1. Objective
To define a standardized and safe method for installing, inspecting, and maintaining conveyor belts in industrial environments, including manufacturing, mining, and cement plants. This SOP is designed to reduce downtime, prevent injuries, and ensure optimal belt performance across various operational conditions.
2. Tools & Materials Required
- Belt cutter & skiver (precision type preferred)
- Vulcanizing press (hot/cold) or mechanical fastener tool
- Torque wrench, spanners, alignment laser
- Clamps, edge guides
- Jointing kit (hot, cold adhesive, or mechanical)
- PPE: gloves, helmet, goggles, high-ankle safety shoes
- Cleaning solvent (non-flammable), lubricator
- Maintenance logbook or digital CMMS system
3. Pre-Installation Checklist
Ensure conveyor frame is level/aligned using a laser level
Confirm all pulleys and rollers rotate smoothly and are wear-free
Validate drive motor and gearbox function under no-load
Confirm belt type, width, and length match system specs
Apply Lockout-Tagout (LOTO) on power and moving parts
Check ambient conditions (e.g., moisture, dust) for safety
4. Conveyor Belt Installation Procedure
4.1 Belt Positioning
- Carefully unroll the belt, avoiding twists or creases
- Use edge alignment tools to guide the belt across pulleys
- Clamp both ends securely before jointing begins
4.2 Jointing Options
Mechanical Fastener Joint
- Cut belt ends square using template
- Install fasteners using approved hand press
- Insert hinge pin and double-check alignment
Cold Vulcanized Joint
- Buff joint areas thoroughly
- Apply bonding agent per manufacturer guidelines
- Clamp and cure as per spec (usually 4–24 hrs)
Hot Vulcanized Joint
- Prepare ends (step or finger pattern)
- Insert into press; apply pressure & heat (145–160°C)
- Cool under tension before trimming excess
4.3 Belt Tensioning & Tracking
- Adjust take-up units for correct belt sag/tension
- Manually rotate belt and inspect for side drift
- Adjust snub and guide rollers to center belt
- Monitor startup with belt empty, then under partial load
5. Maintenance Procedure (Routine)
5.1 Daily Checks
- Visual inspection for rips, tracking deviation, or slippage
- Remove debris from tail and snub pulleys
- Check emergency stop and sensors
5.2 Weekly Checks
- Inspect surface for material buildup, cracks, or hardened wear
- Lubricate bearings and tensioning points
- Review sensor calibration if applicable
5.3 Monthly Checks
- Evaluate belt joints for signs of fatigue
- Inspect pulley lagging and realign if needed
- Log hours of operation and compare to expected lifespan
5.4 Annual Preventive Maintenance
- Full system shutdown for deep inspection
- Replace severely worn components (rollers, seals, drive shaft)
- Conduct belt replacement or re-splicing
- Recalibrate load cells or belt weighers
6. Safety Precautions
- Always apply LOTO before any intervention
- Never attempt to track or adjust belt while running
- Use guards and covers over rotating or pinch points
- Display safety signage and restrict non-essential personnel
- Maintain clear access around work zone
7. Documentation & Reporting
- Record every maintenance action, date, and responsible person
- Track belt wear rate using visual inspection notes/photos
- Note all deviations from standard performance
- Schedule and flag re-checks or critical repairs using a CMMS tool