Two Materials for the Same Job
Both rubber and polyurethane are used as screening media in vibrating screens. They perform differently, and the choice between them is driven by the specific wear mechanism in your application β impact versus sliding abrasion β combined by practical factors like temperature and chemical exposure.
This page compares the two materials specifically for screen panel applications, where the trade-offs differ somewhat from liners and other wear components.
Rubber Screen Panels
Rubber screen panels are manufactured from natural rubber (NR) or SBR compound, typically in the 40β60 Shore A hardness range. They are flexible and absorb impact well.
Strengths in screening applications: - Better for high-impact feed (large lump, high drop onto the screen deck) - More effective noise reduction β rubber absorbs vibration energy rather than transmitting it - Better low-temperature performance β maintains flexibility at -20Β°C and below - Lower cost per panel
Weaknesses: - Faster wear when fine, hard particles slide across the surface at high velocity (wet slurry screening, fine dry ore) - Prone to ozone and UV degradation if used outdoors without stabilizers - Chemical resistance is limited β acids and petroleum products degrade NR
Polyurethane Screen Panels
PU screen panels use cast or injection-molded polyurethane elastomer, typically in the 60β90 Shore A range. They are harder and more abrasion-resistant than rubber at equivalent hardness.
Strengths in screening applications: - Superior sliding abrasion resistance β consistently outperforms rubber in wet fine-ore and slurry applications - Better chemical resistance β handles mild acids, alkalines, and salt water - More precise aperture dimensions β molded apertures hold size better than cut rubber - Self-cleaning behavior in wet applications β PU's hardness reduces blinding tendency - Longer service life in most mineral processing applications
Weaknesses: - Less effective impact absorption β can crack under repeated severe impact with large lump - Stiffer at low temperatures β below -10Β°C, standard PU becomes brittle; cold-flex grades available but more expensive - Higher cost per panel than equivalent rubber
Side-by-Side Comparison
| Property | Rubber Screen Panel | PU Screen Panel |
|---|---|---|
| Sliding abrasion resistance | Moderate | High |
| Impact resistance | High | Moderate |
| Noise reduction | Better | Less effective |
| Chemical resistance | Poorβmoderate | Good |
| Low temperature performance | Good | Moderate (standard grade) |
| Aperture precision | Moderate (cut panels) | High (molded) |
| Self-cleaning tendency | Lower | Higher |
| Typical wear life (wet fine ore) | 4β12 weeks | 3β9 months |
| Cost per panel | Lower | Higher |
| Cost per tonne screened (wet fine ore) | Often higher | Often lower |
Application Guide
Use rubber screen panels when: - Feed material includes large lump that impacts the screen deck directly (top deck, primary screening) - Operating temperature drops below -15Β°C (or specify cold-flex PU) - Noise reduction is a priority (residential area, noise regulation) - Budget is the primary constraint and wear life difference is acceptable
Use PU screen panels when: - Wet screening of fine ore, coal fines, or mineral slurry (most mineral processing applications) - Chemical exposure is present (process water with acid or alkali content, salt water) - Aperture precision is critical (product size specification is tight) - Minimizing screen panel change frequency is a priority (remote operations, limited maintenance windows) - Long-term cost efficiency is the goal
The practical reality: In most mineral processing plant applications β iron ore, copper, gold, coal washing β PU panels are now the standard choice because the economics favor them. Rubber panels remain relevant for specific impact-dominated applications and cold-climate operations.
Frequently Asked Questions
Our screen deck gets hammered by large lump on the top deck. Which should we use? For the impact zone of a top deck receiving large feed, rubber is more appropriate. You might consider using rubber panels for the first third of the deck (impact zone) and PU for the remainder (classification zone) where finer material is sliding through apertures.
We're in northern Canada. Does PU work in winter? Standard PU becomes brittle below -10Β°C. Cold-flex PU compounds are available that maintain flexibility to -30Β°C or -40Β°C but cost more. NR rubber maintains better cold flexibility in standard compounds. For severe cold climates, discuss your minimum operating temperature with us before specifying.
PU panels cost twice as much as rubber. How do I justify the switch? Calculate cost per tonne screened rather than cost per panel. If rubber lasts 6 weeks and PU lasts 6 months on your application, PU is 4Γ cheaper per tonne screened despite higher unit cost. Add the value of reduced screen change downtime and the economics are usually clear.
Contact Elephant Rubber
We supply both rubber and polyurethane screen panels. Contact us with your screen model, aperture size, material type, and current panel life and we'll recommend which material suits your application.