Pit and Quarry Direct
How to get maximum life out of pulleys

One of the most impactful practices aggregate producers can employ to save money for their plant is carrying out proper care and maintenance of equipment, to extend the unit’s lifespan. By conducting regular inspections and following appropriate maintenance instructions, producers can avoid costly replacements.

Most pulleys provide for more than 10-20 years fatigue life if designed properly – as long as wear items, such as lagging and bearings, are maintained. It is more cost effective, in most cases, to refurbish an existing pulley than to buy a new one. Therefore, pulleys should be reworked to save cost and get maximum life out of the machine.

Conveyor pulley lagging should be replaced before any indications of bare steel. If the steel shell is compromised, a new pulley is often required. Therefore, producers should take appropriate steps to inspect and rework pulleys to ensure the pulley is not damaged beyond repair.

Precision Pulley & Idler offers two levels of rework service

PPI (Precision Pulley & Idler) offers customers several means to maintain the condition of its pulleys. In addition to providing a lagging wear strip to help customers identify when the lagging is ready to be replaced, PPI offers two levels of rework service: Tier I and Tier II.


Tier I is a basic strip and relag for a conveyor pulley. This level of rework is for pulleys that do not require any disassembly or re-assembly. PPI offers three procedures for this level of rework: stripping, re-lagging and non-destructive testing. The pulley is typically received completely disassembled.

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Illustration of the "lagging wear strip" from the pulley edge.

This level of rework is the most cost-effective and provides the best delivery. PPI provides a visual-only inspection, which covers the rim shell surface after stripping, a look at the welds for any obvious concerns, broken bushing bolts/hub bore damage for pulleys completely disassembled. Pulleys received with shafts will be visually checked for missing or broken bushing/lock assembly bolts. Areas of concern are communicated to the customer before the rework begins.

This level of rework is streamlined and flows through PPI’s current manufacturing processes. It is also the easiest and most efficient.


Tier II rework covers any pulley requiring disassembly and/or re-assembly. This level of rework can provide new components such as bushings/locking devices, shafting and bearings. The pulley can be received assembled to include couplings and backstops.

PPI provides an Initial Condition Report, which is completed as the pulley is being disassembled, as well as a visual inspection report after the pulley has been stripped. Any concerns will be communicated to the customer before beginning the rework.

For more information about PPI and its reworking services, visit www.ppi-global.com.

Pit & Quarry Direct provides professionals in the aggregate mining industry with insights on timely innovations in equipment and technology. This newsletter was produced by North Coast Media’s content marketing staff in collaboration with PPI.

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