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Quarterly condition assessment: belt, rollers, pulleys, drives, safety devices and structure
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Quarterly Inspection Items
Mark the applicable column for each item: P = Pass | F = Fail | N/A = Not applicable. Record notes for any F.
| # | Check | P | F | N/A | Notes / Action |
|---|---|---|---|---|---|
| Belt Condition | |||||
| 1 | Top cover: no cuts, gouges, heat damage or surface cracking | ||||
| 2 | Bottom cover: no excessive wear from roller contact | ||||
| 3 | Belt edges: no fraying, folding or damage from mistracking | ||||
| 4 | Belt thickness: measured at head, mid-span and tail (record mm in notes) | ||||
| 5 | Delamination: no separation of cover from carcass | ||||
| Splices | |||||
| 6 | Vulcanised splices: no separation, edge lifting, cracking or exposed cords | ||||
| 7 | Mechanical splices: all fasteners intact, no missing clips or plates | ||||
| 8 | Number and location of splices recorded | ||||
| Rollers & Idlers | |||||
| 9 | Carry rollers: spin freely, no seizure, noise or excessive play | ||||
| 10 | Return rollers: spin freely, no seizure, noise or material build-up | ||||
| 11 | Impact rollers (at load zone): condition acceptable, rubber intact | ||||
| 12 | Self-aligning / training idlers: functioning correctly | ||||
| 13 | Number of seized / damaged / missing rollers recorded per section | ||||
| Pulleys | |||||
| 14 | Head pulley: lagging condition, no delamination or wear-through | ||||
| 15 | Tail pulley: condition acceptable, no material build-up or damage | ||||
| 16 | Snub pulleys: condition acceptable, bearings in good order | ||||
| 17 | Pulley bearings: temperature normal, no abnormal noise or vibration | ||||
| 18 | Pulley alignment: pulleys square to belt, no mistracking caused by pulleys | ||||
| # | Check | P | F | N/A | Notes / Action |
|---|---|---|---|---|---|
| Drive System | |||||
| 19 | Drive motor: runs smoothly, no overheating, vibration or unusual noise | ||||
| 20 | Gearbox: oil level correct, no leaks, no abnormal noise | ||||
| 21 | Coupling: alignment correct, no wear or damage | ||||
| 22 | Backstop / holdback device: functional, no slippage | ||||
| Belt Tracking & Tensioning | |||||
| 23 | Belt tracks centrally along full length | ||||
| 24 | Take-up travel: sufficient range remaining | ||||
| 25 | Gravity take-up / counterweight: position and condition acceptable | ||||
| 26 | Belt tension: correct, no slippage on drive pulley | ||||
| Safety Devices (functional test each) | |||||
| 27 | Pull-cord (emergency stop) switches: tested full length, all functional | ||||
| 28 | Belt drift switches (head and tail): trigger correctly on belt misalignment | ||||
| 29 | Speed sensor / zero-speed switch: triggers alarm on belt under-speed or stop | ||||
| 30 | Blocked chute detector: triggers alarm when chute is blocked | ||||
| 31 | Belt rip detection system: sensors operational (if fitted) | ||||
| 32 | Pre-start alarm (audible and visual): operates correctly | ||||
| Structure, Guards & Transfer Points | |||||
| 33 | Stringers and support frames: no cracks, corrosion or deformation | ||||
| 34 | Walkways and handrails: secure, in good condition | ||||
| 35 | Guards and covers: in place at head, tail, nip points and drive | ||||
| 36 | Chute liners: intact, no wear-through or material build-up | ||||
| 37 | Impact beds (load zone): condition acceptable, absorbing impact | ||||
| 38 | Skirt rubber: effective seal, no excessive spillage | ||||
| 39 | Dust suppression system (if fitted): operational | ||||
| 40 | Belt cleaners / scrapers: effective, correctly adjusted | ||||
Defects & Action Required (list any item marked F: reference item # from checklist)
| Item # | Defect description | Action taken / reported to | Rectified by / date |
|---|---|---|---|
Declaration
I declare that I have completed this quarterly conveyor belt inspection thoroughly and accurately. I have recorded all findings, including belt thickness measurements and roller counts, and reported any defects or safety concerns to the maintenance supervisor. The conveyor will not be returned to service until any faults affecting safety or belt integrity have been rectified. I understand that failure to complete inspections or report defects may breach company policy and WHS obligations.