Field Testing of Lightweight Composite Conveyor Support Structures for Coal Mine Applications

This project was undertaken in two stages, focussing on on the commercialisation of lightweight fibre-reinforced polymer (FRP) composite conveyor support structures as an innovative alternative to traditional steel systems in the mining industry. Initiated in 2021, the development process began with the selection of suitable composite materials, followed by the design, manufacturing, and laboratory testing of prototype frames. These early-stage efforts confirmed the potential of FRP composites to provide the required strength and durability while significantly reducing weight.

Stage 2  Published July 2025

Following the successful completion of the initial development phase, a comprehensive field trial was undertaken to evaluate the structural performance of the composite frames under real-world mining conditions. This report presents the findings from the field trial of the lightweight composite prototype frames used in conveyor support structures for the mining industry and is structured into four chapters, each addressing the following topics:

• Chapter 1 introduces the research background, aims, and objectives of the study.
• Chapter 2 details the field trial, including the test site, design optimisation for weight reduction, finite element analysis, installation of composite frames and sensors, and structural monitoring procedures.
• Chapter 3 presents the analysis of weight reduction in the composite frames used during the field trial, along with sensor measurements from foil strain gauges and accelerometers for evaluating structural and dynamic performance.
• Chapter 4 summarises the key conclusions from the project and outlines opportunities for future research.

Stage 1  Published June 2023

Underground mines heavily rely on belt conveyor systems for efficient transportation of mined products, traditionally using steel conveyor structures. However, the weight and manual handling risks associated with steel structures pose safety concerns and productivity losses. Lightweight alternatives, such as fibre-reinforced polymer (FRP) composites, offer a higher strength-to-weight ratio and improved fatigue resistance, making them suitable for conveyor structures. Implementing FRP composites can enhance handling capabilities, facilitate easier installation, and increase transportation capacity. However, fire hazards and stringent safety regulations in underground mines require careful consideration and preventive measures when using non-metallic materials like FRP composites. Understanding the design parameters and requirements of conveyor systems in underground mining is crucial for developing composite conveyor support frames.

This report presents the investigation of fire retardant composite materials for conveyor support structures and discusses experimental testing of a lightweight composite prototype frame for application in underground mines.

The report is structured into seven chapters, each chapter addressing the following topics:

• Chapter 1 introduces the research background, project objectives, and plan overview for conveyor support structures and composite materials.
• Chapter 2 reviews composite materials, including fibre and resin types, and fire-retardant composites.
• Chapter 3 conducts fire and mechanical testing of glass fibre-reinforced composites to select the most suitable candidate.
• Chapter 4 outlines the belt conveyor support structure, prototype frame design, and numerical model creation.
• Chapter 5 presents experimental testing of the prototype support frame, discussing structural performance, load-bearing capacity, safety, and numerical validation.
• Chapter 6 analyses the weight and cost of the composite support structure, highlighting lightweight benefits and cost competitiveness against steel frames.
• Chapter 7 summarises key conclusions from the project and suggests future research opportunities.