mm³) but cannot withstand impacts, being brittle, especially at low temperatures. Steel provides high strength but transmits impacts to the structure, does not dampen vibrations, and is prone to corrosion, which is critical for rollers in open and humid workshops.
How Polyurethane Lining Solves Typical Problems of Rolling Rollers
Replacing rubber or steel linings with polyurethane ones significantly increases the resource of rollers, reduces the number of stops for repair and maintenance. Polyurethane has 10 times higher wear resistance than rubber, which means a real reduction in the frequency of part replacement and line downtime. The working temperature from -60 to +100 °C allows the use of polyurethane lining in all sections of pipe rolling production.
Polyurethane not only resists abrasives but also retains elasticity upon impacts, dampens vibrations, does not crack with temperature fluctuations, and is not afraid of moisture or industrial oils. As a result, the unit operates stably even in challenging conditions, and maintenance is simplified. The absence of corrosion and chipping is an additional argument for choosing polyurethane in critical areas.
Features of Production and Installation of Polyurethane Lining
Roller lining with polyurethane is manufactured by the free casting method according to the customer’s drawing or sample. This allows for an exact replication of the part’s geometry, including complex profiles and seating parts. Before applying polyurethane, the roller surface is cleaned, degreased, and, if necessary, coated with an adhesion agent for maximum bonding strength.
Installation of the lining is carried out in two main ways: mechanical (with keyway, bolts, bushings) or adhesive. In case of wear, the polyurethane layer can be restored without changing the main metal part of the roller, reducing overall repair costs.
Hardness selection is performed individually, for areas with impact loads and abrasive wear, choose 80-95 Shore A, for structural elements, up to 70 Shore D. For more details on technology and material, read the Reference Information section.
Economic Effect and Operational Advantages of Polyurethane Lining
Implementing polyurethane lining for rollers in pipe rolling production directly impacts reducing repair costs, preventing accidents, and productivity losses due to downtime. With 10 times greater wear resistance, polyurethane lasts significantly longer than rubber or caprolon, and lining replacement becomes a planned, not emergency, procedure.
Additionally, polyurethane protects the surface of pipes and rolled products from damage, leaves no marks, and does not exert excessive pressure on the product. This is important where the quality of the outer surface of pipes is crucial. Reducing noise, vibrations, and the absence of frequent part replacements allow enterprises to stabilize production and optimize maintenance schedules.
How to Order Roller Lining According to Drawings and What to Consider When Choosing
To correctly select polyurethane lining, it is important to provide a drawing or sample of the part, as well as specify the application area and type of load. TIMOL factory specialists select the optimal hardness and thickness of the lining for each task. Additionally, the installation method, requirements for oil resistance, temperature, and chemistry are considered.
The factory manufactures lining by the free casting method, allowing for virtually any shape. The minimum batch is discussed individually, which is convenient for both serial manufacturers and repair services needing single unit restoration.
All consultations, resource calculations, and material selection are carried out through TIMOL Factory Contacts or in the Industry Section.
Conclusion: When to Contact TIMOL Factory
Replacing roller lining with polyurethane in pipe rolling production is a direct path to increasing the unit’s resource, reducing maintenance costs, and minimizing emergency stops. If your rollers wear out quickly and line downtimes critically affect production, contact TIMOL factory specialists. You will receive consultation, drawing-based calculations, and recommendations on the optimal choice of material and hardness. Submit a request through Contacts or explore the assortment in the Catalog.