When roller chains fail, production stalls, costs climb, and your maintenance team scrambles to restore order. Thankfully, the majority of these issues are preventable.

With over three decades of expertise supporting industries including mining, metals, food & beverage, timber, cement, and more, the team at B2K has pinpointed the five most frequent roller chain problems and their effective solutions:

1. Chain Elongation

The problem: The chain becomes longer over time due to wear on the pin and bushing, which affects sprocket engagement and causes misalignment.

Why it matters: Elongation leads to poor power transfer, excessive vibration, and eventual chain or sprocket failure.

How to fix it:

• Use high-quality chains designed for wear resistance (e.g., Elite chains by IWIS, available through B2K)
• Install an automatic lubrication system or implement a regular manual lubrication schedule
• Replace the chain before elongation exceeds 3% of its original length

 2. Improper Lubrication

The problem: Either too much, too little, or the wrong type of lubrication.

Why it matters: Poor lubrication is the #1 cause of premature chain wear.

How to fix it:

• Use a high-quality chain lubricant suited for your environment (food-safe, high-temp, etc)
• Lubricate the pin and bushing area – not just the outside plates
• For high-speed or dirty environments, consider sealed chains or automatic lubrication4

3. Misalignment

The problem: The sprockets are not correctly aligned, resulting in side loading and uneven wear on the chain.

Why it matters: Misalignment reduces chain life and can damage shafts, sprockets, and bearings.

How to fix it:

• Use a laser alignment tool during installation
• Regularly check sprocket alignment and shaft parallelism
• Replace worn or damaged sprockets before installing new chains

4. Shock Loading & Overload

The problem: The chain is exposed to high starting torque, jams, or sudden load changes.

Why it matters: Causes bent pins, cracked plates, or snapped chains, especially in mining or crushing equipment.

How to fix it:

• Use chains rated for heavy-duty loads (ask B2K about IWIS or Flexon high-strength chain options)
• Install a torque limiter or overload clutch to protect the system
• Regularly inspect chain components in high-shock environments

5. Corrosion or Contamination

The problem: Dust, water, chemicals, or extreme temperatures degrade the chain.

Why it matters: Corrosion and grit wear down components, increasing the risk of failure.

How to fix it:

• Use corrosion-resistant chains (e.g., stainless steel or nickel-plated)
• Shield the chain using covers or guards in dirty or wet environments
• Clean and re-lubricate the chain if exposed to harsh conditions

How B2K Makes a Difference

• Local stock of premium chains from trusted brands such as IWIS’s Elite, JWIS, and Flexon ranges
• Expert advice on chain selection, setup, and maintenance
• Engineering support for chain drives and complete transmission systems
• Same-day delivery to get you up and running faster
• Need help with a chain problem? Our team is ready to assist you with troubleshooting

Contact us today!