Don't Learn This the Hard Way: My 6-Step Flexco Conveyor Belt Fastener Checklist
Who This Checklist Is For (And Why You Should Follow It)
If you're ordering Flexco fasteners for the first time, or if you've ever had a splice fail in the field, this is for you. It's for the engineer who's had to explain to a plant manager why a new belt is down after three weeks. It's for the maintenance planner who needs to get it right the first time because the cost of a redo isn't just money (it's embarrassment). This is not a theoretical guide.
I’ve been handling belt fastener orders for a mining operation for six years. In my first year (2018), I made the classic rookie mistake: I ordered the wrong bolt length. On a 48-inch belt, for a primary cleaner application. We caught it during installation. The delay cost us roughly $1,200 in downtime plus the rush shipping. This checklist is the direct result of that error, and about 15 others I’ve documented since.
Here are the 6 steps I now use for every single Flexco fastener order. I promise it will save you at least one embarrassing phone call to your maintenance supervisor.
Step 1: Determine the Belt Thickness (Not Guesswork)
This is the number one point of failure. Most order errors trace back to a misread belt spec. Don't rely on the belt's sidewall stamping (circa 2020, that stamping was wrong on a shipment we received; it took three calls to the manufacturer to confirm the actual thickness).
Action: Physically measure the belt at the installation point using a thickness gauge. Do not use a ruler. The difference between a 1/2" and 5/8" belt (6.4mm vs 8.0mm) is the difference between a bolt that will eventually pull through and one that won't.
Checkpoint: Have the measurement verified by a second person. I didn't do this on that first order (time pressure). The measurement was written down wrong. Now it's a non-negotiable step in our workflow (in other words, two signatures or it doesn't get ordered).
Step 2: Match the Fastener Style to the Application (A Common Misunderstanding)
Most buyers focus on the part number and miss the application context. This is the outsider blindspot. The question everyone asks is 'what's the part number for this belt width?' The question they should ask is 'what is the belt doing?'
Flexco makes a variety of mechanical fasteners: bolted (like the SR and BD series) and hammer-on (like the Rivet Hinged system). I once ordered a bolted system for a temporary repair on a high-abrasion chute line. The heads wore down in 4 months. The correct choice was a countersunk bolt for that application, which I only learned after the maintenance supervisor showed me what remained of the fastener.
Checklist actions:
- Consider pulley diameter: A smaller pulley requires a fastener with a smaller profile to avoid belt flex fatigue.
- Consider the material being conveyed: Sharp, abrasive materials require a different fastener design than fine powders.
- Consider the belt tension: Higher tension belts need stronger, more robust fasteners.
Step 3: Verify the Bolt Length with a Formula (Don't Eyeball It)
This is the step that will save you a $500 redo. The standard rule is: bolt length = (belt thickness * 2) + plate thickness + 1/8" for nut and washer clearance. But this is only a starting point.
I learned this when we ordered bolts for a 3/4" belt using the standard formula. The bolts were too long, they bottomed out on the anvil during installation, and the plate wasn't flush. We had to reorder all the bolts (circa September 2021, that error cost us $890 for the new bolts plus a 3-day wait).
Now, we physically dry-fit one fastener with the proposed bolt and nut before ordering the bulk quantity. This is the process_gap we closed. We didn't have a formal dry-fit process. Cost us when a shipment of 200 fasteners wasn't usable.
Step 4: Confirm the Material Grade for the Environment
Flexco fasteners come in carbon steel, stainless steel (like the "SS" series), and sometimes coated options. You might think this is obvious. It's not. Most beginners (myself included) assume that if it's in a coal mine, it's just dirt and grime.
In Q2 2022, we installed a stainless steel fastener in a washdown area. That's fine. But we installed it near a conveyor that moved salt-laden material. The fastener product sheet didn't specify "suitable for salt chloride environment." The salt particulate in the air caused pitting on the plates within 18 months. We should have ordered the marine-grade stainless option (a specific Flexco variant that handles chloride better).
Rule of thumb: If the atmosphere has any chemical vapor, salt spray, or extreme moisture, upgrade the material. The incremental cost is tiny compared to a mid-life splice failure.
Step 5: Order the Correct Installation Tools (This Is Not Optional)
You can't install a Flexco bolt-on fastener correctly with a standard wrench. You need the specific tensioning tools (a torque wrench with a specific adapter, or the Flexco air tool for hammer-on fasteners).
A year ago (Q4 2023), a contractor came in and installed fasteners using a standard impact driver. The bolts weren't torqued to spec. Splicing failed on day two. The contractor cost was already sunk, plus we lost a day of production. The root cause? Nobody verified the contractor's tooling before they started.
I made that verification a mandatory line item on our checklist: 'Quote for installation tools (if not available) and verify contractor equipment matches Flexco specifications.' This is the sort of detail that seems minor until it causes a full system failure.
Step 6: Always (Always) Order a Spare Splicing Kit
This is the one people always forget. You order exactly the number of fasteners for the belt width. You install them. You have no spares. A belt tears elsewhere in the system, you need a quick repair, and you're out of the correct bolt or fastener segment. You're now on an emergency order from Flexco, paying premium shipping.
We had a belt tear on a Saturday night a few years ago when the stock of the exact fastener was zero. The weekend maintenance was stuck waiting for a Monday delivery. Since then, our rule is: we keep a single-row kit (about 10-15% extra fasteners) in storage for each belt we maintain. The inventory cost is < $200, but it's saved us at least two emergency shutdowns.
Common Mistakes & Final Reminders
I've outlined 6 steps, but here's the overarching error: relying on memory. Don't. Use a binder (physical or digital) with the template on it for each belt profile at your site.
- Mistake 1: Assuming the old part number is still correct. Belt suppliers change specs. Re-verify for every order.
- Mistake 2: Forgetting to include shipping and handling time into the production schedule. Flexco ships quickly, but 'quick' doesn't mean 'next day.'
- Mistake 3: Not writing down the procedure. The third time a problem happened (a wrong bolt length), I finally created this checklist. Should have done it after the first.
This list isn't meant to be a sales pitch. It's a 'don't do what I did' guide. Pricing and availability (as of January 2025 based on our last quote) are subject to change, but the process for ordering correctly stays the same. If you order using this checklist, you will avoid the most common pitfalls. If you skip a step... I hope your first failure is as cheap as mine.