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Safety Devices on Conveyor Belt Systems

Safety devices on conveyor belt systems: pull-wire switches, nip guards, alignment and speed switches. Send one free request for quotes across South Africa.

  • Quotes from: Conveyor component suppliers
  • Area: All nine provinces
  • Cost to you: Free, no obligation
Red pull-wire emergency cable and steel guards running along a walkway beside a conveyor belt
Red pull-wire emergency cable and steel guards running along a walkway beside a conveyor belt

Safety devices on conveyor belt systems protect people from moving parts and protect the plant from damage. They include pull-wire switches, nip guards, belt alignment and speed switches, and belt-rip detection. This page explains what each does and how the law applies. ConveyorBelting.co.za is a free quote-request service, not a supplier. Describe your conveyor and we pass your request to independent suppliers and contractors who quote directly on conveyor belt safety devices, with no obligation.

Common conveyor belt hazards

Most conveyor injuries come from a small set of hazards:

  • Nip points where the belt meets a pulley or idler
  • Entanglement in rotating rollers and drives
  • Falling material and spillage on walkways
  • Fire from friction, seized rollers or heat
  • Maintenance on moving or unisolated equipment

A risk assessment of each conveyor should identify these and set the controls. Review it after any change to the layout, speed or material, and involve the operators and maintenance crew who work beside the belt every day. Fire hazards also deserve attention: seized rollers and slipping belts can overheat, so temperature sensors, fire-resistant belting and extinguishers near drives are common controls.

Pull-wire, alignment and speed switches

A pull-wire switch runs along the walkway so anyone can stop the belt from any point. A belt alignment switch trips when the belt drifts to the edge, before it tears or spills. A speed switch or zero-speed switch detects slip or a stalled belt. Other devices include belt-rip detection, blocked-chute sensors, and horn or light warnings before start-up. Each device should be tested on a schedule and wired so a fault stops the belt. Reset switches should be placed so a person cannot restart the conveyor without first checking that the area is clear.

Guards and nip protection

Fixed nip guards and enclosures stop people reaching into pulleys, tail drums, drives and return idlers. Guards must be strong enough to resist impact and be removable only with tools. Where guards are removed for maintenance, the conveyor must be locked out and tagged before work begins. Walkways, handrails and kick plates complete the protection for people working beside the belt.

On mines, the Mine Health and Safety Act and its regulations govern conveyor guarding and emergency stops. Elsewhere, the OHS Act Driven Machinery Regulations apply. Employers must guard dangerous parts, provide emergency stops and train staff. Apply a lock-out, tag-out procedure before cleaning or repairs. Ask your safety officer to confirm which rules and standards cover your site.

Comparing conveyor safety devices quotes

Prices change with rubber and steel costs, the exchange rate and stock levels. When quotes arrive, check:

  • Exact specification: width, carcass and strength, cover grade and thickness, or the part number, size and standard.
  • Quantity and units: per metre, per roll, per item or per set, and any minimum order or cutting charge.
  • Lead time: ex stock, or imported or made to order, and how long that takes.
  • Delivery and VAT: transport to site, offloading of heavy rolls, whether VAT is included and how long the price holds.

What to include in your request

  • Conveyor length, belt width and number of drives
  • Devices needed: pull-wires, switches, guards or sensors
  • Mine or industrial site and area classification
  • Whether installation, testing and certification are needed
  • Site address and when work can be done

Frequently asked questions

Do you supply conveyor safety devices?
No. ConveyorBelting.co.za is a free quote-request service. We pass your request to independent suppliers and contractors who quote you directly on safety devices, guards and installation. There is no charge and no obligation to accept a quote.
Where must pull-wire switches be fitted?
Pull-wires normally run the full length of any walkway or accessible side of a conveyor, so the belt can be stopped from any point. The exact layout depends on your risk assessment, site rules and the Mine Health and Safety Act or Driven Machinery Regulations. Ask a qualified safety practitioner to confirm.
How often should safety devices be tested?
Test emergency stops, pull-wires and alignment switches on a set schedule, often at each shift or weekly, and record the results. The right interval depends on duty, environment and your safety system. Replace any device that fails or sticks, and never bypass one to keep a belt running.
What should I include in a quote request?
Give the belt length and width, the number of walkways and drive and tail locations, the area classification, and whether the site is a mine. List the devices you need, such as pull-wires, drift switches or guards, and say if you need installation and testing.

Conveyor Safety Devices by province

Conveyor Safety Devices by city and town

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