Projects - Belt & Splice Failure Investigations

Technibelt was commissioned to investigate a ply belt splice failure at a hard rock mine in QLD. The splice had been extensively repaired on the top and bottom covers. An existing top cover repair had failed and was exposing the pocket of delamination through several steps of the splice plane. The adjoining parent belt (not within the splice) had alarmingly low ply to ply and cover to ply adhesion levels. The adhesion levels within the splice plane were also low. The alarmingly low parent belt adhesion levels further deteriorated after the hot splice/repair process and contributed to the splice failure. The low adhesion levels through the splice plane due to problems with process control also contributed to the splice failure. Splices cannot be repeatedly repaired as the physical properties of the belt and splice plane deteriorate. The rate of deterioration is dependent on the quality of the belt. Splices that require extensive repair are now scheduled for resplice.

Technibelt was commissioned to work closely with the maintenance and reliability teams at a coal mine in NSW to radically decrease downtime caused by conveyor belt and splice failures. The modern conveyor systems were designed on the lower limits relating to pulley diameters and belt/splice factors of safety. The demand on the conveyor belts and splices is arduous and needs to be technically correct and vigilantly monitored. Belt is purchased against strict technical specifications and verified by independent testing to ensure only quality belt is supplied and installed on the conveyors. Belt change dates are scheduled based on a combination of cover thickness test data and a wealth of knowledge on overall belt condition (site operational information and laboratory test data).

QA supervision of splicing has significantly increased the reliability and life of splices. Belt scraper adjustments and maintenance, based on actual performance (carry-back test data), has decreased carry-back spillage and increased consumable component life. The conveyors continue to exceed operational, maintenance and life cycle cost expectations of the company.

Technibelt was commissioned to investigate ongoing solid woven finger splice failures at an underground coal mine in QLD. The full belt width transverse failures occurred in parent belts within the prepared section of the splices but outside the fingers. Independent laboratory testing of the parent belt found the belt to comply with Australian Standard requirements as well as our Client/Technibelt specifications.  Testing the parent belt after simulating the splice process found no adverse effect on the tensile strength of the belt or the ability of the belt to be spliced. Adhesion levels of the top and bottom covers panels within the finger splice were as expected from a quality constructed splice. Testing found workmanship issues in the preparation of the parent belt and fingers resulted in critical loss in the tensile strength of the parent belt or fingers. An extensive Technibelt R&D program determined the safe workmanship limits for a quality finger splice and identified the trigger point that will result in an imminent splice failure.

Technibelt was commissioned to investigate high belt change rates associated with total/imminent splice failures at a hard rock mine in NT. Independent laboratory testing of the splices found significant issues with splice workmanship and process control. However, laboratory testing of the parent belt found the belt specifications were the major cause of the premature splice failures and belt changes. Technibelt developed site and conveyor specific belt specifications and belt splicing quality assurance documentation. Belt purchased and spliced against the correct technical specifications and verified by independent testing ensured quality belt installations. Belt changes are now scheduled due to cover wear and/or cover wear/impact damage.