Chuquicamata ST10000 belt replacement: design and maintenance notes for engineers
Reviewed by Tom Sullivan
First reported on International Mining – News
30 Second Briefing
ContiTech has completed the first replacement of an ST10000 steel-cable conveyor belt at Codelco’s Chuquicamata copper mine in Chile, one of the largest uphill tunnel conveyor installations in global mining. The ST10000 belt, previously pioneering for high-tension, steep-gradient underground haulage at Chuquicamata, required complex change-out logistics in confined tunnel conditions and precise splice management for ultra-high-strength cords. The project confirms that life-cycle replacement of ST10000-class belts is technically viable, which will influence long-haul conveyor design and maintenance planning for deep and block cave operations.
Technical Brief
- Steel-cord construction required precise cord alignment and constant tension control during each hot vulcanised splice.
- Uphill tunnel geometry constrained reel diameters and belt mass, forcing staged belt pulling and reeling.
- Confined underground installation limited crane access, so belt handling relied on winches, sleds and specialised turning frames.
- Transition zones and curve sections needed careful tracking control to avoid edge damage on the ultra-stiff belt.
- Integration with existing drive stations and take-up systems demanded recalibration of tension set-points after replacement.
- Replacement validates long-haul, high-tension steel-cord conveyors as a life-cycle alternative to deep truck haulage.
Our Take
Codelco’s work at the Chuquicamata copper mine with an ST10000 conveyor belt sits alongside other recent high-capex infrastructure moves in Chile, such as Freeport-McMoRan’s proposed $7.5 billion El Abra expansion, signalling sustained long-life investment in the country’s copper corridor rather than short-term debottlenecking.
Our database shows multiple recent Codelco items pairing heavy-duty fixed infrastructure with fleet modernisation, from Sandvik Toro LH515i loaders at Chuquicamata Underground to the SANY electric haul truck pilot, suggesting the miner is methodically upgrading both bulk materials handling and mobile equipment to cut operating risk and emissions.
With Chile’s government targeting a 30% reduction in mining permit processing times to unlock over $100 billion in investment, high-spec assets like ST10000 conveyor systems at Chuquicamata are likely to become reference points for technical standards on future large copper project approvals in the country.
Prepared by collating external sources, AI-assisted tools, and Geomechanics.io’s proprietary mining database, then reviewed for technical accuracy & edited by our geotechnical team.
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