Brake Roller Epoxy
Coating - for bonding surface friction grits
- How to re-coat brake rollers for testing vehicle braking (MOT Testing)
Grind and solvent clean - surfaces must be immaculate - white cloth test
Warm - using a dry source of heat (not bottled gas)
Apply resin - Thixotropic Epoxy Resin -
Apply grit - Grit Grade 12, 16 or Mixed - 2.5kgs
per square metre.
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Thixotropic Epoxy Resin onto the cleaned roller.
Brake Rollers -
to refinish Brake Rollers used for the testing of vehicle braking systems
Your brake test rollers must
provide a certain level of friction to maintain their accuracy. It is
therefore important that the rollers are resurfaced as soon as the friction
surface becomes worn.
Epoxy Adhesive has a strong bond, high chemical resistance, is easy to apply,
and does not slump or run. It is a no odour, two part epoxy with the consistency
of Vaseline or Swarfega.
How much resin
do I need to re-coat brake rollers?
Epoxy Adhesive is available in 400cc or 1000cc packs.
up to 2 litres per square metre (max. 2mm of resin thickness) for fine aggregate
Allow up to
3 litres per square metre (max. 3mm of resin thickness) for coarse aggregate (12
Allow up to 3 litres
per square metre (max. 3mm of resin thickness) for coarse aggregate (1mm to 3mm
Epoxy 2 part - vivid blue and cream colour before mixing
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How to re-coat brake
rollers for testing vehicle braking (MOT Testing)
Electrically isolate and remove rollers or remove fitting plates to allow full
access (depending on type).
Strip existing grit with an angle grinder, grit blast or needle gun.
Strip the roller surface to bare metal.
Clean the roller with a solvent cleaner to ensure no oil or grease remains in
5. Regrind to
eliminate any solvent cleaner smear film. Wipe over with a clean White Cloth.
Wipe thoroughly again with the White Cloth - if any dark marks appear on the White
Cloth repeat steps 4 - 6 until the cloth remains perfectly white - this is the
secret of success - any dirt left on the roller, no matter how little, with reduce
the resin bond and lead to bald patches, where the resin has fallen off the roller.
6. Lay clean cardboard under
the roller to catch aggregate (grit) that falls off during coating,
Heat the rollers with dry heat - use electrical heaters with fans. Avoid gas heating
(particularly Propane), because of the water produced, which can cause condensation
on the roller and loss of adhesion. Maintain background heat until the resin is
completely hard. This may take up to 2 days during cold weather. Lack of heat
may also allow condensation to form on the resin and the aggregate (grit) may
then fail to bond properly.
Apply Thixotropic Epoxy Adhesive with a smooth plastic spreader or brush, to a
depth of at least 75% of the average diameter of the aggregate (grit), typically
Grade 12, 2mm - 3mm, or Grade 16, 1mm - 2mm, or Mixed Grade
1mm - 3mm.
9. Apply clean,
dust free Aggregate (grit) to the adhesive so that cover is complete, with some
excess. Pat the aggregate (grit) into the resin very firmly with a clean wooden
or metal object (plastering float, batten, cricket bat), or use a piece of clean
hard plastic material. It is not necessary to apply another coat of resin, as
long as the first coat is thick enough and the aggregate (grit) is fully bedded
in. The grit must only protrude out of the resin by 1/4 of its average diameter
- for example, a 3mm grit should only stick above the resin by about 0.75mm. If
too much of the grit shows above the resin the bond will fail and the grit will
be torn out of the resin layer, leaving bald patches.
Leave to cure for at least 24 hours, subject to temperatures being above 15 degrees
C at all times. Maintain the heating for the whole period.
11. Clean and grease the
end bearings and refit the rollers.
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NOTES FOR RECOATING BRAKE ROLLERS
to do this job in the Summer months.
cold weather you must keep the rollers above 5 degrees C. Below 5 degrees the
resin curing will slow and curing will be delayed.
cold, damp days condensation on the rollers or on the resin can reduce resin and
grit adhesion, so screen off the area to prevent draughts and warm up with heaters
in the pit overnight.
Winter adjust the resin temperature by placing the pots of resin in warm water.
For cleaning only
use our Epoxy Cleaning Fluid.
save grit, make a simple trough out of cardboard. Remove the side plates on Brake
Rollers, & fit the 'catcher'.
Rollers MUST NOT BE USED until the coating is really hard. Make a test
piece (of metal or wood) when the resin coating is complete. Coat the test piece
with resin, without grit, and leave next to the gritted area. Test by first thumb
pressure and then with a screwdriver before using the roller. When hard, the coating
still continues to gain strength over several days, so build up the work load.
the Roller too early, before the resin is properly cured, is a false economy -
you will lose your coating and have to repeat the process.
THE RECOATING OF BRAKE ROLLERS
comes off the roller - roller not clean enough, roller too cold when coated,
condensation on the roller when coated, rollers used too hard too soon, resin
not fully cured.
comes off the resin - condensation on the resin when gritted, grit too dusty,
wet grit, grit not tamped into the resin when applied, rollers used too hard too
soon, resin not fully cured.
remains sticky - not mixed fully (look for blue streaks), too cold (resin
stops curing at 5C), too damp, condensation on resin before or after gritting
due to low temperature, or through using bottled gas heating.
Epoxy Adhesive for recoating brake rollers
in 400cc and 1000cc (1 litre) packs, applied at about 2 to 4 litres per square
Supplied in two
coloured parts, vivid blue and cream - makes mixing easy - when the colour is
an even light blue/grey the product is properly mixed.
do I calculate the roller area?
Area = Diameter of Roller in Metres x 3.142 x Width of the roller in Metres
Diameter 300mm = 0.3 metres, Width 1.5 metres
0.3 x 3.142 x 1.5 = 1.41 square metres roller area
volume needed: say at 2 litres per square metre = 2.8 litres = 3 packs of 1 litre.
buy resin click here for Resins Shop
for Brake Roller refurbishing - blasting and refinishing
prime quality fused Alumac produced from stringently controlled raw materials
form the most durable grit surfaces for Brake Rollers.
content 94 -99%.
in plastic tubs.
12, 2mm - 3mm, or Grade 16, 1mm - 2mm, or Mixed Grade 1mm -
Grit Required per
square metre, average:
2.5kgs per square metre
Roller Grit Sizes used:
4 Rollers - 12 or 16 Grit
5 Rollers - 12 or 16 Grit
7 Rollers - Mixed Grit 1mm to 3mm - natural aggregates
Grit to excess
and collect for reuse.
When dry brush off excess grit.
us on 01626 331351 for calculation of your Brake Roller cleaning and finishing
Discuss the Grades
of Grit available to ensure satisfaction.
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written by: David
B.A. (Hons.), C.T.I.S., C.R.D.S. Technical Author
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