{"id":3836,"date":"2026-08-07T08:09:02","date_gmt":"2026-08-07T08:09:02","guid":{"rendered":"https:\/\/pepsenpu.com\/?p=3836"},"modified":"2026-08-07T08:12:35","modified_gmt":"2026-08-07T08:12:35","slug":"ndi-polyurethane-wheel-port-equipment-case-study","status":"publish","type":"post","link":"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/","title":{"rendered":"NDI Polyurethane Wheel Replacement for Heavy-Duty Port Equipment: A Field Validation Case"},"content":{"rendered":"<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_86 counter-hierarchy ez-toc-counter ez-toc-light-blue ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">\u00cdndice<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Alternar tabla de contenidos\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewbox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewbox=\"0 0 24 24\" version=\"1.2\" baseprofile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 eztoc-toggle-hide-by-default' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Project_at_a_Glance\" >Project at a Glance<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Why_the_Previous_Polyurethane_Wheel_Replacement_Failed\" >Why the Previous Polyurethane Wheel Replacement Failed<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Starting_with_the_Real_Operating_Conditions\" >Starting with the Real Operating Conditions<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Engineering_the_NDI_Polyurethane_Wheel\" >Engineering the NDI Polyurethane Wheel<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Laboratory_Validation_Before_Field_Replacement\" >Laboratory Validation Before Field Replacement<\/a><ul class='ez-toc-list-level-3' ><li class='ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#1_Bond_Strength_Evaluation\" >1. Bond Strength Evaluation<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-7\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#2_Heat_Buildup_Monitoring\" >2. Heat Buildup Monitoring<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-8\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#3_Dynamic_Lifespan_Testing\" >3. Dynamic Lifespan Testing<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-9\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Field_Testing_Under_Actual_Port_Operating_Conditions\" >Field Testing Under Actual Port Operating Conditions<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-10\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#From_Technical_Validation_to_a_More_Reliable_Spare-Parts_Supply\" >From Technical Validation to a More Reliable Spare-Parts Supply<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-11\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#What_This_Case_Shows\" >What This Case Shows<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-12\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#FAQ\" >PREGUNTAS FRECUENTES<\/a><ul class='ez-toc-list-level-3' ><li class='ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-13\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Why_are_NDI_polyurethane_wheels_used_in_heavy-duty_port_equipment\" >Why are NDI polyurethane wheels used in heavy-duty port equipment?<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-14\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Why_can_a_standard_MDI_polyurethane_wheel_fail_in_the_same_application\" >Why can a standard MDI polyurethane wheel fail in the same application?<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-15\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#Can_an_NDI_polyurethane_wheel_replace_a_Vulkollan%C2%AE_wheel\" >Can an NDI polyurethane wheel replace a Vulkollan\u00ae wheel?<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-16\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#What_should_be_tested_before_approving_a_heavy-duty_polyurethane_wheel\" >What should be tested before approving a heavy-duty polyurethane wheel?<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-17\" href=\"https:\/\/pepsenpu.com\/es\/ndi-polyurethane-wheel-port-equipment-case-study\/#What_information_does_PEPSEN_need_to_evaluate_a_custom_wheel_replacement\" >What information does PEPSEN need to evaluate a custom wheel replacement?<\/a><\/li><\/ul><\/li><\/ul><\/nav><\/div>\n<p><!--\nWordPress Post Title \/ H1:\nNDI Polyurethane Wheel Replacement for Heavy-Duty Port Equipment: A Field Validation Case\n\nSuggested Slug:\nndi-polyurethane-wheel-port-equipment-case-study\n--><\/p>\n\n\n<p class=\"wp-block-paragraph\">Heavy-duty port equipment places unusually high demands on load wheels. Quay cranes, rail-mounted gantry cranes and container AGVs operate under repeated high loads, frequent starts and stops, continuous rolling contact and demanding coastal conditions. In this project, the customer&#8217;s original equipment used imported Vulkollan\u00ae-based NDI polyurethane wheels, but long international lead times and spare-parts availability created a growing maintenance risk.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The customer had already tested conventional MDI polyurethane replacements, but the trial wheels developed heat, softened during operation, wore rapidly and showed local tearing and polyurethane-to-metal delamination. PEPSEN was therefore asked to develop an <a href=\"https:\/\/pepsenpu.com\/es\/ruedas-vulkollan-duraderas-para-uso-intensivo-y-alta-velocidad\/\">NDI polyurethane wheel alternative<\/a> that could be validated against the original wheels under actual operating conditions rather than accepted on material data alone.<\/p>\n\n\n\n<figure class=\"wp-block-gallery has-nested-images columns-default is-cropped wp-block-gallery-1 is-layout-flex wp-block-gallery-is-layout-flex\">\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" data-id=\"3846\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-1024x768.webp\" class=\"wp-image-3846\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" data-id=\"3845\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/port-machinery-polyurethane-load-wheels-1024x768.webp\" class=\"wp-image-3845\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/port-machinery-polyurethane-load-wheels-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/port-machinery-polyurethane-load-wheels-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/port-machinery-polyurethane-load-wheels-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/port-machinery-polyurethane-load-wheels-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/port-machinery-polyurethane-load-wheels-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/port-machinery-polyurethane-load-wheels.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" data-id=\"3842\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-vulkollan-alternative-1024x768.webp\" class=\"wp-image-3842\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-vulkollan-alternative-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-vulkollan-alternative-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-vulkollan-alternative-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-vulkollan-alternative-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-vulkollan-alternative-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-vulkollan-alternative.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" data-id=\"3837\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-1024x768.webp\" class=\"wp-image-3837\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n<\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Project_at_a_Glance\"><\/span>Project at a Glance<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<figure class=\"wp-block-table\"><table><tbody><tr><th>habituales<\/th><td>Heavy-duty wheels for quay cranes, rail-mounted gantry cranes and container AGVs<\/td><\/tr><tr><th>Original component<\/th><td>Imported Vulkollan\u00ae-based NDI polyurethane wheels<\/td><\/tr><tr><th>Previous replacement issues<\/th><td>Heat buildup, softening, rapid wear, tearing\/chunking and polyurethane-to-metal delamination<\/td><\/tr><tr><th>Engineering priorities<\/th><td>Low dynamic heat buildup, fatigue and tear resistance, wear resistance, reliable bonding and stable performance in coastal service<\/td><\/tr><tr><th>Validation route<\/th><td>Failure analysis \u2192 laboratory testing \u2192 pilot production \u2192 field comparison \u2192 long-term operating observation<\/td><\/tr><tr><th>Project result<\/th><td>The optimized NDI wheels completed the monitored field evaluation without abnormal overheating, cracking or delamination, while wear behavior approached that of the original imported wheels<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-1024x768.webp\" class=\"wp-image-3837\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/heavy-duty-ndi-polyurethane-wheel.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Why_the_Previous_Polyurethane_Wheel_Replacement_Failed\"><\/span>Why the Previous Polyurethane Wheel Replacement Failed<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The customer was not simply looking for a wheel with the same dimensions and hardness. The earlier replacement experience showed that matching static specifications alone was not enough for this application.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Port machinery runs through repeated load cycles. Each rotation deforms the polyurethane tread and releases part of that deformation energy as heat. If the elastomer has excessive hysteresis, internal temperature can continue to rise during prolonged operation. The resulting softening can accelerate wear, increase deformation and make edge damage more likely.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Bonding was another critical failure mode. Under high wheel loads and repeated torque, the polyurethane layer and metal core experience continuous shear stress. Inadequate surface preparation, primer selection or process control can allow local separation to begin at the interface and eventually develop into visible delamination.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The failed wheels collected from the site showed exactly why this project had to be treated as an engineering replacement rather than a simple material substitution.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-delamination-failure-1024x768.webp\" alt=\"Polyurethane wheel delamination failure under heavy load\" class=\"wp-image-3843\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-delamination-failure-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-delamination-failure-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-delamination-failure-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-delamination-failure-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-delamination-failure-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-delamination-failure.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Starting_with_the_Real_Operating_Conditions\"><\/span>Starting with the Real Operating Conditions<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Because the customer had already experienced several unsuccessful replacement attempts, our first step was not to recommend a standard polyurethane grade. The PEPSEN team reviewed the actual operating environment and the failure condition of the used wheels.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Continuous and intermittent load conditions during port operation<\/li>\n\n\n\n<li>Repeated acceleration, braking and directional changes<\/li>\n\n\n\n<li>Operating temperature and heat accumulation during extended runs<\/li>\n\n\n\n<li>Edge loading and localized stress concentration<\/li>\n\n\n\n<li>Wear pattern on the original and previously replaced wheels<\/li>\n\n\n\n<li>Condition of the polyurethane-to-metal bond after service<\/li>\n\n\n\n<li>Exposure to humidity and coastal environmental conditions<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">From this review, we defined the replacement target around four practical requirements: control dynamic heat buildup, maintain tear and fatigue resistance under repeated loading, improve resistance to service-related moisture and wear, and create a stable bond between the cast polyurethane and the steel wheel core.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This same application-led approach is used for other <a href=\"https:\/\/pepsenpu.com\/es\/categoria\/productos\/ruedas-de-poliuretano-productos\/\">ruedas de poliuretano personalizadas<\/a> where load, speed, temperature, tread geometry and metal-core design must be considered together.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Engineering_the_NDI_Polyurethane_Wheel\"><\/span>Engineering the NDI Polyurethane Wheel<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">For the replacement wheel, PEPSEN used an NDI-based cast polyurethane system and adjusted the formulation and processing route for the customer&#8217;s duty cycle. The objective was to reduce dynamic energy loss while maintaining the toughness and wear performance required for heavy rolling contact.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Material selection was only one part of the solution. We also optimized the metal-core preparation and bonding process. The steel surface was prepared to create a consistent bonding substrate, followed by controlled primer and casting procedures designed to reduce the risk of interface failure under repeated load.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"696\" height=\"911\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-bond-strength-test.webp\" alt=\"NDI polyurethane wheel bond strength test\" class=\"wp-image-3839\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-bond-strength-test.webp 696w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-bond-strength-test-229x300.webp 229w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-bond-strength-test-9x12.webp 9w\" sizes=\"auto, (max-width: 696px) 100vw, 696px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Wheel geometry and casting quality were reviewed at the same time. During the early trial stage, minor cracking appeared around a locally stressed edge. Instead of treating the first prototype as the finished solution, the team adjusted the casting process and product structure before continuing the field validation.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Laboratory_Validation_Before_Field_Replacement\"><\/span>Laboratory Validation Before Field Replacement<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The validation plan was deliberately staged. Before a larger quantity was installed, the trial wheels were evaluated for the failure modes that mattered most in this application.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"1_Bond_Strength_Evaluation\"><\/span>1. Bond Strength Evaluation<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Bond testing was used to check whether the polyurethane-to-metal interface could withstand the mechanical stresses expected during service. This was particularly important because delamination had been one of the customer&#8217;s previous failure modes.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"2_Heat_Buildup_Monitoring\"><\/span>2. Heat Buildup Monitoring<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-heat-buildup-test-1024x768.webp\" class=\"wp-image-3841\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-heat-buildup-test-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-heat-buildup-test-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-heat-buildup-test-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-heat-buildup-test-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-heat-buildup-test-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-heat-buildup-test.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Thermal monitoring was carried out during dynamic operation to observe how the wheel temperature developed under repeated deformation. The goal was not simply to record an initial surface temperature, but to identify whether heat continued to accumulate as the test progressed.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"3_Dynamic_Lifespan_Testing\"><\/span>3. Dynamic Lifespan Testing<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-dynamic-lifespan-test-1024x768.webp\" class=\"wp-image-3844\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-dynamic-lifespan-test-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-dynamic-lifespan-test-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-dynamic-lifespan-test-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-dynamic-lifespan-test-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-dynamic-lifespan-test-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/polyurethane-wheel-dynamic-lifespan-test.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">The wheels were also run on a dynamic test setup to observe rolling behavior, surface condition and progressive wear under repeated cycles. Laboratory testing could not fully reproduce every condition at the port, but it helped screen the design before field installation.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Field_Testing_Under_Actual_Port_Operating_Conditions\"><\/span>Field Testing Under Actual Port Operating Conditions<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-field-lifespan-test-1024x768.webp\" class=\"wp-image-3840\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-field-lifespan-test-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-field-lifespan-test-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-field-lifespan-test-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-field-lifespan-test-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-field-lifespan-test-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/ndi-polyurethane-wheel-field-lifespan-test.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">After the laboratory stage, a pilot batch was installed for field testing. The customer and PEPSEN followed the wheel condition during operation rather than relying on a single acceptance inspection.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The main observations included temperature behavior, tread wear, edge condition, cracking and the integrity of the polyurethane-to-metal bond. Where possible, the trial wheels were compared with the original imported wheels working in the same or comparable equipment positions.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Following the earlier design adjustment, the optimized NDI polyurethane wheels completed the monitored operating period without abnormal overheating, visible cracking or delamination. Their wear behavior was also close to the original imported wheel benchmark recorded during the project.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This result gave the customer enough confidence to move from a limited trial to broader replacement rather than changing all critical wheels at once.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"From_Technical_Validation_to_a_More_Reliable_Spare-Parts_Supply\"><\/span>From Technical Validation to a More Reliable Spare-Parts Supply<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The engineering result was only part of the customer&#8217;s objective. The original imported wheels performed well, but their long procurement cycle made spare-parts planning difficult. When a critical wheel failed unexpectedly, waiting months for replacement stock could create an unacceptable maintenance risk.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">After the field trial, PEPSEN moved the validated design into repeat production. Localized manufacturing shortened the replenishment cycle and reduced dependence on overseas spare-part availability. It also gave the customer a direct technical route for future adjustments to wheel dimensions, core design, hardness or operating conditions.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img alt=\"\" loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"768\" src=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-1024x768.webp\" class=\"wp-image-3846\" srcset=\"https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-1024x768.webp 1024w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-300x225.webp 300w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-768x576.webp 768w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-1536x1152.webp 1536w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels-16x12.webp 16w, https:\/\/pepsenpu.com\/wp-content\/uploads\/2026\/08\/rail-gantry-crane-polyurethane-wheels.webp 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">For similar projects, PEPSEN can manufacture <a href=\"https:\/\/pepsenpu.com\/es\/productos\/\">custom polyurethane components<\/a> from customer drawings, worn samples or application requirements, with material selection based on the actual load, speed, environment and failure mode.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"What_This_Case_Shows\"><\/span>What This Case Shows<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">A successful heavy-duty wheel replacement is rarely achieved by copying hardness and dimensions alone. In this project, the critical work was connecting material behavior with the real failure mechanism: dynamic heat buildup, tear and fatigue loading, tread geometry, metal-core bonding and long-term field wear.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The customer did not approve the new wheel because of a laboratory data sheet. Approval followed a staged process of failure analysis, material and process development, laboratory screening, pilot installation, field monitoring and design iteration. That validation route is what turned an NDI polyurethane wheel from a proposed substitute into a practical spare-part solution for heavy-duty port equipment.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"FAQ\"><\/span>PREGUNTAS FRECUENTES<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Why_are_NDI_polyurethane_wheels_used_in_heavy-duty_port_equipment\"><\/span>Why are NDI polyurethane wheels used in heavy-duty port equipment?<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">NDI-based polyurethane can be selected for applications that require a combination of high load capacity, low dynamic heat buildup, wear resistance, tear strength and fatigue resistance. The final performance still depends on formulation, hardness, wheel geometry, metal-core design and manufacturing control.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Why_can_a_standard_MDI_polyurethane_wheel_fail_in_the_same_application\"><\/span>Why can a standard MDI polyurethane wheel fail in the same application?<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A standard MDI polyurethane is not automatically unsuitable, but a formulation designed for general industrial use may generate too much heat or lack the fatigue, tear or bonding performance required by a continuously loaded port wheel. The material system must be matched to the actual duty cycle.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Can_an_NDI_polyurethane_wheel_replace_a_Vulkollan%C2%AE_wheel\"><\/span>Can an NDI polyurethane wheel replace a Vulkollan\u00ae wheel?<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">It can be developed as an alternative, but replacement should be validated for the specific application. Important factors include wheel load, speed, operating temperature, duty cycle, dimensions, hardness, metal-core design and acceptable wear rate. PEPSEN recommends prototype testing and field comparison before broad replacement on critical equipment.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"What_should_be_tested_before_approving_a_heavy-duty_polyurethane_wheel\"><\/span>What should be tested before approving a heavy-duty polyurethane wheel?<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Testing should focus on the actual failure risks. Depending on the application, this may include polyurethane-to-metal bond strength, dynamic heat buildup, dimensional stability, wear, tear or fatigue behavior, and a controlled field trial under representative operating conditions.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"What_information_does_PEPSEN_need_to_evaluate_a_custom_wheel_replacement\"><\/span>What information does PEPSEN need to evaluate a custom wheel replacement?<span class=\"ez-toc-section-end\"><\/span><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Useful information includes a drawing or sample, wheel diameter and width, metal-core dimensions, current hardness and material, wheel load, running speed, duty cycle, operating temperature, environmental exposure and a description or photos of the current failure mode.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p class=\"wp-block-paragraph\"><small><strong>Trademark note:<\/strong> Vulkollan\u00ae is a registered trademark of Covestro. References in this case identify the customer&#8217;s original wheel material and the performance benchmark used for the replacement project. PEPSEN&#8217;s independently manufactured NDI polyurethane wheels should not be interpreted as genuine Vulkollan\u00ae products unless specifically stated.<\/small><\/p>","protected":false},"excerpt":{"rendered":"<p>Heavy-duty port equipment places unusually high demands on load wheels. Quay cranes, rail-mounted gantry cranes and container AGVs operate under repeated high loads, frequent starts and stops, continuous rolling contact and demanding coastal conditions. In this project, the customer&#8217;s original equipment used imported Vulkollan\u00ae-based NDI polyurethane wheels, but long international lead times and spare-parts availability [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":3837,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Vulkollan\u00ae Alternative NDI Polyurethane Wheels | PEPSEN","_seopress_titles_desc":"See how PEPSEN developed and field-tested NDI polyurethane wheels as a Vulkollan\u00ae alternative for heavy-duty port equipment, focusing on heat, wear and bonding.","_seopress_robots_index":"","_seopress_robots_follow":"","_seopress_robots_imageindex":"","_seopress_robots_snippet":"","_seopress_robots_primary_cat":"","_seopress_robots_breadcrumbs":"","_seopress_robots_freeze_modified_date":"","_seopress_robots_custom_modified_date":"","_seopress_robots_canonical":"","_seopress_social_fb_title":"","_seopress_social_fb_desc":"","_seopress_social_fb_img":"","_seopress_social_fb_img_attachment_id":0,"_seopress_social_fb_img_width":0,"_seopress_social_fb_img_height":0,"_seopress_social_twitter_title":"","_seopress_social_twitter_desc":"","_seopress_social_twitter_img":"","_seopress_social_twitter_img_attachment_id":0,"_seopress_social_twitter_img_width":0,"_seopress_social_twitter_img_height":0,"_seopress_redirections_value":"","_seopress_redirections_enabled":"","_seopress_redirections_enabled_regex":"","_seopress_redirections_logged_status":"","_seopress_redirections_param":"","_seopress_redirections_type":0,"_seopress_analysis_target_kw":"","footnotes":""},"categories":[48,3],"tags":[],"class_list":["post-3836","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog","category-newsblog"],"_links":{"self":[{"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/posts\/3836","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/comments?post=3836"}],"version-history":[{"count":7,"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/posts\/3836\/revisions"}],"predecessor-version":[{"id":3854,"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/posts\/3836\/revisions\/3854"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/media\/3837"}],"wp:attachment":[{"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/media?parent=3836"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/categories?post=3836"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/pepsenpu.com\/es\/wp-json\/wp\/v2\/tags?post=3836"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}