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MORE ABOUT SECTION REPAIRS

THE RE-EMERGING IMPORTANCE OF SECTION REPAIRS FOR TODAY’S TIRE INDUSTRY

As early as 1950, the founder of VULCAN Industries, Mr. E. J. Alm worked on a revolutionary Vulcanizer which he perfected just in time to meet the casing shortage for retreaders, with the introduction of the tubeless tire. The VULCAN MPB Passenger Section Repair Mold for passenger tires was a huge success with over 10,000 machines sold in 40 countries around the world. Some 50 years later, VULCAN-VULCAP Industries still supplies parts for these Molds as well as new MPB’s and many other truck and OTR models which continue in operation world wide.

Recently, the ITRA (International Tire and Rubber Association) now called Tire Industry Association (TIA) reported a growing interest in Section Repairs for both truck and OTR tires. Many calls were received by ITRA Headquarters and Training Centre from companies requesting information on how to properly repair tires with Section Repair Molds. Many of these inquiries were from companies who did not previously perform tire repairs.

Due to the high cost of labour and our North American "throw away" mentality the repair of passenger tires is declining. This however, does not apply to truck and OTR tires. Inquiries received came from areas all over the U.S. and Canada, where certain sizes of large earthmover and other OTR tires are scarce and expensive.

Even with Section Repairs on the increase, there are still many tires disposed of daily, which could be repaired and returned to normal service. This practice is costly to the end-user and environmentally unsound. Many shops miss profitable opportunities to increase their business by avoiding Section Repairs.

The tire companies are reluctant to invest millions of dollars in order to keep OTR tires in stock for immediate delivery. Section repairing is often the only way to keep millions of dollars worth of equipment in service until such time as new tires are available. The goodwill earned from grateful customers, whose equipment is kept operational until replacement tires are available, is a valuable asset to any tire repair organization.

There is a lot of misconception concerning the amount of investment required to purchase the proper equipment to perform Section Repairing. On close examination it is surprising how fast VULCAN-VULCAP Section Repair Molds and Systems can be paid for and amortized. Truck tires generally can be repaired for 1/3rd of the cost or less of a new tire, while the price for a good Section Repair on an OTR tire can range from 8% to 15% of the cost of the tire. Actual repair costs for an experienced shop can be much lower, thus guaranteeing healthy profit margins.

 

VULCAN-VULCAP SECTION REPAIR MOLDS OFFER COST EFFECTIVE TRUCK AND OTR TIRE REPAIRS

VULCAN-VULCAP Section Repair Molds are the result of over 50 years of research and development by VULCAN. All models of the new MV Series Mobile Section Repair Molds for OTR tires are patented. Section Repair Mold patents were first issued to VULCAN several decades ago.

The key to a good, cost effective tire repair is a  true Vulcanizer repair. Rubber flows during curing in both the plug area and between the patch and inner liner of the casing. This rubber flow will fill any existing air pockets, which are dangerous in a repair, since these air pockets will expand as the tire heats up and therefore will lead to premature failure of the repair. As existing air pockets are filled, the result is a dense, sealed repair that will not leak or fail prematurely.

During the curing process 45 lbs. of pressure per square inch is applied to the area of the injury from the inside and 30 lbs. from the outside of the tire. Maximum patch sizes range from 18" x 20" (45.7 cm x 50 cm) for the V-14 Truck Mold to 36" x 36" (91 cm x 91 cm) for the largest MV-50 OTR Section Repair Mold. A compression cure or mold is achieved due to the pressure applied to the patch. The total force applied in the smallest OTR Mold is 18,000 lbs. and 58,320 lbs. for the largest model. The result is a densely sealed repair that will not leak or fail prematurely.

Flexible Section Systems, like the VULCAN-VULCAP Vulcaflex®  OTR Repair System will do a similar job.  Flexible Systems are more labour intensive due to set-up and cannot provide the same pressure as rigid Section Molds do.  The advantage however of a Vulcaflex® system is that the full OTR tire range can be repaired with one system with the proper accessories.   

The results achieved in a VULCAN-VULCAP Section Mold is a good compression mold with adhesion values exceeding 100 between patch and tire due to pressure applied during curing. The use of uncured cushion with a semi-cured patch eliminates the problem of air pockets. The shape of the patch may not conform to the inside contour of the tire and therefore careful stitching should prevent most air pockets. It is important that the repair is done in the relaxed state of the tire. In other words, at the 3 or 9 o’clock position of the tire when it is resting on the floor. The use of patches as described above with proper heat, pressure and temperature applied in a VULCAN-VULCAP Vulcanizer assures optimum compression cure. This means no under-cure or over-cure of material.

During proper curing (pressures guaranteed by a VULCAN-VULCAP Vulcanizer), materials will flow, air pockets are eliminated and when the tire flexes and heats up during operation, there will be no tendency for the patch to leak or cause under-inflation. In a VULCAN-VULCAP Vulcanizer, the patch and plug are cured in a single operation. Relatively large areas of the tire depending on maximum patch size can be properly cured in a single operation.

Earlier models of Vulcanizers had solid cores or mandrels, which were heated. However, this method was replaced with the flexible models where air mandrels, internal and external airbags together with heatpads are used for a broad range of tire sizes. The old solid cores were only practical for a specific shape of tire, usually bias type, whereas the new method allows the system to conform to each tire (whether radial or bias tires) under repair.

VULCAN-VULCAP Vulcanizers will provide heat and pressure without distorting the tire. The MV series, although big for large tires, is still truly portable and reasonably priced. Time, temperature and pressure are the 3 critical elements to successfully vulcanize a repaired tire injury. VULCAN-VULCAP Vulcanizers supply all 3 elements with their unique Section Repair Mold Systems. To repair today’s radial tires distortion free, VULCAN-VULCAP Section Repair Molds with inflated mandrel systems will supply:

  1. Correct pressure both inside and outside the tire.
  2. Provide even pressure over the injured area.
  3. Heating units for both inside and outside with molded heatpads to allow controlled curing temperatures for good solid cure.
  4. Time, which is very critical as rubber cures at different rates.

It is important to remember that tire repairs rarely fail if the right time, temperatures and pressures are utilized during the repair/vulcanizing process. The art of repairing tires lie in the hands of the tire repair person, who must inspect, skive, cement and complete the repair properly. VULCAN-VULCAP Section Repair Vulcanizers will cure the repair and do the rest for a tire repair that will last as long as the tire will.

 

Other methods of Section Repair

There are other methods of Section Repair used in the marketplace. These machines are commonly referred to as "C" Clamps. These units often use chemical patches after the plug has been cured, giving rise to possibly the following problems especially on off-the-road tires:

  1. The chemical patch is precured in a given shape, which may or may not fit to the inside radii of the tire. Accordingly, the patch may not fit perfectly to the contour of the tire and air pockets can be created between the patch and the inner liner.

  2. The chemical materials result in a tack or bond wherever the patch touches the inner liner first, again creating air pockets and the impossibility of clearing them out from between the patch and the inner liner.

  3. The patch then cures by the chemical acceleration, the way it has been applied to the inside of the tire, i.e., there is no flow of the rubber into the air cavities.

  4. Assuming it is a tubeless off the road tire, there is no significant pressure being applied to the patch during the curing process, with the result that as the patch was inserted this is how it will remain.

  5. Failure of the patch is likely to occur as the tire is flexing in operation. The air pockets expand until finally there is migration and a leak between the patch and the inside of the tire, which can potentially result in under-inflation of the tire and overloading with eventual failure of the repair.

  6. The plug area, cured with a "C" clamp and presuming that pressure and heat are applied from both inside and outside of the tire, will normally cure properly. However, any available size "C" clamp may not cover the full area of the injury that requires repair and likewise it may not conform to the contours of the tire inside and out, causing further problems.

  7. "C" Clamps usually are unable to supply the force required for a good compression cure.

 

The versatile VULCAN-VULCAP VRC OTR Tire Repair Clamp and VTRC Truck, Tractor and Grader Tire Repair Clamp employ aluminum plates with twin Heatpads and Airbags, thus eliminating the shortcomings of standard C-Clamps listed above.  They perform distortion free repairs due to the flexibility of the Heatpads and Airbags compared to the rigidity of standard C-Clamps.

 

Autoclave Repair of Truck or Earth Mover OTR Tires

  1. The problem, of course, with an autoclave is the high cost of the autoclave and particularly for the large diameter tires required, such as 40.00 x 57 and larger.

  2. Assuming that an uncured patch is used on a tire to be cured in an autoclave and the patch is stitched very carefully onto the inside of the tire, the possibility of air pockets between the patch and the inner liner is substantially less. On the other hand, due to the fact that there is no flow in this process, i.e., again how the patch is stitched in is the way it will remain. The chances for this type of repair to stand up are better than the chemical patch but still relies on the quality of the operator and his ability to eliminate air pockets between the patch and the casing.

  3. The energy consumed by an Autoclave, which has to heat up the complete tire to curing temperature and hold this temperature (particularly for large OTR Tires) is very high and costly.

  4. Heating up the complete tire and holding it at cure temperature till cured rather than just the patch area certainly does not improve the quality of the tire and its life span.

  5. Most importantly the repair will come out of the Autoclave exactly the same way it was put in. If the patching is rough, it will come out that way. The rubber is not cured under compression and therefore less wear resistant.

 

Conclusion:

It is the partnership between the skill and art of properly preparing and patching the area of the tire injury and vulcanizing it subsequently with the proper equipment that will guarantee a perfect repair consistently.

VULCAN-VULCAP Industries Inc. has technical facts on the repair of truck and OTR tire repairs available upon request.

 

 

TIME, TEMPERATURE AND PRESSURE - THE KEYS TO PROPER AND LASTING TIRE REPAIRS! 

VULCAN-VULCAP INDUSTRIES INC. - The World Leader in Section Repair Equipment supplies these important elements with their Section Repair Molds, MV Series, Vulcaflex® and VRC OTR and VTRC Truck, Tractor and Grader Tire Repair Clamps.


To successfully vulcanize a repaired injury in a tire, three things are needed:

Time, Temperature and Pressure

VULCAN-VULCAP  Industries supplies all three with our unique Section Repair Mold Systems.  Molds are compact, rugged and light-weight.  The unique Airbag System provides even pressure.  The thermostatically controlled heating pads supply the correct curing temperatures.  The experienced operator then has to ensure proper curing times.

From  the smallest passenger tire through to the largest  OTR  (earthmover) tire, we have a proven system for your tire repair operation.

We repair today's radial tires distortion free by using our VULCAN-VULCAP Inflatable Mandrel System.  A shaped air mandrel is utilized that grows to fit the tire you are repairing, using an air differential control panel, supplying the correct pressure both inside and outside of the tire, providing even pressure over the injured area.

Heating units for both inside and outside are provided with moulded Heatpads, which are controlled at curing temperature for a good, solid cure.  Time is very critical, as rubber  cures at different rates.  Follow carefully  the instructions of the rubber manufacturer.

As all VULCAN-VULCAP Section Molds cure from both inside and outside generally, a curing cycle of approx. 2 minutes per 1/32" of rubber thickness (depending on type of rubber) can be cured, temperature being held at approx. 280-300°F automatically.  Please determine exact curing times for the rubber you are using from the manufacturer!

VULCAN-VULCAP offers a complete line of Section Molds and it is easy to pick the right model  for your tires, as each Mold is designed to handle a particular tire size and range:

  1.     VULCAN-VULCAP MPB  Section Repair Mold for passenger, industrial and commercial truck tires from 
        10" in rim size through 16"  =  10", 12",  13",  14", 15" and 16".   

  2.     VULCAN-VULCAP  RTV-12  Radial Tire Vulcanizer covers truck tires from 8.25 x 15 through 1200 x 24 and our V-14 covers truck 
    tires 8.25 x 15 through 1200 x 24.

  3.     VULCAN-VULCAP  V-14 Section Repair Mold with built-in air operated tire spreader for radial and bias truck 
    tires 8.25 x 20 - 12.00 x 24.

  4.      VULCAN-VULCAP  MV-20 Section Repair Mold covers truck, tractor, skidder and grader tire sizes.  Truck 1400 x 24 to 1800 x 22.5, 
    tractor 12.6 through 18.4 x 38 and Skidder/Grader tires 1200 x 24 through 17.5 x 25.

  5.      VULCAN-VULCAP  MV-30 Section Repair Mold covers tractor, skidder, grader, earthmover and OTR sizes from 
    1800/24/25 through 26.5, 1800 x 20.5, 23.5 x 2100, 2400 x 26.5-25.  With the addition of an optional top clamp 
    extension this model will handle tires up to 29.5 x 25/29.

  6.      VULCAN-VULCAP MV-40A Section Repair Mold covers OTR tires from 29.5 x 29 to 37.5 x 51, 29.5, 33.5, 33.25, 27, 33, 49, 30.00 x 51, 33.00 x 51, 37.5 x  51.

  7.      VULCAN-VULCAP MV-50A Section Repair Mold covers OTR tires from 36.00 x 51 to 40.00 x 57 including the new generation 
    sizes 50/80/57,54, 5/80/57 and  53, 5/85/55.

  8.      VULCAN-VULCAP Vulcaflex® OTR Curing System covers all tire sizes from 13.00 through 55.5/85-57 with one system 
    with the purchase of all required Heatpads and Airbags.

  9.      VULCAN-VULCAP VRC OTR Tire Clamp  for smaller repairs on tires from 20.5 x 25 to 45/65/45.

 

 

VULCAN-VULCAP  OTR  Repair System

The Inflatable Mandrel System is the most adaptable Tire Vulcanizer System, using an assortment of Inflatable Mandrels and flat Airbags, Inside and Outside Heatpads.  Parts can be interchanged to suit the tire size and shape to be repaired.

The VULCAN-VULCAP line of Section Repair Equipment is known for quality repairing, easy operation and lasting service.  This new generation of VULCAN-VULCAP Section Repair Molds and Systems are light-weight and cost-effective.  If proper repair procedures are followed, repaired injuries can  be guaranteed for the life of the tire.  The repair is a true vulcanizing repair, where the rubber flows during curing both in the plug area and between the patch and inner casing liner.  This is not the case with chemical pre-cured patch repairs.  All VULCAN-VULCAP models of Section Repair Molds are patented and are the result of over 50 years of successful research  and development for the independent Tire Repair and Tire Retread Industry.

The rigid VULCAN-VULCAP Section Repair Molds are designed for a specific tire range per model for quick set-up and high pressure curing.  The Vulcaflex® OTR System takes longer to set-up, however, with the proper accessories will accommodate practically all sizes of OTR tires.  The VULCAN-VULCAP VRC OTR and VTRC Truck, Tractor and Grader Tire Repair Clamps will do smaller repairs efficiently and distortion free.

 

WHEN YOU BUY VULCAN-VULCAP, YOU GET THE BEST

Our equipment is patented worldwide - designed by tire people for the tire industry.  We have supplied over 1,400 tire shops in more than 40 countries with our equipment and based on recently published figures in a trade magazine, VULCAN still is the leader on a percentage basis of installed equipment to the independent tire industry.

Please Note:  The art of repairing tires lies in the hands of your tire repair man.  He must  inspect,  skive, cement and  build the repair.  VULCAN-VULCAP Section Repair Vulcanizers will cure the repair the way the repair was built.

A repaired tire rarely fails if the right time, temperature and pressure is utilized during the Repair/Vulcanizing process.  VULCAN-VULCAP Section Repair Molds and Systems are designed and built to guarantee these three critically important elements in the repair process.  It is the partnership between the skill and art of properly patching the area of the tire injury and vulcanizing it subsequently that will guarantee a perfect  repair consistently.