Soultions:
ASGCO’s Impact Beds^™ and Modular Impact Beds^™ provide critical protection for the conveyor belt, as well as control spillage in the conveyor-loading zone to give maximum conveyor load zone support. Impact beds are custom built for multiple angles within the conveyor system.

• Absorbs Impact – with our impact bars that are manufactured with absorbent, 40-durometer rubber that can really take the shock of large material.
• Dustless Transfer – created by eliminating the gaps/sag in between the idlers as well as the vibration caused as the material is being loaded onto the receiving conveyor belt.
• Modular Design – Impact beds can be manufactured in 2′ (600mm), 4′ (1200mm) or 5′ (1500mm) in length, depending on the size of the conveyor material impact area.

Learn more about Conveyor Load Zone products on our web site.

Solution
ASGCO-Fourthane is a synthetic rubber/urethane composite that has superior adhesion characteristics to the original conveyor belt cover.  The product also has a high tensile strength, elasticity and impact resistance, formulated to be applied on conveyors that work under high impact and abrasion conditions.  The product allows rubber conveyor belt covers to be repaired in the field / on the system with very few tools and personnel required.  An additional benefit is that the product dries within 15 minutes after being applied and only needs 1 hour of cure time before the conveyor belt be run in normal production.

Results
ASGCO-Fourthane, once cured, achieves the physical properties similar to that of the conveyor’s original rubber belt and allows production to resume on the conveyor system.  This repair system accomplished a cost effective way to repair  potentially several million dollars worth of damage. Fourthane has proven to be a large cost savings solution for the plant.

Contact us today to learn more. Or go the the Fourthane® Conveyor Belt Cover Repair System page on our web site.

Unguarded machinery

Before assessment:

Numerous tail sections, drives and take-ups were not adequately guarded allowing access to moving components. Some walkway areas also needed to be protected since they were between a permanent wall and the conveyor system(s). The facility also had multiple roadways and railroad tracks that passed underneath conveyors which posed a problem if any of the return idlers broke loose from their drop brackets.

Site assessment was completed, along with detailed drawings, for safety equipment and guarding placement. This will insure that all personnel and visitors are entering and working in a safe environment, while still being able to perform any PM or replacement issues that might arise.

Results:

Safe-Guard Modular Conveyor Flat Guard protecting workers from moving machinery

By using various standard sizes of the ASGCO Safe-Guard Modular Conveyor Flat Guards, we were able to protect the hazardous areas and still allow them access as needed by easily removing and replacing the lightweight powder coated panels. Conveyor guarding placement was achieved using both the existing structure and some minor modifications for floor mounts. With standard panels sizes implemented into the system, there was no need for special orders.

All overhead areas were secured using the ASGCO Safe-Guard Conveyor Return Idler Cage, which were easily mounted to the existing conveyor truss on a variety of belt widths. In these difficult to reach areas, where easy access is a major issue, the ASGCO Return Idler Cage has been an ideal selection.

Industry: Major Iron Ore Shipping and Handling Terminal on the Great Lakes.

Solution
Replacing the standard return roll brackets with the Return Roll Changers allowed the maintenance personnel to safely remove the return idler from the catwalk. The Return Roll Changer also increases conveyor safety by providing pinch point protection between the idler and the belt while the conveyor is running.

Results
With the new addition of the conveyor Return Roll Changers, no pry bars or hammers are needed to replace return idlers, even further reducing the possibility of injury. The maintenance worker replacing the idler does not have to put on a harness and crawl out on to the frame work of the conveyor structure in order to access the idlers. Utilizing the design of the idler hold down clips that are bolted in place, idlers are not able to pop out of the brackets and fall onto personnel or mobile equipment on the ground. The result is that the Return Roll Changers provide a safe, reliable, and ergonomic way for maintenance crews to change out return idlers.

Industry: Copper Mining Operation
Application: Hard to Access Return Idlers
Material: Copper Concentrate
Product: Return Roll Changers
Objective: Reduce down time with easy idler change out
Detail: 36” wide belt located approximately 110’ above the ground in an A-frame building with access to only one side of the conveyor.

The tripper component of the coal handling conveyor system was a major issue for several reasons, with the current OSHA NEP combustible dust requirements, to address any airborne dust issues, being the top priority. Also the timeline for dismantling the existing conveyor system and installing the new tripper cars and transfer chutes was on tight schedule and had to be accomplished by dismantling them one at a time so at least one of the trippers could run during the day to fill the coal bunkers below.

Solution

Two new tripper cars were designed and modeled using ASGCO’s 3-DEM material modeling software for conveyor chute analysis. The new design allows the coal to be deposited into the bunkers or loaded back onto itself, all while moving in the same direction, speed and in the center of the receiving conveyor. The improved model enhances the flow of the coal and in combination with new internal wear liners also helps in stopping excess wear within the conveyor system. By using a combination of X-Wear conveyor wear liners, ceramic cylinders encased in rubber for the impact area and chromium carbide overlay plate (double pass and polished) we were also able to address the sliding abrasion issues inherent with the old design. The success of the new design is evident in the before and after pictures. The addition of clamp mount skirting, dust curtains and Skalper conveyor belt cleaners were also instrumental in further eliminating any dust and carry-back.

Result

The newly installed transfer chutes now operate with improved coal flow through the tripper system without any buildup. Nearly all spillage as well as the airborne dust has been eliminated, as well as improved life of the wear liners.

Once implemented, the new design enabled the plant to not only meet, but exceed its goals for the project.
The overall project was a great success and ASGCO has once again provided a “Complete Conveyor Solution”.

Industry: Coal Fired Power Plant
Application: Dual Tripper conveyors carrying coal to bunkers
Material: Blend of Sub-Bituminous and Bituminous Coal 1″ minus
Product: 3-DEM Chute Design, Fabrication and Installation
Objective: Improve material flow, reduce airborne dust on tripper floor and improve life of internal wear liners
Detail: Two (side-by-side) tripper conveyors 36″ wide at 400′ FPM and 600 TPH that feed the coal bunkers below

Solution
ASGCO worked in conjunction with the plant’s employees to realign the conveyor belt idlers and tail pulley to determine the proper placement of the Tru-Trainer conveyor belt idler. After testing, a suitable location was determined and the equipment installed. The area best suited, it was determined, was close (20′) from the tail pulley to insure the conveyor belt would track properly into the tail and that there would be sufficient room for the install.

After the installation of the return Tru-Trainer and some adjustments of idlers and the tail pulley, we were able to keep the belt within acceptable parameters – even under heavy usage. The belt no longer walks off the framework of the conveyor system causing costly damage.

Conclusion
The conveyor belt is tracking perfectly. As seen in the before/after images, the belt is maintaining alignment. The plant is no longer concerned about belt tracking and very satisfied with the performance of the Tru-Trainer.

Industry
Cement Producers and Distributors
Application: Wash Plant Conveyor
Product: Concrete, Aggregates
Objective: Conveyor Belt Tracking
Conveyor: 50 ft. long 10% incline, 48″ wide belt 45 degree troughing idlers, Conveyor runs intermittently.

View our full line of Conveyor Belt Tracking Idlers >>

As an initial solution the customer installed AR500 1” thick cast type liner instead of original AR400, 1” thick. The result was that the customer experienced a “longer” life out of the AR500 cast liners (approximately 3-4 weeks total life versus the AR400) but still NOT what they were expecting. The AR500 liner life was 7-10 days maximum. The liners were being changed out EVERY down day (7 day interval) due to excessive wear. Unscheduled down time due to wear continued to be an issue in this application.

Solution:
ASGCO Armorite™ 700 was selected for a 6 month test.  After 12 months the Armorite 700 conveyor wear liners were still in service with little signs of wear.  The customer stated that our wear liner products exceeded all expectations and are currently reviewing all other high wear areas on the conveyor system for ASGCO to solve.

ASGCO Armorite™ 700 is a combination of high chromium and molybdenum white iron metallurgically bonded to a mild steel plate. Armorite provides mazimum protection in high water areas, with the mild steel backing cushioning the white iron enabling it to withstand impact. Armorite is easily weldable with minimal preparation.

Result:
The customer has standardized on the Armorite 700 product in this application on all sizes of wear liners, and has mentioned that the cost savings in maintenance out weighs the additional cost of the product a minimum of 10 fold.

They have now gone to a visual inspection of the tripper “pant-leg” once a month, instead of daily as previously required with the competitor’s liners.

These results have been typical in most applications where Armorite has been installed, with a minimum life of 6-8 times that of AR500.

Industry:
Copper Mining

Application:
Copper Ore Tripper
(2260TRP001) / Tertiary
Crusher Feed System

Material:
2½” minus Secondary
Crushed Copper Ore

Material Spec:
105#/cuft @ 2.5% moisture

Capacity:
6800TPH

Liner Installation Location:
Tripper Car “Pant Leg” Chutes

View our full line of Conveyor Wear Liner Products >>

The conveyor is 54” wide, handling 5500 tons per hour @ 15% moisture. With Copper ore 3” minus traveling to leaching area.

Tiles fully encapsulated in rubber - In service barely 6 months.

Challenge – The main challenge on the conveyor system was premature wear on the pulleys.  The original lagging was a rubber with ceramic tiles pressed into the rubber (see left).  The issue was that the tiles were not separated by any rubber to allow them to flex under tension. There was no adhesion between the tiles, and, under the high tension of bulk material, they would fracture, break and fly off the pulley. Also, the tiles were square which makes it difficult to get a good bond on a 90-degree point verses a radius curve.

In addition, an area for water did not exist and caused material to shed away from the center of the pulley.  As mud build up in the center, it forces its way under the tiles through a hydraulic action further compromising the pulley lagging.

Because of these factors, in some applications the conveyor was achieving barely 6 months of pulley life before it was time for a change out.

Solution – We recommended installing Arrowhead pulley ceramic lagging. The unique Arrowhead pattern provides effective water and material shedding away from the center of the pulley.  Each 3-¼” long by ½” tile is completely encased in rubber on all five sides around and under each tile.  Every tile is molded with rounded corners to provide a better adhesion to the tile and rubber lagging. The Arrowhead line is MSHA approved for mine use and meets all requirements for flame resistant solid products taken into mines. Acceptance Marking No. MSHA IC -174/2

Arrowhead Ceramic Pulley Lagging

Results – The mine has now made the ASGCO Arrowhead lagging its standard pulley lagging solution, which has solved the problems with high pulley wear.  In as case of a high production facility, thousands of hours can be saved in the time it takes to shutdown the conveyor system to replace a pulley. With ASGCO Arrowhead Ceramic Lagging the company is able to increase its production and minimize its downtime.

Learn more about Conveyor Pulley Lagging on our web site >>

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Each year workers are injured, sometimes fatally, because the appropriate guarding is not in place to protect unsafe areas of the conveyor. A good safe-guarding system eradicates the possibility of the operator (or any employee) coming dangerously close to hazardous moving parts. In general, the areas require conveyor guarding are as follows;

• The point of operation where labor is preformed on material.
• On a power transmission mechanism that supplies energy to the conveyor.
• Any moving parts on the conveyor while it is in operation.

Designed to prevent injuries from contact with pinch points and with other dangerous moving machine parts, ASGCO’s MSHA accepted products are vital to ensure employee safety and prevent injuries. Our conveyor guarding and safety equipment delivers safety, versatility as well as rock solid construction.

Our Conveyor Guarding products include;

The Return Roll Changer Conveyor Guard supplies pinch point protection for maximizing safety and eliminating the need for high-lift equipment.

Safe-Guard Belt Clamps are a patented positive tensioning system conveyor guarding, that applies even tension across the entire width of the belt.

Safe-Guard Return Idler Guard is our innovative return idler conveyor guard that has been awarded a U.S. patent; uniquely designed and engineered to prevent injuries from pinch points and to catch the return idler if it should fall.

V-Return Idler Conveyor Guard protects workers and equipment from falling idlers. It’s durable UHMW slotted cage stops material buildup and offers easy access for belt maintenance.

Return Idler Conveyor Guarding Cage is designed to catch the return idler if it would become unseated. This immensely reduces the risk of parts falling onto unsuspecting workers or equipment, preventing injuries and down time.

Modular Conveyor Flat Guards is a modular guard mounted on the conveyor to guard against moving equipment.

Wear liners in Application

ASGCO manufactures a variety of conveyor wear liners with many options and sizes to choose from. Designed to handle any tough hard rock mining application. Abrasion resistant, modular, high- wear material to line belts, chutes, and bin impact areas; ASGCO  wear liner products are the longest lasting, most cost effective in the industry.

ASGCO wear liners are made of Armorite 700 – a combination of high chromium and molybdenum white iron metallurgical bonded to a mild steel plate. Armorite provides maximum protection in high water areas, with the mild steel backing cushioning the white iron enabling it to withstand impact. Armorite is easily weldable with minimum preparation. Custom designed to meet customer applications.

ASGCO Armorite 700 Skirtboard Liners: Protects the skirt board and provide a significantly longer wear life than currently used skirt liners. These liners are for all conveyors and transfers where the eradication of spillage or centralization of load is required. Produced from 20mm thick Armorite that is enhanced with a 10mm thick mild steel creating a product that is 700 BHN with a high impact resistance.

Armorite 700 Smooth Wear Plates: A very cost effective method of extending wear life in chutes, bins, impact walls, and screen plates, as well as extreme abrasion resistance across a wide range of applications. With a liner size that allows for localized replacement in high-wear areas.

Armorite 700 Grizzly Screen Cap Wear Bars: Increases life and reduces wear on crusher. Removes fines upstream as well as spreading material evenly over width of the crusher, causing even wear and extended life, ideal for aggregates, coal, and all types of mining.

Armorite 700 Chocky Bars: Protects contoured surfaces on buckets, loaders, excavators, dragline machines, chute linings, and rock box edges. An excellent alternative to expensive, labor intensive, hard-facing welding methods, it bends easily – prenotched backing plate and allowing the ability to bend, cut, or shape to suit any application.

Armorite 700 Wear Buttons: The perfect alternative to expensive, labor intensive, hard facing – no need to cut wear strips from full sheets of wear plate. Wear Buttons are easy to use and install with no need for pre or post heating and are ideal for smaller areas requiring wear resistant material and specific wear protection on chutes, conveyor transfer points, and buckets.

Armorite Star Plate: Is wear-resistant and multi-shaped; offers a long wearing, cost effective, alternative to standard sheets and AR wear plate, and is ideal for chutes, bins, buckets, hoppers, and truck bed lining. The Star Plate extends less weight, is more cost effective, has a longer wear life, and sectional replacement (when compared to traditional sheet or plate).

ASGCO X-Wear: At a lower cost per ton, X-Wear has a substantial reduction in operating cost compared to any other lining material.
It’s energy absorbing design dramatically reduces noise, and smooth Laminar surface provides optimum sliding surface with a low coefficiency of friction.

ASGCO Mine Duty X-Wear: Has a wide range of use in the mining and quarry industries. Anywhere severe abrasion occurs and the angles of impact are low such as: transfer points, screen chutes, deflectors, and feeders. Mine Duty X-Wear is made of extremely hard ceramic that provides unsurpassed resistance to abrasive wear. The rubber matrix effectively dampens the impact forces that can crack the ceramic rods, and superior adhesion is the result of hot-vulcanization of the resilient rubber matrix that surrounds the ceramic rods. With both excellent wear protection and low noise materials for any tough mining or quarry condition, X-Wear’s smooth surface wear plate is made of the most advanced hard ceramic on the market.

ASGCO X-Wear (AR): Made with Hardox 400 Steel, X-Wear (AR) wear liners extend the life and effectiveness of the sealing compound while protecting the skirt board. The straight design is used where belts are fully loaded and full chute width needs to be maintained, while the angled deflector wear plate liner forces larger material to the center of the belt.

Learn more about ASGCO Conveyor Wear Liner products »