Bulk Material Mining Conveyors
Bulk material mining conveyor sprockets drive the primary and secondary conveyor systems that transport iron ore, coal, copper, gold ore, and other minerals from pit to processing plant and port. These are the largest, most heavily loaded sprockets in any industrial application.
Technical Specifications
| Parameter | Range | Custom |
|---|---|---|
| Pitch | 25.4–50.8mm | Yes |
| Chain | ANSI #80–#160 / ISO 16B–32B | Yes |
| Teeth | 15–45T | 9–76T |
| Material | 4140 Alloy Steel | 4340 |
| Hardness | HRC 45–55 | — |
| Hub | QD / Split | TL |
| Bore | H7, 40–150mm | QD extends |
| Strand | Duplex / Triplex | — |
| Speed | Up to 300 RPM | — |
| Surface | HDG / Zinc-nickel | — |
| Temp | -20°C to +60°C | — |
| TIR | ≤0.03mm | — |
| Keyway | DIN 6885 / AS 1403 | Imperial |
| Lubrication | Oil bath | — |
| Fatigue | >5M shock cycles | — |
| Safety Factor | ≥6:1 | — |
| Weight | 5–45 kg | — |
| Noise | <80 dB | — |
| Dust/Debris | Extreme | — |
| Cert | ISO 9001, EN 10204 3.1 | — |
Advantages vs Inferior / Working Principle
✅ 4140 alloy steel for extreme shock loads — C45 fails in this application.
✅ HRC 45-55 hardened teeth — resists rock/mineral abrasion.
✅ Split hub / QD for field replacement — minimises expensive downtime.
✅ Full EN 10204 3.1 material traceability — meets audit requirements.
Locations: Primary overland conveyor head, secondary conveyor, stacker-reclaimer, ship-loader chain. Function: Convert motor torque into precise material transport motion.
Compatibility / Selection
OEM: Fenner Dunlop*, Continental*, Rema Tip Top*, Metso* systems. *Compatibility reference only.
Select: ❶ Match chain pitch ❷ Shaft bore → hub type ❸ Tooth count for speed ratio ❹ Material grade for environment ❺ Surface treatment for corrosion protection.
Install / Troubleshoot
Install: LOTO → release chain → remove old sprocket → mount new (split hub = no chain removal) → align → tension 2-3% → lubricate → test.
Issues: Chain riding teeth = worn sprocket (replace both). Vibration = misalignment/bore runout. Excessive noise = dry chain. Chain skipping = elongated chain + worn teeth (replace both).
Case Studies
Pilbara, WA: “4140 sprockets on our primary drive. Extreme conditions, excellent performance.” ★★★★★
Newman, WA: “Split hub saved hours during shutdown. Material certs provided.” ★★★★★
Mackay, QLD: “Consistent quality across multiple orders. Hardened teeth lasting well.” ★★★★☆
Perth, WA: “QD bushed on large shaft. Rapid installation, running true.” ★★★★★
Gladstone, QLD: “Professional documentation, competitive pricing, reliable supply.” ★★★★★
FAQ
Best material for this application?
Compatible with OEM equipment?
Split hub available?
Material cert included?
MOQ?
Transmission Chains
Bushings
✅ ISO 9001 ✅ ANSI/ISO ✅ EN 10204 3.1
Ever-Power Australia: 15+ years, 3,200+ SKUs, 4140 alloy, engineering support.
