Custom Engineered Covers
Precision-engineered roll coverings designed for your specific process requirements.
Roll Coverings Engineered for Performance
At Vail Rubber Works, we understand that every manufacturing process has unique demands. That's why we don't offer generic, one-size-fits-all roll covers. Instead, our engineering team works closely with your maintenance and production staff to analyze your specific application requirements — including operating temperatures, pressures, chemical exposures, line speeds, and nip loads — and designs a custom cover solution that delivers optimal performance and maximum service life.
Our in-house rubber mixing capabilities give us complete control over compound formulation, allowing us to fine-tune hardness, resilience, chemical resistance, and wear characteristics to meet the exact demands of your process.
See Our Custom Covers in Action
Watch how our precision-engineered covers are manufactured and applied.
Rubber Covering
Rubber roll covers are the backbone of our business and have been since the early 1900s. We offer an extensive range of natural and synthetic rubber compounds, each formulated to address specific process challenges.
Our rubber covering process begins with careful preparation of the roll core, followed by application of bonding agents and the rubber compound itself. Every cover is vulcanized under precisely controlled conditions and precision-ground to the required diameter and surface finish.
Z-Series
Premium roll covering formulation for problem applications when it comes to heat exposure, steam exposure, or a position that creates excessive wear.
X-Series
Cost-effective premium roll covering formulation with properties surpassed only by our Z-Series.
WearGuard
Cost-effective elastomeric material formulated for roll coverings used in the flat-rolled metals industry.
F-Series
Premium roll covering designed and formulated for applications requiring high coefficient of friction and wear resistance.
Orange Squeeze
Premium elastomeric covering that offers abrasion resistance approaching that of polyurethane.
NiChem
Premium elastomeric material formulated for roll coverings used in the flat-rolled metal industry.
DuraSqueeze XT
High-performance premium roll covering offering a combination of good temperature resistance at elevated line temperatures and excellent abrasion resistance.
K-Series
High-performance compound adder with high-strength fiber making — an excellent option for physically demanding applications.
A-Series
Premium roll covering designed and formulated for applications requiring dynamic durability, and cut, tear, and wear resistance.
Polyurethane Covers
Polyurethane and urethane roll covers offer superior abrasion resistance, load-bearing capacity, and durability compared to conventional rubber in many applications. These materials are ideal for high-wear environments where roll life is critical.
We offer cast polyurethane systems, with hardness ranges from very soft (30 Shore A) to very hard (60 Shore D). Polyurethane covers typically outlast common rubber covers by 3–5x in abrasive environments.
Polytek
Advanced polyurethane formulation engineered for extended roll life and consistent performance.
Polycast
Cast polyurethane system delivering precise hardness control and exceptional wear resistance.
Polylast
High-performance compound designed for maximum durability in abrasive environments.
Polyfire
Higher heat resistance combined with excellent wear and abrasion resistance.
PolyCoat
Designed for coater and applicator rolls.
Tungsten Carbide Covers
Tungsten carbide coatings provide the ultimate in wear resistance and surface hardness. Applied through our thermal spray processes, these coatings create an extremely hard, dense surface that resists wear, corrosion, and material buildup far longer than other coating materials.
The superior hardness (typically 1100–1400 HV) and low porosity of tungsten carbide coatings ensure consistent surface quality and extended roll life — often 4x longer than chrome plating.
Non-Woven Fiber & Masroll Covers
Non-woven fiber covers provide unique surface properties ideal for cleaning, polishing, and surface conditioning applications. These covers feature excellent fluid absorption and release characteristics.
Masroll covers combine advanced materials and construction techniques to deliver superior performance in demanding environments, including applications such as vacuum rolls. Every custom-engineered cover we produce begins with a thorough analysis of your application.
Need a Custom Cover Solution?
Our engineering team is ready to analyze your application and design the optimal cover.
Contact Our Engineers