Polyurethane wheels and rollers serve for a long time, but the coating still wears out eventually, and the mechanic faces a choice: buy a full set of new wheels or restore the existing ones. Restoration with polyurethane means that a new band is cast onto the old metal hub, keeping the expensive bearing assembly. Let us look at how this is done, how much the savings amount to and why a polyurethane band outlasts a rubber one several times over.
What wheel restoration with polyurethane gives you
Restoration returns a wheel’s working life at a fraction of the cost of a new one, because it keeps the most expensive part: the metal hub, the axle and the bearings. Only the outer band wears out, while the hub itself is fully usable, so there is no sense in replacing the whole assembly. You pay for the new polyurethane layer and the labour, not for a set from scratch.
Besides the direct saving, restoration reduces downtime. The old wheel geometry is reproduced exactly, so the renewed wheels fit into place without reworking the assembly. For warehouse and in-shop equipment, where every unit is in constant motion, this means a fast return of the trolley or conveyor to service.
Why polyurethane and not rubber
Polyurethane is chosen for its resistance to abrasion and to aggressive environments. Mechanisms with a polyurethane coating work normally in contact with technical oils, petrol and weak acids, do not rust and are not afraid of fungus or mould. Cast polyurethane withstands heavy loads without deformation and does not lose its direction of travel, while moving almost silently and not getting stuck in sand.
Another practical advantage is floor cleanliness. A polyurethane band leaves no marks on parquet, linoleum, tiles and wood, is not punctured by construction debris and does not conduct electricity. It is convenient to pick the type of wheel from the catalogue of rollers and wheels, where the typical sizes are gathered.
Comparison of band materials: the numbers
The table brings together reference engineering data based on standard test methods. For abrasion, a lower value is better, and a lower density means a lighter wheel at the same size.
| Parameter | Cast polyurethane (PU) | SBR rubber | Natural rubber (NR) |
|---|---|---|---|
| Abrasion, DIN 53516 | 38-39 mm³ | 100-200 mm³ | 60-130 mm³ |
| Operating temperature | -60 to +100 °C | -40 to +80 °C | -50 to +70 °C |
| Tensile strength | 39-87 MPa | 8-20 MPa | 20-30 MPa |
| Hardness, Shore scale | 50 Shore A to 70 Shore D | 40-80 Shore A | 30-80 Shore A |
| Tear resistance | 40-120 kN/m | 8-35 kN/m | 20-60 kN/m |
The difference in the first row is what determines the band’s service life: polyurethane abrasion of 38-39 mm³ against 100-200 mm³ for SBR rubber means that at the same mileage the polyurethane layer wears out several times less. Tear resistance is also on the side of polyurethane, 40-120 kN/m against 8-35 kN/m, so the band edge does not crumble under load and over floor irregularities.
Engineer’s tip: the key to durable restoration is surface preparation. Clean the old hub down to bare metal, fully remove any remnants of the old coating and thoroughly degrease before applying the adhesive layer. Poor adhesion is the main cause of the new band peeling off, and no material hardness compensates for it. As for hardness, choose it according to the floor: harder for concrete, slightly softer for sensitive and slippery surfaces.
How restoration is carried out
First, the wheel is cleaned of the old coating, the hub surface is treated and complete degreasing is achieved. A layer of adhesive is applied to the clean dry surface and left to cure. Then, using open casting, a new polyurethane band of the required hardness is poured, after which polymerisation and machining to the final diameter follow.
The open casting method is also economical because you pay for the material actually used without significant waste, and the band is cast exactly to your drawing or from a sample of the old wheel. This makes it possible to restore both standard and non-standard sizes without expensive tooling. The list of restoration and lining services is in the services section.
Practical conclusion
Wheel restoration with polyurethane is a way to return service life to your equipment while keeping the metal hub and bearings, and at the same time getting a band that wears out several times more slowly than rubber. Send the hub dimensions and the required diameter, or the sample itself, to the TIMOL factory via contacts, and the engineers will select the hardness and calculate production to match your equipment.