Problems with cleated Maxoflex belts

Posted in: , on 24. Apr. 2006 - 14:49

Dear Sir,

I need your help on steep angle conveyors [similar to flexowell].

We , Essar Steel Limited, Hazira, India ,have 2 steep angle conveyor belts, bought from Roulunds, Denmark through SYNERGY INDUSTRIAL SERVICES PVT. LTD at Kolkata. After running for about 7-8 months, we found the steel cords were exposed at the joint area. Also, there were cracks on free zone. So, we stopped the belt and called representatives of Belt manufacturer. After a lot of discussions and talking, we decided to open and redo the joint.

When we opened the joint, we found the joint was done very poorly. Out of total 125 nos of cords, only 84 cords were going inside the joint. 41 cords were cut at the edge of joint. Also, the vulcanizing was very poor.

We repaired the joint to the best extent possible. Also, we repaired the edges with an edge repair machine. But we have again found cracks on the edge repaired portion.

My question is what could be the reason for the free portion i.e. edge developing cracks?

Also, what could be the reason for cutting of cords , while joining? We could not get any response from the belt manufacturer about this.

I am enclosing a sketch of the opened joint.

Does anybody have similar experience with flexowell belts from this or any other company?

Re: Problems With Cleated Maxoflex Belts

Posted on 24. Apr. 2006 - 01:23

The cracking problem could relate to the poor splice execution. The belt splicers used do not appear to be at all competent if your description of the splice is accurate. Cutting cables out of a splice is usually done because the cable lay up has been poorly executed. This in turn can be caused by using tie gum that is too thick. Once cables have been cut out of a splice you cannot just re-lay the splice as the balance may now be all wrong. Find someone who knows how to splice steel cord belt is your starting point

Col Benjamin

Gulf Conveyor Systems

Re: Problems With Cleated Maxoflex Belts

Posted on 30. Apr. 2006 - 09:30

Perhaps insist on a stamped belt splice and XRAY image of the spilce as well as their QA/QC and certificates of test/quilifications etc. No payment until these are received..

Re: Problems With Cleated Maxoflex Belts

Posted on 1. May. 2006 - 05:25

Dear Ravindral,

Depending on the type and direction of the edge zone (i.e area outside of the sidewall boudries) cracking, possible causes can be from the stresses resulting from your side guide rollers or from the stub return idlers. Note that I am assuming that this is a corrugated sidewall belt with sidewalls of 8 inches or higher.

The side guide roller can fold the belt edge, thereby causing cracking - normally on the bottom cover and edges.

The stub idlers can cause cracking as the belt bows - normally on the top cover. Good cross-belt stiffeners help to prevent this problem.


Dave Miller ADM Consulting 10668 Newbury Ave., N.W., Uniontown, Ohio 44685 USA Tel: 001 330 265 5881 FAX: 001 330 494 1704 E-mail:

Re: Problems With Cleated Maxoflex Belts

Posted on 10. May. 2006 - 05:37

Very interesting..

I seem to recall mentioning to Don and Russ at Essar when I was there that you may have a lot of trouble with those pocket belts.

Why not ask them for a copy of my report.

(And please give them my regards)


LSL Tekpro

Graham Spriggs