Conveyor pulleys are components that form the backbone of resource operations across Western Australia. From bulk handling on mine sites to load out facilities at ports, they keep systems moving. But like any other mechanical unit under constant stress, pulleys can wear over time.
Being able to spot warning signs can help you prevent costly downtime, reduce safety risks and extend the life of your wider system. Here are 8 of the most common signs that your conveyor pulley may be due for a replacement.
If your conveyor belt is slipping more often than usual, it could indicate the lagged pulley is worn and struggling to maintain proper traction. Slippage increases heat, accelerates belt wear and reduces overall efficiency. In environments with high loads, those can quickly become a serious issue - so if you're in mining or resources in Australia, it might be time for a conveyor pulley replacement.
Grinding, knocking or persistent vibration in the pulley area is rarely a good sign. These noises indicate worn bearings, misalignment or damage to the pulley shell. Left unchecked, they can quickly escalate into complete failure and halt operations.
Regular inspections should take a close look at the pulley shell and lagging. Grooves, cracks or rubber delamination are all signs that the pulley is under stress and may not be providing even belt support. In the abrasive conditions of WA's regions, this type of wear is a common reason for replacement or refurbishment.
If bearings are failing or overheating regularly, it can indicate deeper issues with the pulley's alignment, lubrication or housing. If they continue to fail after maintenance, the shaft or structure may be compromised and will need a full replacement.
If your belt is consistently running off-centre despite regular adjustments, the head, tail or snub pulley are the likely culprits. Misaligned pulleys put strain on the belt and drive system, increasing energy use and accelerating wear. If left too long, replacement or refurbishment will be necessary.
While some build-up is to be expected in wet and dusty environments, excessive material on the pulley will cause imbalance, mis-tracking and damage to the lagging. In most cases, excessive build-up indicates that the lagging surface has lost its self cleaning properties and will need to be replaced.
Pulleys can suffer from corrosion or pitting on coastal or chemical-exposed sites. Structural damage includes issues like bent rims and dented shells, which weaken the pulley's integrity. Ignoring corrosion can be particularly risky because it leads to a lessened load bearing capacity and can result in catastrophic failure.
Signs of wear and tear aren't always obvious. If your conveyor is using more power than usual, struggling with throughput or requires frequent belt adjustments, the pulley might be part of the problem. When refurbishment won't cut it, replacement can restore balance and reduce operating costs.
While refurbishment can sometimes extend the life of a pulley, it often only provides a short-term fix. Processes like re-lagging or re-machining restore surface performance, but they don’t always address underlying wear or structural fatigue.
Replacement, on the other hand, gives you a pulley built to required specifications, free from hidden defects and ready for the full demands of operating in WA's harshest conditions. In high-load mining and resource environments, investing in a replacement means better reliability, safer performance and lower long-term operating costs.
It's also worth noting that for pulleys with cracks, severe shell wear or repeated failures, full replacement might be the only practical solution.
At Promet, we understand the demands placed on conveyor systems in WA’s mining and resource sectors. That's why we provide full pulley replacements at a price cheaper than refurbishment. We deliver practical solutions backed by local experience, ensuring your systems operate reliably and safely.
Conveyor pulleys might not be the most attention grabbing asset, but their role is critical. Spotting the early signs of wear and tear will allow you to act promptly and save thousands in lost production. It also helps avoid safety incidents.
If you are in need of a replacement pulley, click here to submit your drawings for a free quote returned in 5 days.