Conveyor Belt Splicing and Maintenance for Mining Operations
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Flexco manufactures mechanical belt fasteners, belt cleaning products, and tools for the mining industry. The company is a world leader in maximising belt conveyor productivity and its products set the industry's highest standards for design, ease of installation, and reliability.
Mining operations around the world turn to Flexco for belt conveyor solutions that help maximise uptime, productivity, and safety. Flexco takes a holistic approach to belt conveyor systems, recognising each system as a whole and working to address challenges and develop solutions.
Mechanical fasteners for underground, sand, gravel and hard rock mining
For underground mining applications, the Flexco® SR™ Rivet Hinged System is durable, long lasting, and simple to install on-site. The hinged mechanical fastener has self-setting rivets and features a scalloped-edged, low profile design that provides compatibility with cleaners and other conveyor accessories.
For sand and gravel, hard rock mining, and cement, the Flexco BR™ Rivet Solid Plate System is the preferred choice for the mining industry. These fasteners are recognised for their wear and longevity, as well as a smooth coin-edge profile that also promotes compatibility.
Both the SR and BR fasteners feature multi-point rivet attachments that pass between the belt's carcass fibres to ensure maximum grip without damaging the carcass. Additionally, because a mechanical splice is visible, any wear or deterioration is immediately apparent. Replacement or repairs can be scheduled during brief periods of downtime or at the end of a shift.
The Pneumatic Single Rivet Driver makes installation of SR and BR fasteners even quicker. With one pull of the trigger, the durable tool drives each rivet in, producing consistent splices 33% faster than manual installation.
Belt maintenance products for the mining industry
Even the most routine belt maintenance carries the risk of injury for mine site staff. Flexco has developed an exclusive line of tools with built-in safety features to deter such injuries. The Flex-Lifter™ Conveyor Belt Lifter allows operators to safely lift a tensioned belt high enough to provide sufficient room for repairs, while Far-Pul® HD® Belt Clamps securely grip the belt to keep it from moving during the splicing process.
Flexco encourages skiving of the belt for cleaner-fastener compatibility and offers the lightweight, portable FSK™ belt skiver to ensure accurate cutting depths with an enclosed blade and plastic or metal guard. Flexco also offers manual belt cutters, the 900 series and 840 series aluminium, as well as power-assisted electric belt cutters that are available in corded and cordless versions capable of cutting belts up to two inches.
Belt conveyor cleaners
Cleaning is essential to ensuring your beltline runs smoothly. Over time, carryback can create serious problems for your conveyor system, including mistracking, accelerated belt wear, and the seizing of return idlers. Flexco offers a wide variety of belt cleaning systems that can remove even the toughest, stickiest material. Our systems are specially designed to minimise belt wear and interface seamlessly with mechanical fasteners.
The MMP Medium Mine-Duty Precleaner is just one of many cleaner offerings from Flexco. It features a visual tension check and a TuffShear™ blade. The MHS Heavy-Duty Secondary Cleaner with Service Advantage Cartridge™ boasts patented PowerFlex™ cushions which maintain optimal belt contact, and when combined with the tensioners, create four points of relief for maximum belt compatibility.
Load-point products to improve throughput
Flexco offers high-quality skirt clamp systems to keep material flowing safely. These systems create an effective seal at load points, without damaging the top cover of your belt. The Flex-Seal™ Skirting System is constructed with sturdy, corrosion-resistant components that deliver long service life. Easy to install and maintain, Flexco skirt clamps are a smart way to improve throughput.
When it comes to load zones, Flexco impact beds deliver the highest level of material containment and belt protection. DRX™ impact beds are specially designed to control acceleration, deaden impact energy, reduce damaging vibrations, and extend belt life.
Pulley lagging and belt trackers
When belt slippage is a problem, Flexco offers several pulley lagging solutions. Flex-Lag® ceramic pulley lagging has 80% tile coverage and features the highest co-efficient of friction available in lagging materials, two to three times the friction of rubber in wet, muddy, or dry conditions.
Even the slightest movement or change in the conveyor can throw a belt off track. Misalignment of rollers or pulleys, an incorrect splice, and material build up are just a few things that can get a mining operation's belt off track. Flexco offers the PT Max™ belt trainer to help combat belt mistracking. A unique 'pivot and tilt' action delivers superior belt training performance, which makes it easy to keep even the most troublesome belts on track. The PT Max is also available for return side belting.
Available White Papers
Variant Friction Coefficients of Lagging and Implications for Conveyor Design For many decades lagging has been used to both protect conveyor pulleys and to increase the available friction for driving the conveyor belt. Today lagging is available in various designs with differing stated capabilities and strengths.
Flexco Releases Free Paper on Diversion Technology Flexco has released a free paper on how diversion technology is changing operations. The function of a transfer chute system varies depending on its operational requirements, but in all cases, the transfer chute system has a basic functional requirement to direct the material stream from the feed conveyor to somewhere else.
Managing Your Load Zones: Increasing Belt Conveyor Productivity Load zones manage the transfer of materials from one belt to another, but the role that these load points can play in the productivity of an operation is often overlooked.