The Potential Impact of Conveyor Belt Aging on Production Safety
2026-02-08 13:43In continuous-production industries such as mining, power generation, cement, and metallurgy, many safety incidents are not caused by sudden equipment failure. Instead, they often result from conveyor belts that have aged over time without being properly identified or addressed.
When a conveyor belt deteriorates, the issue is not limited to reduced efficiency—it can directly affect worker safety and the overall stability of the system.
What Does Conveyor Belt Aging Mean?
Conveyor belt aging does not simply mean that the surface looks worn. It refers to a gradual decline in material performance caused by long-term operation. Common signs include hardened or cracked covers that reduce wear and impact resistance, fatigue in the belt carcass that lowers tensile strength and load capacity, loosened internal structures that lead to local delamination or hidden damage, and weakened resistance to heat, fire, and corrosion.
In harsh conditions such as high temperatures, heavy dust, moisture, or corrosive environments, a Rubber Belt will typically age much faster than expected.
Major Safety Risks Caused by Conveyor Belt Aging.
1. Higher Risk of Belt Breakage and Unexpected Downtime.
As a conveyor belt ages, its effective tensile strength decreases. Under heavy loads or during start-up with high impact forces, local tearing or even complete belt breakage can occur. This kind of failure often leads to sudden shutdowns and may pose serious risks to nearby equipment and operating personnel.
2. Slippage and Belt Misalignment Leading to Secondary Accidents.
Aged belt covers tend to have unstable friction properties, which can cause slippage or tracking issues. These problems may result in abnormal heating of drive pulleys, accelerated edge wear, and material spillage or buildup along the conveyor line.
In industries such as coal mining and power generation, these conditions are common contributors to fire hazards. In many cases, aging of the Rubber Belt is the underlying cause.
3. Reduced Fire Resistance and Increased Fire Risk.
For fire-resistant conveyor belts, aging can significantly weaken flame-retardant performance. When exposed to friction heat, sparks, or hot materials, an aged belt is more likely to ignite. If a fire spreads along the conveyor route, the consequences can be severe and difficult to control.
4. Increased Maintenance Frequency and Higher On-Site Safety Pressure.
Older belts require more frequent repairs, adjustments, or replacements. This increases maintenance workload and also raises the number of manual interventions near operating equipment, which indirectly increases human-related safety risks.
Performance Comparison: New vs. Aged Conveyor Belts.
| Item | Conveyor Belt in Normal Condition | Aged Conveyor Belt |
| ensile strength | Stable and meets design requirements | Significantly reduced, prone to fatigue failure |
| Cover performance | Good elasticity and wear resistance | Hardened, cracked, easy to peel |
| Friction coefficient | Stable operation, low slippage risk | Unstable friction, frequent slippage |
| Fire/heat resistance | Meets safety standards | Performance degraded, higher risk |
| Operational stability | Suitable for long-term continuous use | Higher failure rate |
How to Reduce Safety Risks Caused by Belt Aging.
In heavy-duty and high-risk operating conditions, safety depends not only on replacing old belts but on choosing the right belt from the start.
Proper selection is essential. Belt structure and grade should be matched to material characteristics, conveying distance, tension level, and ambient temperature rather than focusing solely on initial cost.
Working with a reliable manufacturer also plays a key role. Suppliers with standardized production processes and strict factory testing can effectively reduce early aging and performance degradation. For example, our industrial Rubber Belt solutions are designed with stable tensile strength and consistent cover performance to support long-term continuous operation.
Finally, establishing a regular inspection and monitoring system helps identify aging signs early, allowing issues to be addressed before they develop into serious safety incidents.
Conveyor belt aging is not just normal wear—it is a system-level issue that directly affects production safety. Through proper belt selection, consistent quality control, and routine inspection, safety risks can be significantly reduced while extending overall system service life.
As an experienced industrial conveyor belt manufacturer, we provide application-specific belt solutions for mining, power generation, cement, and other demanding industries. If you are assessing the safety condition of an existing conveying system or need belt selection and customization based on operating conditions, we can offer practical technical support and tailored product solutions.