Signs of Damage That Indicate a Conveyor Belt Needs Replacing
Regular inspection of conveyor belts is essential to ensure they operate efficiently and to prevent unexpected downtime. Over time, conveyor belts can suffer wear and tear, which, if left unchecked, can lead to operational failures. Here are the key types of damage to watch out for, indicating that a conveyor belt may need replacement:


1. Excessive Wear and Tear
Symptoms:
– The belt shows visible signs of wear, including fraying edges or a thinning surface.
– Uneven wear across the width of the belt, indicating alignment issues.
Causes:
– Prolonged use without proper maintenance.
– Misaligned rollers or pulleys causing uneven pressure on the belt.
Action:
– Replace the belt if wear compromises its strength or ability to carry the load effectively.
2. Tears, Holes, or Cuts
Symptoms:
– Visible tears, punctures, or cuts on the belt surface.
– Sections of the belt look damaged or torn, affecting material flow.
Causes:
– Sharp or heavy objects falling onto the belt.
– Misaligned or damaged rollers causing cuts on the belt surface.
Action:
– Replace the belt if the tears or cuts are severe enough to impact its performance or safety.


3. Cracks or Splits
Symptoms:
– Cracking along the length of the belt or splits appearing at joins.
– The belt surface looks brittle or dry.
Causes:
– Exposure to extreme temperatures or harsh chemicals.
– Overloading or excessive tension causing stress on the belt.
Action:
– If the cracks or splits compromise the structural integrity of the belt, it should be replaced immediately.
4. Delamination
Symptoms:
– Layers of the belt start to separate, especially in multi-ply belts.
– The belt feels loose or unstable during operation.
Causes:
– Poor-quality adhesive or extreme operating conditions.
– Excessive tension causing the layers to separate.
Action:
– Replace the belt as delamination cannot be repaired effectively.


5. Glazing or Polishing
Symptoms:
– The belt surface appears shiny or glazed, reducing grip.
– Slippage occurs on drive pulleys, impacting performance.
Causes:
– Excessive heat from friction or prolonged use.
– Inappropriate belt material for the application.
Action:
– Replace the belt to restore proper grip and performance.
6. Edge Damage
Symptoms:
– Frayed or damaged edges that catch on conveyor components.
– Material spills due to a lack of proper edge sealing.
Causes:
– Misaligned pulleys or rollers causing excessive pressure on the edges.
– Rough handling or poor installation practices.
Action:
– Replace the belt if edge damage causes operational inefficiency or safety concerns.


7. Worn or Missing Top Covers
Symptoms:
– The top layer of the belt is worn thin or has sections missing.
– Material sticks to or damages the exposed surface.
Causes:
– Handling abrasive materials without proper belt material.
– High friction or poor cleaning practices.
Action:
– Replace the belt to prevent further wear and improve operational efficiency.
8. Issues with Splices or Joints
Symptoms:
– Weak or damaged splices that cause the belt to separate.
– The belt makes unusual noises or vibrates at splices.
Causes:
– Improper installation or vulcanising of splices.
– High tension causing stress on the joints.
Action:
– Replace the belt if splices cannot be repaired or reinforced effectively.


9. Contamination or Chemical Damage
Symptoms:
– Visible discoloration, swelling, or soft spots on the belt.
– The belt material becomes brittle or sticky.
Causes:
– Exposure to harsh chemicals, oils, or solvents.
– Use of the wrong belt material for the application.
Action:
– Replace the belt with a chemically resistant material suited to the operating environment.
10. Belt Tracking Problems
Symptoms:
– The belt repeatedly shifts to one side or slips off pulleys.
– Uneven wear along one edge of the belt.
Causes:
– Misaligned conveyor components or poor installation.
– Belt wear causing loss of proper tracking.
Action:
– Replace the belt if tracking issues persist after alignment adjustments.


11. Loss of Structural Integrity
Symptoms:
– The belt sags or stretches excessively under load.
– Belt tension cannot be maintained despite adjustments.
Causes:
– Aging belt material losing elasticity.
– Overloading beyond the belt’s capacity.
Action:
– Replace the belt to restore operational safety and efficiency.
When to Replace a Conveyor Belt
- Regularly inspect your conveyor belts for these signs of damage.
- If repairs are not cost-effective or damage is beyond repair, replacement is the best option.
- Consult with experts to ensure the replacement belt is suited to your application and operating conditions.
By addressing these issues promptly, you can prevent costly downtime and ensure the smooth operation of your conveyor system.

Contact Us Today!
Maximise your operational efficiency with our robust conveyor systems. Get in touch with Hoverdale for expert guidance and a free consultation.