SCGR & Steel Breaker Belt

SCGR & Steel Breaker Belt


Grade of Cover SCGR

Comes with steel breaker top cover


1) Introduction

Rexline Engineering had supplied Operations with Steel Breaker Belt in July 2018.

This belt was proposed to by Rexline Engineering Technical Team after conducting site audit at request. As part of its re-initiation of operations, all its conveyor systems were audited to identify issues. During the extensive survey of the Site, Rexline Engineering identified issues with the current conveyor belt that it uses against the parameters of operation at site.

Upon approval, Rexline Engineering got its factory to exclusively manufacture and supply this belt for.

Rexline Engineering with its technical expertise in the conveyor industry manufactured the belt to specifications and supplied to on schedule.

2) Case Study

As per Audit conducted by Rexline Engineering on Site, the Site Engineers identified the issues pertaining to the existing conveyor belt. Most sections of the belt are worn out along the length of the belt. Also, there are areas where cuts and gouge have been observed.

Rexline Engineering has identified various factors that led to the belt being cut and gouge. The Rollers used on the conveyor system was way past its service life and required urgent replacements. This led to the belt not being conveyed as required and tracking of the belt.

The Belt Currently in place was not rated for Super Cut and Gouge Resistance. Furthermore, the Belt was only rated for 800/4 Ply Rating with only Fabric Ply as its setup

Rexline Engineering Proposed a SCGR Belt with Steel Breaker along with Higher rating catering to existing conveying tonnage rates.

Also, Rexline Engineering supplied the splice kit necessary on site for splicing of the belt.
Super Cut and Gouge Resistance (SCGR) delivers superior resistance to heavy impacts, abrasion and gouging. Super Cut and Gouge Resistance (SCGR) rubber cover compound provides high end performance in applications where increased resistance to heavy impacts, abrasion and gouging is required in Nickel Operations.

Benefits of High Tensile engineered reinforcement on the top cover:
The Super Cut and Gouge Resistance (SCGR) Belt that we offered is equipped with High Tensile engineered reinforcement on the top cover to provide efficient protection. This High Tensile engineered reinforcement on the top cover provides extra impact and rip protection for the belt and potentially allow smaller pulley diameters, serving as the basis for a longer service life and a lower risk of severe damage.

3) Technical Specifications

1.1 Process Parameters

Material Properties: Nickel Ore

Take Up Type: Gravity

Take Up Mass (Kg): 12000Kgs

Tonnage (t/h): 500

Maximum Lump Size(mm): 400 x 550 x 200

Conveyore Ore: Lumps

Material Profile: Flat

1.1        Technical Data Sheet

Item Description Unit Specification
1 Dimensions
1.1 Width of belt mm +/-1%
1.2 Tolerance in belt length m +/-2.5%
1.3 Belt edge cut
1.4 Total thickness mm 21.1+/-0.5
1.5 Cover thickness
1.5.1 Top cover mm 10+/-0.5
1.5.2 Bottom cover mm 3+/-0.5
1.6 Belt weight kg/m ~28.14
2 Rubber cover
2.1 Specific gravity g/cm3 1.15+/-0.05
2.2 Tensile strength n/mm2 min.18
2.3 Ultimate elongation % Min.400
2.4 Tensile strength after 70° C x 168h n/mm2 Min.200
2.5 Ultimate elongation after aging 70° C x 168h % Min.200
2.7 Abrasion resistance mm3 Max.90
2.8 Hardness shore A 65+/-5
2.9a Tearing resistance n/mm Min.12
2.9b Ozone resistance 69h 50pphm No crack
3 Adhesion
3.1 Top cover to ply n//mm 7
3.2 Bottom cover to ply n/mm 7
3.3 Ply to ply n/mm 7
4 Full belt elongation
4.1 At 10% reference load % Max.2.5
4.2 At breaking % Min.14
5 Trough ability at 40° troughed idlers 0.16 0.16
6 Tracking mm 60
7 Full belt tensile strength n/mm min.1250
8 Steel breaker Top
8.1 Cord diameter mm 1
8.2 Cord pitch mm 10

3.3 Testing Conducted

Test Type: Thickness of belt
Test Standard: AS 1334.2 Determination of thickness of belting and rubber covers across the width
Required properties: Meet the requirements of AS12-2000 clause 5.3 Tolerance on thickness of belting across width
Sample ID: AWBH18157
Note 1:
Discussion: Pass
Property AWBH18157 Minimum requirements AS 1332-2000
Minimum thickness of belt (mm) 21.1
Maximum thickness of belt (mm) 22.1
Maximum difference between any two  measurement of thickness of belt (%) 1.0 AS 1332-2000 CI  5.3 Thickness of belt >10 variation 1.1 max variation
Test Type: Tensile strength and elongation of full thickness belt
Test Type: AS 134.4 Determination of full thickness tensile strength and elongation of conveyor belting
Required Properties:
Meet the requirements of AS 1332-2000 clause 6.1 tensile strength of belt carcass
Meet the requirements of AS 1332-2000 clause 6.2 elongation of belting
Sample ID: AWBH1857
Note 1:
Discussion: Pass
Property AWBH18157 Minimum requirements
AS 12-2000
Average longitudinal tensile (kn/m) 1320 AS 1322-2000 CI 6.1
1250 kn/m minimum
Longitudinal elongation at 10% of the tensile strength as appropriate to the 2.0 AS 132-2000 CI 6.2
4% max elongation
Longitudinal elongation at breakpoint (%) 22.1 AS 132-2000 CI 6.2
10% minimum
Average transverse tensile strength (kn/m) 408 AS 1332-200CI 6.2
Specified by purchaser
Transvers elongation at break point (%) 26.7 AS 1332-2000 CI 6.2
10% Minium
Test Type: Cover and ply adhesion
Test Standard: AS 1334.7- Determination of ply adhesion of belting- longitudinal direction
Required Properties:
Meet the requirements of As 1332-2000 clause 6.6 cover  and ply adhesion.
Sample ID: AWBH18157
Note 1:
Discussion: pass
Property AWBH18157 Minimum requirements
AS 132-2000
Ply adhesion Carry-Ply 1-Top Cover (kn/m) 9.8 AS 132 CL 6.6 Cover to ply 4.3 kn/m mean
Ply adhesion Carry-Ply 2 (kn/m) 9.0 AS 132 CL 6.6 Adjacent plies 5.3 kn/m mean
Ply adhesion Carry-Ply 3 (kn/m) 9.1
Ply adhesion Carry-Ply 4 (kn/m) 8.7
Ply Adhesion Ply 4- Bottom cover (kn/m) 6.0 AS 132 CL 6.6 Cover to ply 4.3 kn/m mean

4) Project Benefits Review

SERVICE LIFE The beltis currently in operation since it has been installed in October 2018.

Previous service life of the beltis 6 Months

Expected service Life of RexConveyOre Belt: 12 Months

COST Replacement and Maintenance costs of these belts was reduced by 40% considering for a year’s worth of service life.

5) Photos

5.1 Case Study Photos

Figure 1. Previous Fabric Conveyor Belt

Figure 1. Previous Fabric Conveyor Belt

           Figure 2. Condition of Previous Belt – Worn Out Belt

Figure 3. Gouge and Cuts on the Belt

1.1       Steel Breaker Conveyor Belt Supplied