Built for Extremes: How We’re Powering South America’s Toughest Mining Challenges
Across South America, mining operations play an important role in supplying the world with critical minerals that impact everyday life. Accessing, moving, and processing the material is a demanding undertaking due to harsh conditions in remote locations. In addition, the process requires an “always on” approach at a significant speed. Any issues can lead to unsafe situations and supply chain disruptions, ultimately impacting consumers with higher costs or product scarcity.
Therefore, mining uptime is of utmost importance. To accomplish that, it takes a combination of high-quality solutions that are properly engineered, installed, and maintained to meet the unique demands of the specific application.
Two recent conveyor belt replacement projects in Chile and Brazil demonstrate how Continental continues to lead the industry by combining advanced product engineering with world-class field services, enabling customers to operate safely, efficiently, and reliably.
Setting New Benchmarks in Chile
First-Ever Replacement of an ST10000 Conveyor Belt
At one of the world’s largest copper mining operations, we successfully completed the first-ever replacement of an ST10000 steel cord conveyor belt. This is a major achievement for the global mining industry.
Designed for high-tension, steep-gradient underground conveying or long-haul overland conveying without the need for transfer points, the ST10000 belt represents the strongest-rated conveyor belt class available, engineered for extreme operating conditions.
The scale of the system underscores the complexity of the project:
- Approximately 13 km total belt length installed across underground and overland conveyors
- Transport of material through a ~7 km underground tunnel with nearly 1 km vertical elevation change
- Integration into a system powered by advanced gearless drive technology, delivering high efficiency and reduced maintenance requirements
Executing a replacement of this magnitude required detailed planning, specialized equipment, and precise coordination, particularly within confined underground conditions. Complexities included staged belt pulling, careful tension control, and advanced splicing techniques to maintain performance and reliability.
Beyond being a technical achievement, this project validates the long-term viability of ultra-high-strength conveyor systems and reinforces their role in enabling sustainable, high-capacity material transport in modern mining operations.
Delivering Speed and Precision in Brazil
A 7 km ST8000 Conveyor Belt Replacement
In Brazil, Continental further demonstrated its ability to execute complex projects at scale. Executed between January and May 2026, the conveyor belt replacement project encompassed both preparation and installation phases, requiring seamless coordination across engineering, logistics, and on-site execution teams.
Key project highlights include:
- 7.4 km of ST8000 conveyor belt prepared and installed
- 27 belt reels managed throughout the operation
- Deployment of custom-designed conveyor belt equipment
- A team of 85 Continental professionals on-site
- Installation completed in just 3.4 days
This accelerated installation timeline highlights our ability to minimize downtime for mission-critical operations, ensuring customers can maintain productivity without compromising safety or quality.
Engineering Leadership and Teamwork from Product to Service
These projects demonstrate our ability to deliver end-to-end conveying solutions across the entire lifecycle:
- Advanced product engineering – From ST8000 to ST10000 steel cord belts, we design solutions capable of handling the most demanding loads and environments.
- Integrated service expertise – Comprehensive services, including planning, installation, and maintenance, ensure optimal performance and reliability.
- Execution in extreme conditions – Whether in confined underground tunnels or large-scale surface operations, our teams consistently deliver under complex operational constraints.
Commitment to safety and efficiency – Every project is executed with a focus on reducing operational risk while maximizing uptime and performance.
“One of the most rewarding parts of working on complex conveyor belt projects is seeing world-class teams come together to solve extraordinary challenges,” said Bret Hall, Head of Conveyor Services for the Americas. "We have some of the best people from across the globe collaborating on what is undoubtedly some of the most difficult and complex conveyor belt installations in the world. The level of expertise, teamwork, and commitment is truly impressive.
“Conveyor belt systems are evolving, and so are the expectations placed on them. By continuously advancing both technology and service delivery, we're helping customers unlock new levels of performance in material handling. As mining operations push into deeper, more complex environments, the need for trusted partners with proven expertise has never been greater. Continental remains at the forefront of delivering those solutions,” added Hall.
Learn more about these projects:
International Mining Magazine’s article about the ST10000 replacement in Chile
Check out posts on LinkedIn from our Head of Conveyor Services for the Americas, Bret Hall
