Belt Conveyors: an overview of degradation mechanisms and operational reliability

Abstract

Conveyor belts are among the bulk material handling systems in modern industry and are widely used in mining, steelmaking, civil construction, and port logistics. Despite their high operational efficiency, these systems are subject to degradation mechanisms that may compromise reliability, safety, and service life. This article analyzes the primary causes of degradation in conveyor belt systems, with emphasis on corrosion processes in metallic structures, tribological phenomena and lubrication practices, mechanical failures associated with fatigue and fracture mechanics, and the role of technical standards and laboratory testing applied to belts and associated components. The adopted approach combines engineering fundamentals with the analysis of practical industrial examples, particularly from mining and port operations. The results demonstrate that degradation mainly arises from the interaction of aggressive environmental conditions, cyclic mechanical loads, inadequate maintenance practices, and deficiencies in design or inspection, underscoring the need for an integrated approach as a basis for mitigating failures and increasing operational reliability.