The Challenge

Our client operates a large iron ore operation in the Pilbara that relies on a coarse ore transfer belt that moves unsorted ROM material between key areas of the operation, the system must handle an extreme mix of ore sizes, shapes, and weights.

Large, sharp ROM pieces ocassionally became lodged in the belt, causing rips and tears. Every forced stoppage to repair or replace the belt halted production across that entire section of the operation, creating costly downtime due to the operational bottleneck.

The rate of belt damage and the frequency of replacements had become unsustainable. The client approached Fenner Conveyors seeking a more durable, long term solution capable of withstanding continuous heavy impact and sharp ore to improve overall site throughput.

The Solution

Fenner Conveyors engineered a custom belt design using a hybridised cut and gouge and abrasion resistant IronDrive cover compound, optimised to cope with the highly variable and abrasive ROM ore stream.

A key enhancement was the inclusion of a heavy-duty breaker fabric, strategically positioned between the belt cover and the carcass. This layer delivers:

• Additional protection against sharp ore impacts
• Greater force dispersion across the belt surface
• A significantly reduced risk of penetration into the carcass or through the belt.

In high impact areas where heavy, sharp ore drops are unavoidable, this breaker fabric acts as a critical barrier, preventing damage from escalating into full belt failures, providing excellent resistance to stuck materials for belts.

The Results

Not long after installation, the true value of the new belt design became clear. A large piece of ore penetrated the belt cover, but failed to breach the breaker fabric layer, resulting in:

• A torn cover, but no carcass damage
• A minor shutdown for a simple repair, not a full belt replacement
• Continuous operations restored with minimal disruption

At the time, the site had no spare belt available. Had the carcass been compromised, the operation would have faced an indefinite shutdown until a replacement belt could be manufactured and installed, at enormous cost in both throughput and productivity.

Impressed by the performance and durability of the upgraded belt, the client has since ordered additional belt for use across this high impact application.