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Conveyor Chain Selection for Wet, Abrasive, and High-Temperature Service

Conveyor chain in heavy process service runs through water, grit, corrosive liquors, and sometimes heat, and in that service the environment is a selection input alongside the load. UTEC Industrial designs, engineers, machines, fabricates, and installs custom material handling systems for aerospace and heavy industry from its Spokane Valley, WA facility, integrating Allen-Bradley PLC and motion control with in-house CNC machining, heat treating, and stress relief. This article sets out what three chain makers' texts (Renold 2010, Rexnord 2014, Tsubaki 1997) say about chain for wet, abrasive, and hot duty, where their figures differ, and how wear strips, sprockets, lubrication, guarding, and monitoring complete the selection. Chain selection sits in the build chain, design → engineering → parts machining → fabrication → assembly → weld fatigue → stress relief → drives → controls → tuning → monitoring, between the conveyor's structural design and the drive and controls that run it.

Why does the service environment decide how long conveyor chain lasts?​

Renold's 2010 designer guide says the pin/bush joint carries the chain tension and articulates at the sprockets as a plain bearing, and it puts the design basis in one figure: experience has shown that, given a good environment and a clean, well-lubricated chain, a pin/bush bearing pressure of up to 24 N/mm² (3,500 lb/in²) will give an acceptable pin/bush life, and a factor of safety of 8 on breaking load gives this pressure. In anything other than a clean, well-lubricated environment, the guide says, the factor of safety should be increased, lowering the bearing pressure, if some detriment to the working life of the chain is to be avoided.

Rexnord's 2014 engineered-steel-chain catalog says the subject of wear is extremely complicated, and that it is impossible to predict with accuracy the wear life of various chain–liner combinations because of variable and uncontrollable factors such as abrasion, corrosion, lubrication, load, speed, and break-in period. Prior experience of a successful chain–liner combination for a specific application is, in the catalog's words, the best guide to predict performance.

This article therefore treats wear life as experience-based, and uses the makers' rules to set margins and features, not to forecast a life. The maker documents are dated 2010, 2014, and 1997, and none is presented as current guidance (Renold REN16/ENG/10.10, p. 26; Rexnord 5050, 2014, p. 105).

Which chain families and ASME B29 standards is the choice made between?​

Several ASME B29 standards cover conveyor, mill, and drag chain families. This article cites them at standard level only, by title, scope description, and edition status:

  • ASME B29.12M-1997 (S2025) and B29.15M-1997 (S2025): steel bushed rollerless chains, and steel roller type conveyor chains, with their attachments and sprocket teeth. ASME's product pages state both were placed on stabilized maintenance in 2025 and remain in effect.
  • ASME B29.200-2001 (R2021): welded-steel-type mill chains and drag chains, attachments, and sprocket teeth, which ASME's page says was reaffirmed in 2021 and remains in effect.
  • ASME B29.400-2001 (S2025): combination and "H"-type mill chains and sprockets. The ANSI webstore marks the 2001 (S2025) listing as the most recent; it revises the 2001 (R2023) listing, and the edition is still the 2001 edition. Its description says it consolidates the former combination-chain and H-type mill-chain standards (B29.11M-1994 and B29.14M-1996).

The American Chain Association's Standard Handbook of Chains (2nd edition, 2005) is cited here at book level only. On the choice between cast and steel chain, Rexnord's catalog says cast chains in general do a good job in sliding applications and have excellent corrosion resistance. In critical applications where overloads may be encountered, it says engineered steel and welded steel chains will usually provide longer and more dependable service, and it recommends making the final selection from those listings. It does not recommend cast, cast combination, or welded steel chains for elevator service (ASME B29.12M-1997 S2025; ASME B29.15M-1997 S2025; ASME B29.200-2001 R2021; ASME B29.400-2001 S2025; American Chain Association 2005; Rexnord 5050, 2014, p. 109).

How do chain makers add margin for dirty and abrasive service?​

Renold and Rexnord add margin in different ways. Renold raises the factor of safety on breaking load. Its Table 1, which it calls a general guide, gives:

LubricationCleanModerately cleanDirtyAbrasive
Regular8101214
Occasional10121416
None12141618

Each increase, the guide says, lowers the pin/bush bearing pressure to improve chain life, and if an extremely abrasive material cannot be kept away from the chain, the bearing pressure must be reduced. The abrasion resistance of chain components can be improved by more sophisticated heat treatments at extra cost, but the guide calls reducing the bearing pressure the usual way of ensuring acceptable life. The guide also warns that a chain selected with a factor of safety of 8 on breaking load is in effect operating with as low as 4 on the material's yield, and 2 when the possible instantaneous overload on the drive is considered, since motors can deliver up to 200% of full-load torque for a short period.

Rexnord's 2014 conveyor procedure multiplies the static chain pull instead. Design working load is chain pull (Pm, for static conditions) × service factor × speed factor. For a multiple-strand conveyor, the result is also multiplied by 1.2 and divided by the number of strands, the 1.2 providing for unequal load sharing. Its service factors rise with duty, for 8–10 hours and 24 hours of daily operation respectively: 1.0 and 1.2 for uniform load (fewer than 5 starts a day under load, less than 5% of the load added at a time), 1.2 and 1.4 for moderate peaks (5 a day to 2 an hour, 5–20%), and 1.5 and 1.8 for high peaks (2 to 10 an hour, 20–40%), using the more severe category where the two parameters differ. Rexnord's +0.25 addition "for extremely wet or abrasive environments" is a note to its AGMA-based drive-chain service factors, not a step in the conveyor procedure.

As engineering reasoning, a Renold factor of safety on breaking load and a Rexnord design working load compared against a chain's working load are two different methods, and a factor from one should not be dropped into the other (Renold REN16/ENG/10.10, p. 26 and Table 1; Rexnord 5050, 2014, pp. 92, 108, and 109).

Which chain features resist abrasive wear and packing?​

Renold's Table 17 rates conveyed materials on an abrasive index of 1 (non-abrasive), 2 (mildly abrasive), or 3 (highly abrasive), and says its values are a guide only. It lists cement clinker, iron ore, dry silica sand, and loose coke at 3, and crushed limestone and wood bark and refuse at 2. Liner hardness and laboratory abrasion ranking are covered in the wear-liner article.

Tsubaki's guide says strong abrasive materials, such as sand, coke, metal particles, or substantial dust, may affect wear life by getting into the chain's working parts and its engagement with the sprockets. The guide's remedies for chain in general are working parts hardened to be harder than the foreign objects, and a larger chain to reduce bearing pressure and increase the abrasion-wear area. For conveyor chain it adds three design points:

  • Thicker bushings, to increase the abrasion-wear area.
  • Plates that slide on the rails rather than roll, because the bottom edge of the plate may accept much more abrasion wear than the area between the bushings and rollers.
  • Many small rollers in the equipment instead of rails, which it calls especially useful when conveying objects that cause significant wear.

Where particles get into the working clearances and stiffen the chain, Tsubaki lists seals and grease nipples, both limited in applicable size, and larger clearances so particles fall out, which it calls "the most common method". It also says bearing-roller and bearing-bush chains are very sensitive to particulate contamination and should have fixed seals.

Rexnord says conveyors operating in highly abrasive surroundings require hard bearing surfaces, which "would suggest a steel chain", while mildly abrasive or moderately corrosive conditions may make a cast chain the economical choice. Renold says block chain, with fewer moving parts, is used extensively in highly abrasive environments, though without rollers it slides on its side-plate edges, raising the power requirement through a higher friction factor. For excessive roller-bore wear caused by packing of abrasive particles, Renold's troubleshooting table says to minimise chain/material contact and "consider chain as pulling medium only" (U.S. Tsubaki 1997, The Complete Guide to Chain, §5.4.3, pp. 60 and 62; Rexnord 5050, 2014, p. 109; Renold REN16/ENG/10.10, pp. 19 and 43).

How should wear strips, liners, and sprockets be matched to the chain?​

Both the Renold and Rexnord texts say it is desirable for the chain to wear more slowly than the wear strips or liner, because the chain is the more critical and expensive part. They then add different detail on strip hardness:

  • Renold (2010). Wear strips should not be as hard as the chain running on them. Bright mild steel flats are satisfactory for most applications, and a harder material can be used under more arduous conditions. Low-friction plastics can be used where chains slide on their plate edges, but not where severe impact loads or abrasive conditions exist.
  • Rexnord (2014). For a new installation with no prior experience, a metal liner slightly softer than the chain protects the chain by making the liner wear first. Where wear is a problem, neglecting corrosion, the catalog says experience has shown that increasing the hardness of either the chain or the metallic wear strip in an abrasive environment should generally decrease the wear on both, and that lubrication, even if only water, will reduce wear. Wood and plastic liners should not be used where severe impacting loads exist or under extremely dirty conditions.

Both call for weld spatter, slag, metal filings, and scale to be removed from the conveyor, and Rexnord adds, before start-up, a no-load break-in with plenty of lubricant, generally 8–24 hours or until the mating surfaces are polished.

For sprockets, Renold's Table 10 gives cast iron for abrasion without shock, and 0.4% carbon steel with hardened teeth for abrasion with heavy shock loading. It notes that stainless steel is used in high-temperature or corrosive conditions, and that sprockets with removable tooth segments are particularly useful where tooth wear is much more rapid than chain wear, since segments can be replaced one at a time without disconnecting the chain. Liner plate hardness classes for bulk chutes and troughs are compared in the wear-liner article (Rexnord 5050, 2014, p. 105; Renold REN16/ENG/10.10, pp. 18 and 47, Table 10).

What does wet and corrosive service do to steel chain?​

When metal chains are splashed with water or pass through heated vapor, Tsubaki's guide says wear may increase from improper or insufficient lubrication, strength may fall from corrosive attack, and life may be shortened by rust or corrosion. Its remedies are a larger chain to decrease bearing pressure, a corrosive-reduction factor in the calculation, or plated or stainless steel chain. It also states that in wet applications stainless steel chains will wear less than engineered plastic chains. A chain exposed to an electrolytic liquid, such as sea or mine water, may develop pitting corrosion, electrocorrosion, or electrochemical corrosion. In general, corrosiveness changes with the strength and temperature of the liquid, and the guide's corrosion table is to be used only as a reference, with chains selected after thorough testing.

Renold's guide describes the mechanism in bearing terms:

  • Section and surface loss. Corrosion can reduce the side-plate section, and therefore chain strength, or pit the pin, bush, and roller surfaces. Pitting reduces bearing area, which raises bearing pressure and wear rate.
  • Abrasive products. Corrosion products introduced onto the bearing surfaces are themselves abrasive.
  • Cracking. Materials such as nitrates will cause the failure of stressed components by nitrate stress cracking.
  • Material table. Its Table 18 rates carbon steel, martensitic stainless (AISI 420 or similar), and austenitic stainless (AISI 316 or similar) from 1 (fully resistant) to 3 (not resistant): water 3/1/1, sea water 3/2/2, and brine 3/2/1. The guide says the table is for corrosion resistance only, and a material may be affected by other factors, such as abrasion.

Rexnord adds that corrosive atmospheres reduce the fatigue strength of component parts, and recommends chain with armor-cased pins in that case. Stainless grade choice for wet, washdown duty is covered in the wet-end corrosion and washdown article (U.S. Tsubaki 1997, The Complete Guide to Chain, §5.4.1 and §5.4.2, pp. 59–60; Renold REN16/ENG/10.10, p. 26 and Table 18, p. 59; Rexnord 5050, 2014, p. 109).

How is chain lubricated when it runs wet, dirty, or submerged?​

The three texts give specific cases:

  • Submerged chain. Renold notes that chains in sewage treatment works are frequently completely immersed and, apart from prelubrication, cannot be lubricated regularly. Such chains are selected to operate sacrificially, or special materials are chosen for a continuously wet environment. Where chains are accessible, the guide says grease-gun lubricated chains should be used with water-repellent grease, to periodically flush out old grease and contaminants.
  • Dusty chain. Renold says chain should be prelubricated with a suitable dry-film lubricant, to prevent dust adhering to the lubricant, and that grease-gun lubricated pins and bushes are most effective there. It warns that a molybdenum disulphide pre-treatment film is only a few microns thick and is eroded in abrasive conditions, and that too much lubricant is as harmful as too little.
  • Dirty chain. Rexnord says oil flow or brush lubrication is adequate under relatively clean conditions but ineffective in dirty conditions, where flush lubrication, flooding the chain, once per day is normally adequate. Under normal conditions, it says, chains with rollers are selected only when proper lubrication is possible.
  • Large-pitch chain generally. Tsubaki says large-pitch conveyor chain is usually shipped without lubrication or rust protection, must be oiled before start-up, and should be lubricated at least once a week during normal operation. It advises lubricating more often right after installation and in harsh conditions such as high speed, high load, or high temperature.

Renold also says an automatic lubricator should not be run continually unless the process continually washes lubricant off the chain (Renold REN16/ENG/10.10, pp. 10–12; Rexnord 5050, 2014, p. 117; U.S. Tsubaki 1997, The Complete Guide to Chain, §7.2.4, p. 81).

What happens to chain above its tempering limit?​

Tsubaki's guide lists the problems that may occur when heat-treated chains are run at temperatures higher than their tempering limits: increased wear from decreased hardness, improper lubrication from lubricant deterioration or carbonization, stiff joints and increased wear from oxide scale, and decreased strength. It says to pay special attention to chain composition and heat treatment above 250 °C. It gives its 304 stainless chain a maximum working temperature of 650 °C at low speeds, suggests its 316 stainless chain for an adequate margin there, reporting it has worked at low speed up to 700 °C, and says to consult the manufacturer above 400 °C.

Renold's guide gives temperature bands for block chain, which it says is often used for high-temperature applications where the chain cannot be protected from heat:

  • Up to 300 °C: low-carbon steel materials can be used for heat-treated components such as the pin.
  • 300 °C to 450 °C: materials with tempering temperatures above 450 °C must be used to avoid softening and loss of wearing properties.
  • Above 450 °C: either special heat-resistant steels, which it says are rarely economic in the small batches of block-chain production, or a sacrificial chain with a relatively short life.
  • Otherwise: the system design is examined for a way to protect the chain from the heat.

On scale, Chen and Yuen's review abstract states that iron oxidation above 700 °C follows the parabolic law with a three-layer hematite, magnetite, and wüstite scale; the abstract does not mention chain. As engineering reasoning read alongside Tsubaki's stiff-joint warning, a chain beside hot steel can collect scale shed by the product as well as grow its own. Scale and radiant heat on heavy transport equipment are covered in the ingot and hot-metal handling article (U.S. Tsubaki 1997, The Complete Guide to Chain, §5.1.1, p. 57; Renold REN16/ENG/10.10, p. 43; Chen and Yuen 2003, abstract).

How do chain makers derate chain for temperature, and why don't their figures transfer?​

Each maker publishes its own temperature adjustment, for its own chain and method:

  • Renold (2010), factor of safety on breaking load. With regular lubrication, 8 at −30 to +150 °C, 10 at 150–200 °C, and 12 at 200–300 °C. With occasional lubrication the figures are 10, 12, and 14, and with none they are 12, 14, and 16.
  • Rexnord (2014), conveyor service factor. 1.0 up to 200 °F (93 °C), 1.1 from 200 to 350 °F (93–177 °C), and 1.2 from 350 to 500 °F (177–260 °C); above 500 °F (260 °C), contact Rexnord. The same catalog's Step 4 says its selection procedure applies only if chain temperatures remain within −40 °F and +350 °F, and that special lubricants may be needed above 250 °F.
  • Tsubaki (1997), allowable load. Its Table 5.1 is for power-transmission roller chain with high-temperature lubricant: the catalog maximum allowable load up to 150 °C, three-quarters of it at 150–200 °C, one-half at 200–250 °C, and out of use over 250 °C.

These are three different quantities, and Tsubaki's applies to transmission chain. Rexnord's own service-factor table runs to 500 °F while its Step 4 limits the procedure to 350 °F, so a selection above 350 °F goes to the maker in any case. As engineering reasoning, the named failure mode is a hot-service selection built from one maker's temperature figure applied to another maker's method or chain type.

Lubricant choice changes with temperature too. Renold says that in high-temperature service (100–450 °C), a wet-film lubricant is generally used up to 160 °C, and a dry-film, non-carbonising lubricant is generally used above 160 °C, with a stated range of 0 to +450 °C for the molybdenum disulphide or graphite dry film (Renold REN16/ENG/10.10, p. 26 Table 1 and pp. 10–11; Rexnord 5050, 2014, pp. 108–109; U.S. Tsubaki 1997, The Complete Guide to Chain, Table 5.1, pp. 57–58).

Which guarding and maintenance rules apply to the chain drive?​

In US general industry, the conveyor's drive falls under OSHA's mechanical power-transmission section:

  • Enclosure. 29 CFR 1910.219(f)(3): all sprocket wheels and chains shall be enclosed unless they are more than seven (7) feet above the floor or platform. Where the drive extends over other machine or working areas, protection against falling shall be provided, and the paragraph does not apply to manually operated sprockets.
  • Oiling access. 1910.219(f)(4): when frequent oiling must be done, openings with hinged or sliding self-closing covers shall be provided. All points not readily accessible shall have oil feed tubes if lubricant is to be added while machinery is in motion.
  • Inspection and oiling. 1910.219(p)(1) requires power-transmission equipment to be inspected at intervals not exceeding 60 days and kept in good working condition at all times, and (p)(7) says machinery shall be oiled when not in motion, wherever possible.

The section covers mechanical power-transmission apparatus, including drive sprockets and chains. It does not say whether a conveyor's carrying strand is a power-transmission chain, so this article does not claim that it governs the conveying chain itself. Ingoing nip points are among the hazards named in the general machine-guarding requirement of 1910.212(a)(1), and conveyor-specific safety is the subject of ASME B20.1-2024. B20.1 is cited here at standard level only.

As engineering reasoning, chain work also involves stored energy in the tensioned strand. Renold's installation safety list says to always loosen tensioning devices and always support the chain to avoid sudden unexpected movement of chain or components. ISO 14118:2017 specifies requirements for designed-in means to prevent unexpected start-up, to allow safe human interventions in danger zones, for all energy sources (OSHA 29 CFR 1910.219; OSHA 29 CFR 1910.212-1974; ASME B20.1-2024; ISO 14118:2017; Renold REN16/ENG/10.10, p. 18).

What sensing and controls track chain condition in harsh service?​

Renold's guide says chain needs to be checked on a regular basis throughout its life, so that faults in the machine are detected at an early stage and rectification work can prevent further damage. Its troubleshooting table lists symptoms, and as engineering reasoning, several of them show in drive and motion signals before an inspection finds them: tight chain joints from material packed or frozen in the joints, chain whip from excessive slack or long centres with periodic on-loading, and fractured plates or pins from overload above breaking strength. For that last case, its solutions include investigating foreign objects causing jams and protecting the chain with a shear-pin device.

The intelligence layer below is this article's engineering practice, built on those symptoms, not a requirement of the cited sources:

  • Drive load. Motor current or drive torque trended at a known feed rate shows packing, frozen joints, and liner wear as a rising load, and an overload trip can stop the drive before a jam breaks the chain.
  • Motion. A zero-speed or motion sensor on the tail shaft detects a broken or derailed chain while the drive is still turning.
  • Temperature. A chain-zone temperature reading, checked against the maker's limit for the selection method used, such as the 350 °F limit on Rexnord's 2014 procedure.
  • Lubrication. Confirmation that a flush or automatic lubricator ran, with an alarm if it did not.
  • Logging. In Logix controllers, a periodic task performs a function at a specific time interval, which suits trending these values.

The drive and panel fall within IEC 60204-1:2016, which applies to electrical, electronic, and programmable electronic equipment and systems of machines not portable by hand while working. UTEC Industrial, a Rockwell Automation Recognized System Integrator, builds UL 508A control panels and integrates Allen-Bradley ControlLogix and CompactLogix controllers with VFD drives for this kind of monitoring (Renold REN16/ENG/10.10, pp. 12 and 19–20; Rockwell Automation 1756-RM094N-EN-P-2025, Ch. 5 p. 41; Rexnord 5050, 2014, p. 109; IEC 60204-1:2016).

Where does chain selection sit in the design-to-monitoring chain?​

As this article reads the chain, the steps around a bought chain set its life:

  • Design and engineering. As engineering reasoning, material, duty hours, and strand count set the chain family, the margin, and the running arrangement.
  • Parts machining. Renold says shafts should be of such proportions and strength that sprocket alignment remains unimpaired under load, with sizes selected taking into account combined bending and torsional moments. Where two or more strands side by side have to be matched, Renold says matched drive sprockets should be bored and keywayed as a set, and recommends a machine-cut tooth form as well, to ensure equal load sharing.
  • Fabrication, weld fatigue, and stress relief. As engineering reasoning, a frame that twists under load misaligns the sprockets and loads one strand more than the other, which Rexnord's 1.2 multi-strand factor exists to cover but cannot correct.
  • Drives, controls, tuning, and monitoring. As engineering practice, soft starting within the service-factor assumptions, overload protection, and the condition trends in the previous answer close the loop.

UTEC Industrial machines to tolerances as tight as ±0.001 in and performs automated vibratory stress relief, NDT, and CMM inspection on the frames and machined parts it builds, which is where shaft and sprocket alignment can be set and checked (Renold REN16/ENG/10.10, pp. 32 and 47; Rexnord 5050, 2014, p. 108).

What should a chain specification for wet, abrasive, or hot service state?​

UTEC Industrial has built heavy-duty conveyor systems for Kaiser Aluminum for aluminum production loads. A harsh-duty chain request should give the builder and chain maker the inputs their methods use:

  • The material. Abrasive index, moisture, corrosive constituents such as nitrates, and maximum temperature at the chain.
  • The duty. Hours per day, starts under load, share of load added at a time, chain speed, and strand count.
  • The environment. Wet, submerged, dusty, or hot, and whether lubrication is regular, occasional, or excluded.
  • The chain. The ASME B29 family where one applies, hardening or stainless material, sealing or clearance strategy, and the maker's margin method.
  • The wear parts. Wear-strip hardness relative to the chain, and sprocket material and tooth hardening.
  • Guarding and access. Drive enclosure under 1910.219(f)(3), oiling access under (f)(4), and the 60-day inspection under (p)(1).
  • Monitoring. Drive load, motion, temperature, and lubrication confirmation.

The margin and wear-part items trace to the makers' own texts, which this article cites as dated documents, not as current or general practice (Renold REN16/ENG/10.10, p. 26 and Table 1; Rexnord 5050, 2014, pp. 105 and 108; OSHA 29 CFR 1910.219).

Related Articles

References​

  • Renold REN16/ENG/10.10: Conveyor Chain Installation, Maintenance & Designer Guide. Renold Power Transmission, 2010.
  • Rexnord 5050: Rexnord and Link-Belt Engineered Steel Chains (Conveyor, Elevator & Drive Chains Catalog). Rexnord, 2014.
  • Otoshi K (supervising ed.), Kanehira M (ed.). The Complete Guide to Chain, 1st English ed. U.S. Tsubaki, 1997. ISBN 0-9658932-0-0.
  • ASME B29.12M-1997 (S2025): Steel Bushed Rollerless Chains, Attachments, and Sprocket Teeth. ASME, 1997.
  • ASME B29.15M-1997 (S2025): Steel Roller Type Conveyor Chains, Attachments, and Sprocket Teeth. ASME, 1997.
  • ASME B29.200-2001 (R2021): Welded-Steel-Type Mill Chains, Welded-Steel-Type Drag Chains, Attachments, and Sprocket Teeth. ASME, 2001.
  • ASME B29.400-2001 (S2025): Combination, "H"-Type Mill Chains, and Sprockets. ASME, 2001.
  • American Chain Association. Standard Handbook of Chains: Chains for Power Transmission and Material Handling, 2nd ed. CRC Press, 2005. ISBN 9781574446470.
  • Chen RY, Yuen WYD (2003). "Review of the High-Temperature Oxidation of Iron and Carbon Steels in Air or Oxygen." Oxidation of Metals, 59, 433-468.
  • OSHA 29 CFR 1910.219: Mechanical Power-Transmission Apparatus. U.S. Department of Labor, 1974 (as amended through 2004).
  • OSHA 29 CFR 1910.212-1974: General Requirements for All Machines. U.S. Department of Labor, 1974.
  • ASME B20.1-2024: Safety Standard for Conveyors and Related Equipment. ASME, 2024.
  • ISO 14118:2017: Safety of machinery — Prevention of unexpected start-up. International Organization for Standardization, 2017.
  • Rockwell Automation 1756-RM094N-EN-P-2025: Logix 5000 Controllers Design Considerations. Rockwell Automation, 2025.
  • IEC 60204-1:2016 (Ed. 6.0): Safety of Machinery -- Electrical Equipment of Machines -- Part 1: General Requirements. International Electrotechnical Commission, 2016.

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