UsFlex Almost Triples Belt Lifetime on High Impact Minesite

At Saraji Mine in Queensland’s Bowen Basin, a high-impact run-of-mine (ROM) coal conveyor system was facing frequent downtime due to belt damage. Despite using a robust 5-ply Crows Foot Weave carcass with M-grade covers, the system struggled against the harsh conditions of metallurgical coal and tramp metal, resulting in regular gouging, cutting, and ripping of the belt, leading to costly repairs and replacements every 15 to 23 months.

To address this challenge, Saraji Mine partnered with Fenner Conveyors to trial a new solution. Our engineering team recommended a conveyor belt featuring the UsFlex carcass for superior rip resistance, paired with ArmorShield covers for enhanced impact protection. Manufactured locally in Australia, the belt was custom-built to meet the site’s demanding conditions. During the trial, the belt withstood a 400mm gouge from tramp metal, damage that would have typically torn through other belts, saving the site 24 hours of unplanned downtime.

The UsFlex belt delivered a 289% improvement in belt life, significantly reducing the frequency of repairs and maintenance. This helped avoid regular 36 hour repair periods to manage belt rips and tears, translating into substantial savings in lost revenue.

By April 2025, the UsFlex belt had been in operation for 62 months, far exceeding the lifespan of its predecessor. It even survived an incident in March 2022, when a large wear plate passed through the ROM system, causing minimal damage. The client was highly satisfied with the belt’s durability and performance, noting its resilience and cost-effectiveness.