Escolar Documentos
Profissional Documentos
Cultura Documentos
CONVEYOR AND
ELEVATOR BELT
HANDBOOK
2011 by the Association for Rubber Products Manufacturers, Inc.
Published in the United States of America
RMA First Edition 1973
RMA Second Edition 1980
RMA Third Edition 1989
ARPM Fourth Edition 2011
INTRODUCTION
PREFACE
Conveyor and elevator belts are made to precise specifications and standards to service many useful functions. A better understanding
of the complexities involved in manufacturing belting and the standards that are applied to it will be helpful in selecting the proper belt
for the intended use and in obtaining good service after installation.
Belting covered in this Handbook includes conveyor belting, used to transport bulk or packaged, boxed and bagged materials, and
bucket elevator belting. The belting may be made of natural and synthetic rubbers as well as plastics, such as vinyl, with carcasses of
textile fabrics, which are woven, nonwoven, solid woven, or stitched; fabric cords; or of steel cables.
This handbook is intended for the general guidance and reference of persons interested in the selection and use of conveyor and
elevator belting, but readers are urged to consult individual manufacturers for specific information and recommendations.
ACKNOWLEDGMENT
The Association for Rubber Products Manufacturers is the national trade association of the non-tire rubber manufacturing
industry in the United States. ARPM represents manufacturers of finished rubber products (excluding tires), and their related
suppliers. This publication is provided as a public service, and reference for users of conveyor belt products by U.S.
manufacturers of conveyor belt products, including:
Airboss Compounding Rubber (NC)
Fenner Dunlop Americas (Pittsburgh, PA)
Garlock Rubber Technologies (Paragould, AR)
Price Rubber Corp. (Montgomery, AL)
Veyance Technologies Inc. (Fairlawn, OH)
TABLE OF CONTENTS
Page
PREFACE..................................................................................................................................................................................................2
ACKNOWLEDGMENT...........................................................................................................................................................................2
CHAPTER 1 - MATERIALS...................................................................................................................................................................4
CHAPTER 2 - ELASTOMER CHARACTERISTICS........................................................................................................................11
CHAPTER 3 - TEXTILE BELT TYPES AND MANUFACTURING METHODS..........................................................................18
CHAPTER 4 - TEXTILE BELT CHARACTERISTICS AND BELT RATINGS.............................................................................23
CHAPTER 5 - TEXTILE BELT TOLERANCES................................................................................................................................35
CHAPTER 6 - TEXTILE BELT TEST METHODS............................................................................................................................36
CHAPTER 7 - SPLICING CONVEYOR AND ELEVATOR BELTS................................................................................................40
CHAPTER 8 - STEEL CORD BELT TYPES AND MANUFACTURING METHODS..................................................................51
CHAPTER 9 - STEEL CORD BELT CHARACTERISTICS & BELT RATINGS..........................................................................53
CHAPTER 10 - STEEL CORD BELT TOLERANCES......................................................................................................................56
CHAPTER 11 - STEEL CORD BELT TEST METHODS..................................................................................................................58
CHAPTER 12 PART A - SPLICING FABRIC CORD CONVEYOR BELTS..................................................................................61
CHAPTER 12 PART B - SPLICING STEEL CORD CONVEYOR BELTS.....................................................................................75
CHAPTER 13 - BELT MONITORING.................................................................................................................................................91
CHAPTER 14 - OPERATION AND MAINTENANCE......................................................................................................................96
CHAPTER 15 - STORAGE OF BELTING........................................................................................................................................112
CHAPTER 16 - GLOSSARY OF CONVEYOR BELTING TERMS...............................................................................................113
CHAPTER 17 - USEFUL TABLES.....................................................................................................................................................130
APPENDIX............................................................................................................................................................................................136
CHAPTER 1
MATERIALS
INTRODUCTION
The purpose of this chapter is to present general descriptions of the construction elements of conveyor belts and the materials which
are presently available to produce belts for the various materials conveyed with suitable strength for the tensions and other conditions
encountered in service. Conveyor belts are sometimes classified as Light and Heavy Weight belts.
Light Weight = RMBT* < 160 PIW
Heavy Weight = RMBT > 160 PIW
*RMBT = Rated Maximum Belt Tension, in pounds per inch width (PIW)
Light weight belting generally is used in very diverse applications such as food and tobacco products, agricultural products, wood
products, baggage and packaging handling, metal stampings, and materials handling in the textile, printing, paper processing, postal,
and electronics industries. Heavy weight belting generally conveys heavy and/or coarse abrasive materials like mineral ore, rock, sand,
gravel, coal, and cement.
In general, most conveyor belts consist of three elements: a top cover or conveying surface; a carcass; and a bottom cover, or pulley
surface. In light weight belting there is a great diversity among the top cover or conveying surfaces used such as smooth or rough
covers and raised patterns; whereas heavy weight belting often has smooth top covers. Custom fabrications with light weight belting
are also more common, including attaching of cleats or V guides or hole punching, for example.
The elements may also be grouped under several general classifications such as: elastomers; fabrics (woven or non-woven); spun;
filament, or monofilament yarn or cord; and steel cords.
A rubber or plastic elastomer is a compounded material that returns rapidly to approximately its initial dimensions and shape after
substantial deformation by a weak stress less than the yield point.
A fiber is a unit of matter having a length at least 100 times its diameter and which can be spun into a yarn.
A steel cord, when used as the tension member, is usually multiple strands of steel wire twisted together.
Yarn is a generic term for continuous strands of textile fibers or filaments.
A fabric is a planar textile structure produced by interlacing yarns, fibers, or filaments. A fabric may be composed of yarns of cotton,
glass, nylon, polyester, steel or other materials. A fabric may be made from one material or a combination of materials.
RUBBER/PLASTIC ELASTOMERS
Polymers are mixed with various chemicals to obtain reinforcement and develop the physical properties of the resulting elastomer
necessary for meeting service conditions. Since it is not the purpose for this Handbook to discuss compounding ingredients or methods
of compounding, discussion of polymers will be restricted to the general properties of the basic polymers.
A wide choice of polymers is available. They can also be blended together to obtain many combinations with intermediate properties.
Elastomeric compounds are used for the top and bottom covers or surfaces of conveyor belting and for bonding together components
of the belt carcass. The elastomeric covering on belts is there to provide protection for the carcass and/or provide a specific property.
The coverings are applied by several processes, depending on the material (rubber vs. thermoplastic) or thickness of the covering.
It is possible to classify elastomers to some extent by the basic polymer used. They are listed in Table 1-1 with a brief description of
their general properties.
Table 1-1.
Rubber/Plastic Polymers Used in Belting
Common Name
ASTM
Designation
D 1418-10
Composition
General Properties
Acrylic
ABR
Acrylate-butadiene
Brominated Butyl
BIIR
Bromo-isobuteneisoprene
Butyl
IIR
Isobutene- isoprene
Chlorinated Butyl
CIIR
Chloro-isobuteneisoprene
EPDM
EPDM
Ethylene-propylenediene terpolymer
Ethylene Propylene
EPR
Ethylene-propylene
Hydrin*
CO
Polychloromethyloxirane
Hydrin*
ECO
Hypalon*
CSM
Chloro-sulfonyl-polyethylene
Hytrel*
PET
Polyethylene
Terephthalate
Natural Rubber
NR
Rubber, Natural
Neoprene*
CR
Chloroprene
Nitrile
NBR
Nitrile-butadiene
Polybutadiene
BR
Butadiene
Polyisoprene
IR
Isoprene, synthetic
SBR
SBR
Styrene-butadiene
Silicone
VMQ
Modifiedpolysiloxanes
Common Name
Common
Name
ASTM Designation
Designation
ASTM
D 1418-10
D 1418-10
Composition
Composition
General Comments
General
Comments
Urethane
AU
Polyester
Urethane
Urethane
EU
Polyether
Urethane
Vinyl
PVC
Polyvinyl
Chloride
Viton*
FKM
Fluorocarbon
Teflon*
see manufacturer
Polymers
*Trade Names
TEXTILES
Many types of textiles are used in conveyor and elevator belting. Their use is based on their physical properties, such as strength,
elongation, dynamic fatigue resistance, aging resistance, mildew resistance, heat resistance, and other special properties depending on
service requirements. For special applications, consult the manufacturer.
Yarns used for belt textile reinforcement are classified as either spun or filament depending on whether the base fiber is in staple (3/4
- 2 1/2 in long single fiber) or endless filament form.
A spun yarn is made by twisting relatively short lengths of staple fiber together to form a continuous yarn, called a singles yarn.
When two or more of these singles yarns are twisted together, the result is a plied yarn. When two a more plied yarns are twisted
together, the result is cable cord. The tensile strength, elongation, and thickness of a yarn of any fiber type can be changed by varying
twist, size and number of singles yarns included. Spun yarns may be made from natural or synthetic fibers.
Spun yarn sizes are designated by the number of hanks of yarn it takes to weigh one pound. In the cotton system, one hank is 840
yards (770 m) long. One pound of a 12s cotton yarn is:
12 x 840 yd (770 m) = 10,080 yd (9217 m) long
A filament yarn is produced by extruding synthetic materials through an orifice in a continuous process. A single filament is called a
monofilament. A number of small filaments are combined to form a multifilament yarn, which is normally called a filament yarn.
Filament yarns are stronger than the same-size spun yarns of the same synthetic material.
Filament yarns are designated by a denier number which is the weight in grams of 9000 meters of yarn, or a decitex number, which is
the weight in grams of 100 meters of yarn.. Thus a 1650 denier yarn will weigh 1650 grams per 9000 meters.
Table 1-2 provides information on some of the fiber yarns used in belting fabrics or cords.
Table 1-2.
Some Materials Used in Belting Reinforcement
Common Name
Composition
General Comments
Cotton
Natural Cellulose
Glass
Glass
Kevlar*
Aramid
Nomex*
Aramid
Nylon
Polyamide
Polyester
Polyester
Steel Cord
Steel
*Trade Name
TEXTILE REINFORCEMENTS
Textile fabrics are the most commonly used materials for reinforcing plies in conveyor and elevator belting. Textile fabrics are also
used for conveyor belt breakers plies. Fabric properties are governed by the yarn material and size and by the fabric construction
and weave.
Fabric is made of warp yarns, which run lengthwise, and filling (weft) yarns, which run crosswise, as the fabric is woven, usually at
right angles to each other.
Non-woven fabric is a mat of fibers bonded together chemically and/or needle-punched, usually to a single-ply of woven scrim.
The most common, and least complicated, fabric pattern used for flat belts is the plain weave, Figure 1-1. In this construction the warp
and filling yarns cross each other alternately. A belt with two or more of these plies of fabric is known as a multi-ply belt. Other
common constructions used to a lesser degree include broken twill, Figure 1-2 and Leno weave, Figure 1-3, which has an open mesh
and is usually used for a breaker fabric.
Solid woven, Figure 1-4, consists of interwoven multiple layers of warp and filling yarns.
Straight warp weave, Figure 1-5, contains basic tension-bearing warp yarns which are essentially straight, that is, without crimp.
Also, binder warp yarns are interwoven with the filling yarns to provide mechanical fastener holding strength. Some of the most
commonly used belting fabrics known by their major fiber content are:
Cotton - A fabric with cotton in both the warp and filling yarns.
Cotton-Synthetic - A fabric with cotton warp yarns and synthetic filling yarns or a fabric with cotton/synthetic blended warp and/or
filling yarns. The synthetics most commonly used are nylon, and polyester.
Polyester - A fabric with polyester fiber warp yarns and filling yarns.
Nylon - A fabric with nylon fiber warp and filling yarns.
STEEL REINFORCEMENTS
Steel Cord
Steel cord is used in belting where the properties of steel cord reinforcement are better able to satisfy the requirements of the service
conditions. Steel cord is used to obtain high strength, excellent length stability, low bending stresses and, in some cases, to provide
superior troughing characteristics. The wires, or filaments, used in conveyor belt steel cords are usually made of high carbon steel and
have a surface finish to facilitate adhesion to the surrounding rubber, and provide protection against corrosion. Common constructions
are 7 x 7, Figure 1-6, and 7 x 19, Figure 1-7, although many other constructions are possible.
Steel cords used in conveyor belts are specially manufactured from high carbon steel to meet the high strength requirements demanded
of these belts. The cord is fabricated from strands of wires, or filaments, twisted together. This gives the cord good flexibility and
fatigue resistance when subjected to cyclic loading and bending around pulleys. Two common constructions are illustrated in Figures
1-6 and 1-7.
In order to protect the steel from corrosion, zinc or brass coatings are applied to the wire before drawing it to the final filament size.
Zinc is the most commonly used coating. Typically, the minimum zinc coating expressed in grams per square millimeter is 60 times
the filament size in millimeters.
During belt manufacture, the steel cord is encapsulated in a special core rubber that normally has properties different to the belt
covers. It is important during manufacture that the core rubber penetrates right to the center of the steel cord as this stops adjacent
filaments from contacting one another and fretting during bending and stretching of the cord in service. Once embedded in the core
rubber, the cord strength increases by up to 5% and it becomes less likely to suffer from corrosion caused by water penetrating the
cord. The effectiveness of the rubber penetration can be determined by a special test (AS 1333) which measures if there is any loss in
air pressure along the cord when air is applied to one end of the cord at 14.5 psi (1 bar), and maintained for 1 minute on a 16 in long
belt sample. 5% is the maximum acceptable pressure loss.
Core rubber to cord adhesion should be adequate to maintain the belt and its splices integrity during its normal service life.
Due to the very specialized nature of this cord and the difficulties in manufacturing cord to achieve these properties, there are only a
few manufacturers in the world producing steel cord for conveyor belts.
Other Wire Components
Several other forms of wire are used in belting for special purposes, such as rip resistance and transverse stiffness. A variety of wire
structures are used, some of which include: (1) steel filling leno weave breakers, (2) straight warp steel fabrics.
10
CHAPTER 2
ELASTOMER CHARACTERISTICS
HEAVY WEIGHT CONVEYOR BELT
RUBBER COVER CHARACTERISTICS AND CLASSIFICATIONS
Elastomeric covers for general purpose conveyor belts with textile/cord reinforced carcasses will be defined as either Grade 1 or Grade
2. The properties, test values and minimum requirements described below can serve as a guideline for acceptable performance in most
general purpose applications. It is recognized however that there is no direct correlation between test results and the performance of
the belt in service. The test values as outlined are recognized as obtained from new or factory condition belting.
Reference Documents
ASTM D 378
ASTM D 412
Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers -- Tension
ABRASION RESISTANCE
As per RMAs description and classification for both Grade 1 and 2 belt covers; both of these cover types will provide good to
excellent abrasion resistance. There are several specific tests used by manufacturers to determine the relative abrasion resistance of
different cover formulations. The most common is ISO 4649 (DIN 53516).
While there are no specific U.S. industry limits, maximum or minimum, for test results from abrasion test for General Purpose (ARPM
Grades 1 & 2) Belt Covers; there is enough data to suggest acceptable abrasion values.
11
A customer preparing to purchase a conveyor belt for abrasion service should, therefore, proceed as follows:
1. Describe as accurately as possible the conditions under which the belt will operate, the nature and composition of the material being
carried, the range of particle size, loading conditions, and tons per hour being handled. In those instances where a replacement belt
is being ordered, indicate in as complete detail as possible the construction of the belt being replaced and describe the nature of its
failure.
2. Point out any condition which might accelerate cover wear, such as excessive heat, moisture, or the presence of oil or other solvents
in the installation.
Table 2-1. Properties of Covers
Grade
Minimum Tensile
Strength (p.s.i.)
Minimum Tensile
Strength (MPa)
Minimum Elongation
at Break (%)
2500 p.s.i.
17 MPa
400%
125 mm3
2000 p.s.i.
14 MPa
400%
175 mm3
5 kN/m
3 kN/m
5 kN/m
COVER THICKNESS
Top Cover Thickness
The major function of a heavy weight belt cover is to protect the strength-bearing carcass from wear or damage during the life of the
belt.
In a light weight belt, the cover functions also to provide the required degree of sanitation in food contact applications or the desired
friction characteristics, or the required surface characteristics for incline/decline conveying.
The cover thickness required for a specific belt is a function of the material conveyed and the handling methods used.
Increased cover thickness is required as the conditions become more severe: e.g. material abrasiveness, maximum lump size of
material, material weight, height of material dropped onto the belt, loading angle, belt speed, frequency of loading, etc. The following
table shows the suggested minimum belt cover thicknesses for favorable conditions. Wear rates with identical material under adverse
loading conditions have been observed to be as much as 6 times the wear rate under favorable conditions.
Grade 1 - Top Cover Thickness
Grade 1 covers should be considered for heavy crushed material over 3 in (75 mm) and when large lumps occur if cut or gouge
resistance is the main design criteria. Consult the manufacturer for cover thicknesses.
Grade 2 - Top Cover Thickness (Table 2-3)
Table 2-3. Guide for Minimum Top Cover Thicknesses Under Favorable Conditions for Grade 1 and Grade 2 Belting
Note: Cover thicknesses are nominal values subject to manufacturers tolerances.
Table 2-3
Class of Material
Examples
Minimum Thickness
in
mm
Package handling
1/16
1.5
1/8
1/8
3/16
12
Figure 2-1.
Protective covering for cords during the entire belt life. (A = 2F + D)
Amount of top cover used for the service life of the belt.
Amount of bottom cover used for the service life of the belt.
Diameter of the cord.
Rubber encapsulating the steel cords and especially compounded for compatibility with the cover rubber and bonding to the steel
cords.
F = Thickness of rubber to protect the cords during service. This protective rubber is not part of the top or bottom wear covers used
to estimate belt tonnage.
A=
B=
C=
D=
E=
Cord Diameter
Minimum Thickness F
(above & below cords)
mm
mm
in
4.1
5.6
8.3
9.5
3.5
3.9
5.8
5.8*
0.137
0.157
0.228
0.228
* This value has been lowered from the calculated 6.6 mm as a result of favorable field experience. For thickness of
covers B and C consult belt manufacturer.
Note: Minimum thickness of protective rubber F should not be less than 3.5 mm or 0.7 times the cord diameter,
whichever is greater.For larger diameter cords contact manufacturer.
13
Operating Conditions
in
mm
Abrasive materials
1/32
*Impact loading
3/32
2.5
* Increased cover thickness helps protect the carcass; however, if impact is severe, the complete system design, including carcass construction, top cover thickness, and
impact rolls in the conveyor, must be considered.
Note: Cover thicknesses are nominal values subject to manufacturers tolerances.
14
Test Method
Friction (Coefficient)
ASTM D 1894 -- Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Filmand
Sheeting
Flame Resistance
ASTM D378 13.1 (MSHA -- 30 CFR: part 14) ASTM D378 13.2 Heat Resistance
Heat Resistance
ASTM D 865 -- Standard Test Method for Rubber-Deterioration by Heating in Air (Test Tube
Enclosure)
Heat Resistance
ISO 4195-1 -- Conveyor belts -- Heat resistance -- Part 1: Test method; ISO 4195-2 -- Conveyor belts -Heat resistance -- Part 2: Specifications
Low Temperature
ASTM D 2136 -- Standard Test Method for Coated Fabrics -- Low Temperature Bend Test
Low Temperature
ASTM D 2137 -- Standard Test Methods for Rubber Property -- Brittleness Point of Flexible Polymersand Coated Fabrics
ASTM D 471 -- Standard Test Method for Rubber Property -- Effect of Liquids
Ozone
ASTM D 1149 -- Standard Test Method for Rubber Deterioration -- Surface Ozone Cracking in a
Chamber
Tear Resistance
ASTM D 624 -- Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and
Thermoplastic Elastomers
ASTM #1 Oil
MOR / VOR
Moderate / Vegetable Oil Resistant
15% Max.
140% Max.
EOR / SOR
Extreme Oil Resistance
5% Max.
30% Max.
MOR / VOR - Belting is designed to resist swelling and deterioration from vegetable based oils as well as light (napthenic / paraffin /
low aromatic) petroleum oils.
EOR / SOR - Belting is designed for use in extremely oily environments, especially where polar aromatic materials are expected to be
encoutered. Depending on temperature requirements and manufacturers recommendations, this class of belt may be suitable in Hot
Asphalt applications. Additionally, in coal fired power generation facilities where the fuel is being enriched with petroleum waste oils
or fuel / diesel oils, this may be the belt type required. Consult the manufacturer for recommendations when abnormal conditions are
anticipated.
Most of the cover formulations for belting meeting these classifications will be comprised of, or contain a certain percentage of, one
or more of the following polymers: CR (Polychloroprene / Neoprene), NBR (Nitrile), PVC, Urethane (AU / EU), CPE (Chlorinated
Polyethylene) or other oil resistant types listed in Table 1-1.
15
Retained Elongation
from original
ARPM-HR Class 1
212F (100C)
-25% (max.)
-50% (max.)
+20 (max.)
ARPM-HR Class 2
257F (125C)
-30% (max.)
-50% (max.)
+20 (max.)
ARPM-HR Class 3
302F (150C)
-40% (max.)
-60% (max.)
+20 (max.)
ISO 4195 is referenced as another testing and classification tool. While the classifications and value limits are similar between these
tests, they differ in both time of exposure (70 hr vs. 168 hr) and method of sample preparation. ISO 4195 calls for the entire belt
sample to be exposed, with test specimens to be cut / prepared from the exposed belt samples. ASTM D 865 allows for test
specimens to be prepared before exposure. The correlation between these methods has not been determined and differences are
expected, since the mass of ASTM sample is small relative to the dimensionally large ISO sample size. Hence the shorter time of
exposure per the ASTM / ARPM protocol.
While these tests and classifications do not validate product usefulness or acceptability in specific environments, they are used as
tools by the industry to more narrowly define criteria for applications involving elevated temperatures. It must be noted that
temperature alone may not be the overriding / determining factor in product suitability. Certain conveyed materials may degrade
various elastomers at test temperatures that the elastomers may be expected to perform based on test conditions. Consult the belt
manufacturer for specific recommendations.
Method (Time)
ASTM D378 13:1
Burner (5 min)
ASTM D378 13:2
Bunsen Burner (1 min)
Pass Criteria
Some undamage belt in
each sample
Flame out average < 1 min
No afterglow after 3 min
A wide variety of flame tests for conveyor belts exists throughout the world. The standard used in a particular country is usually
dictated by a national or local governing body. For general flame resistant conveyor belting, the selection of the most suitable quality
may be made by the ARPM-FR class designations.
ARPM-FR Class I
Based on the December 31, 2008 U.S. Mine Safety & Health Administrations (MSHA), CFR Title 30 Section 14, Requirements for
the Approval of Flame-Resistant Conveyor Belts, also known as the Belt Evaluation Laboratory Test or BELT test, this new
ARPM-FR standard provides a flame resistance quality that is currently mandated by MSHA in the USA for underground coal mines.
This belt quality is appropriate for belts that require flame resistance and which are included in the December 31, 2008 CFR, Title 30,
Mineral Resources, Section 14, which primarily applies to conveyor belts used in underground coal mines.
The test procedure is described in ASTM D 378 Section 13.1 and employs 60 in x 9 in sized belt test samples. Following the original
MSHA guidelines, the acceptance criteria for three belt samples tested to this ARPM-FR Class I standard is each tested sample must
exhibit an undamaged portion across its entire width.
16
ARPM-FR Class II
Based on the pre - December 31, 2008 U.S. Mine Safety & Health Administrations (MSHA), CFR Title 30 Section 18.65,
Requirements for the Approval of Flame-Resistant Conveyor Belts, also known as the 2G test, this new ARPM-FR standard
provides a basic flame resistance quality that was formerly mandated by MSHA and was used successfully in the USA for many years.
This belt quality is appropriate for belts, such as above ground belts, that require flame resistance and which are not included in the
December 31, 2008 Code of Federal Regulations, Title 30, Mineral resources, Section 14, which primarily applies to conveyor belts
used in underground coal mines.
The test procedure is described in ASTM D 378 Section 13.2 and employs 6 in x 0.5 in sized belt test samples.Following the original
MSHA guidelines, the acceptance criteria for belt samples tested to this ARPM-FR Grade II standard is defined as the tests of four
specimens cut from any belt sample shall not result in, either duration of flame exceeding an average of 1 minute after removal of the
applied flame, or the continuation of visible glowing of a specimen after flaming has ceased (afterglow) exceeding an average of 3
minutes duration.
ARPM-FR Class Test Responsibility
Each belt manufacturer is responsible to ensure tests are conducted to the appropriate ARPM-FR class specification on each belt order
claiming the ARPM-FR class quality. Tests may be witnessed at any time by the customer or his representative to ensure compliance
to the test standard.
Marking
A ARPM-FR class conveyor belt must be permanently and legibly marked with the appropriate ARPM-FR class designation (and/or
MSHA approval number for ARPM-FR Class I) for the service life of the product. The marking must be at least 0.5 in (1.27 cm) high
and placed at intervals not to exceed 60 ft (18.3 m) repeated once every foot (.3 m) across the width of the belt. Records of the initial
sale of each belt order having the ARPM-FR class marking and actual test conditions and test results must be retained for at least 5
years.
Effective December 31, 2008, the United States changed the minimum standard for flame performance of underground coal mine conveyor testing.
Until December 31, 2009 conveyor belts placed in service in underground coal mines shall be either approved under Part 14; or accepted under Part 18.
Part 18, is an old MSHA standard, Code of Federal Regulations, Title 30, Mineral Resources, Section 18.65, Flame Testing of Conveyor Belting and
Hose. Part 18 is commonly known as 2G. Effective December 31, 2009 conveyor belts placed in service in underground coal mines shall be approved
under Part 14. If MSHA determines that Part 14 approved belt is not available, the Agency will consider an extension of the effective date. Effective
December 31, 2018 all conveyor belts used in underground coal mines shall be approved under Part 14.
Effective December 2, 2005, in Canada, the CAN/CSA M422 M87 Fire Performance and Antistatic Requirements for Conveyor Belting standard was
withdrawn. Formerly this standard was the minimum standard for flame performance and electrostatic conductance for underground belting which was
tested in accordance with the CAN/CSA M422 M87 Fire Performance and Antistatic Requirements for Conveyor Belting by Energy, Mines and
Resources, Canada, Canadian Explosives Atmospheres Laboratory. They formerly assigned an approval number for each different belt which number,
together with other information in M422, which was branded on the belt at least once every 15m (approx. 50). Conformance to the M422 specification
about branding was enforced by Provincial Regulatory Agencies.
17
CHAPTER 3
INTRODUCTION
This chapter describes types of textile belting in terms of carcass types and of edge protection. This will be followed by a description
of belt cover designs and textile belt manufacturing methods.
Figure 3-1.
Textile Fabric -- Multi-Ply Belt Shown with Three Fabric Plies and Cut Edges*
* Refer to Glossary for definition of cut and slit edges..
Solid Woven Carcass
Solid woven belting consists of a single ply carcass made up of multiple layers of warp and filling yarns interwoven. The carcass is
usually impregnated and/or coated with thermoplastic compounds.
18
Figure 3-2.
Multi-Ply Belt Shown with Four Plies of Reinforcing Fabric, A Breaker Ply, Covers and Rubber-Capped Edges
Cut/Slit Edge Belting
The general use of nylon and polyester yarn for conveyor belt carcasses has eliminated the concern for protecting the belt carcass with
molded edges. The nylon and polyester fibers are resistant to mildew attack and the polyester to most chemicals. Thus most belting is
now supplied with slit edges.
CARCASS PROTECTION
Breaker
Before the use of nylon and polyester carcass fabric, breaker plies of open texture leno weave cotton or nylon yarn were frequently
used between the carrying cover and the belt carcass. It was believed a breaker ply improved the adhesion of the cover. The breaker
ply next to the carcass improved cover cut and gouge resistance and provided material loading impact resistance. Breaker plies are
used where severe impact conditions exist. Sometimes a breaker fabric in a molded edge is wrapped around the fabric edge to provide
edge protection.
19
20
Release Coating
After applying the last cover, a light coat of release agent, is applied to one or both surfaces of the belt. This is done to prevent the
unvulcanized belt from sticking in the roll before cure and to help in stripping the belt from the press surface after cure.
After release coating and before curing, the cover is usually perforated with fine pricker needles to help release gases that may be
present withing the body of the belt. These holes are completely sealed during the vulcanization operation.
Curing
The belt is vulcanized in either a flat platen press (index cure) or a rotary press (continuous cure). In either case, curing is done at a
temperature in the range of 280-320F (140-160C) while under pressure. Edge irons or rings are set at the desired belt width to retain
and/or mold the rubber covered edges.
Since it is essential that a small excess of material be present to create proper pressure during cure, a small overflow of cover occurs
at the side retaining irons. This is removed by trimming or buffing as the cured belt comes from the press. Slab belts which are slit to
width have the entire edge cut away during a subsequent operation.
Tension is generally applied to the belt during cure so that the elongation of the finished product is within acceptable limits.
Branding of the belt with the manufacturers name, grade or type of belt, and date of manufacture is generally accomplished by
placing a metal stencil on the uncured belt at regular intervals. This produces an embossed label cured onto the surface.
Slitting
Slab belting is slit to the final width after it is cured. Full-width rubberized fabric is used to build the carcass.
21
22
CHAPTER 4
INTRODUCTION
The tension rating for a belt is the recommended maximum safe working stress that can be applied to the belt.
Belt tension is commonly referred to as the force applied to the belt per unit of belt width, such as Pounds per Inch width (PIW), or
Kilo Newtons per Meter width (kN/m). Textile fabrics are frequently rated for their maximum safe working stress which is expressed
as the force applied per ply of fabric per unit width of the belt.
There is variation among manufacturers about the following information that relates to number of plies of fabric, belt carcass
thickness, minimum pulley diameter, troughability, etc., to the belt maximum safe working stress because of differences in materials
and manufacturing methods.
Some key differences which exist are:
1.The fiber, polyester and/or nylon, used for the fabric.
2.Recommended safe working strength for the fabric used.
3.Ratio of belt breaking strength to belt maximum safe working stress (safety factor).
These factors also affect the belt carcass thickness, belt weight, minimum pulley diameter, troughability, load support with different
angle idlers, transition distance, impact resistance, etc. Thus, it is essential to confer with the belt manufacturer about the belt proposed
for each application.
23
Safety Factors
Conveyor belt operating tensions are chosen as a small percentage of the belts breaking strength. This provides spare strength for (1)
temporary higher transient loads such as during starting and stopping, (2) handling unusual system loads such as misalignments or
frozen idlers, and (3) loss of strength due to materials aging and other degradation factors. The ratio of original belt strength to
operating tension is called the belts Safety Factor. Traditionally, the conveyor industry has used safety factors around 10:1 for fabric
belts and around 6.7:1 for steel cord belts, however, higher and lower factors are common. It is recommended to contact the belt
manufacturer for a safety factor recommendation for a specific application.
In recent years, studies have linked a belts safety factor to its dynamic splice strength and tests have been developed to measure the
dynamic strength of the splice. There are now international standards, such as DIN 22110, that define how the dynamic splice strength
can be measured. There are also standards, such as DIN 22101, that provide a method to calculate the safety factor for a belt. A general
guideline is that fabric belt splices have a dynamic splice efficiency of 35% of the belts breaking strength and steel cord belt have
45%. In practice, many conveyor belts deteriorate due to abuse or accidental damage and historical data should always be considered
when selecting a safety factor. Other factors that should be considered when selecting a belts safety factor include the effects of a
catastrophic belt break. For example, personnel safety, loss of production, clean up cost, repair time, accessibility of the belt for repair,
and availability of repair labor and materials. There are examples where a critical conveyor belt has broken due to loss of strength
from accidental damage combined with a high peak transient load. Such events can cost millions of dollars of lost production. The
recent availability of cord monitoring systems for conveyor belts offers improved capability of accidental damage surveillance in steel
cord belts. When used correctly, such systems offer additional safeguards for the operation of belts with lower safety factors.
24
220
2
.12
250
2
.146
330
3
.16
375
3
.20
400
2
.182
440
4
.220
500
4
.254
600
3
.258
750
3
.27
800
4
.265
1000
4
.28
1000
5
.335
1200
6
.38
.70
.81
.94
1.12
1.02
1.3
1.39
1.42
.135
.125
.141
.165
.188
16
14
24
20
24
20
24
20
22
24
30
20
30
24
36
24
42
30
10
10
12
14
12
18
18
18
20
16
20
20
24
To 40%
10
10
12
12
10
16
16
16
18
14
18
18
20
18
24
18
24
30
24
36
24
30
24
30
36
30
36
30
36
30
36
42
36
42
Maximum Belt Width (in) for Empty Troughing
36
30
36
42
36
42
48
42
48
NR
42
48
TROUGHABILITY
Idler Troughing
Angle
20
35
45
18
24
30
48
48
54
48
60
60
72
60
60
54
72
66
84
72
84
72
84
72
72
72
84
72
84
84
84
84
81-120
42
42
54
54
48
60
72
72
72
72
72
84
84
Over 120
36
36
48
48
42
54
60
60
60
60
60
72
84
0-40
42
48
54
60
54
60
72
72
84
72
72
84
84
41-80
36
42
48
60
48
60
60
60
72
60
66
72
84
81-120
36
42
48
54
48
54
60
60
72
60
60
72
84
Over 120
30
30
42
42
36
48
54
54
60
54
54
60
72
0-40
36
48
48
60
54
54
72
72
72
72
72
84
84
41-80
36
36
42
48
42
48
54
54
60
54
72
72
84
81-120
30
30
42
48
42
48
54
54
60
54
72
72
84
Over 120
NR
NR
36
36
30
42
48
48
54
48
54
54
72
81-100% tension
18
18
20
20
18
30
30
30
36
22
30
36
42
61-80%
16
16
18
18
16
24
24
24
30
20
24
30
36
Up to 60%
12
12
14
14
14
20
20
20
18
20
24
30
36
10
11
10
11
10
11
12
Spaced Continuous
10
11
12
14
12
14
16
35
45
ELEVATOR
Minimum Pulley Diameter
Note 1: These are typical values only, please consult your belt manufacturer for specific product values.
Note 2: Table 4.1 includes expanded product ratings.
IP:1 2011 Conveyor and Elevator Belt Handbook
25
Table 4-2. Typical Ratings - Straight Warp Conveyor or Elevator Rubber Belting
CONVEYOR
Single-Ply Straight Warp Fabric
Working Strength (PIW)
190
220
275
Approx. Carcass Gauge (in)
.078
.103
.125
Approx. Carcass Weight
.038
.049
.056
(PIW) Factor (lb)
390
.131
385
.157
440
.165
440
.195
.064
.067
.072
.105
.114
.120
1500
.359
.134
.148
.165
.172
16
16
18
20
24
24
24
30
30
36
42
42
42
61-80%
14
14
16
18
20
20
20
24
24
30
36
36
36
Up to 60%
12
12
14
16
18
18
18
20
20
24
30
30
30
30
36
42
30
36
42
30
36
42
30
36
42
TROUGHABILITY
Troughing Angle
20
35
45
12
14
16
14
20
24
36
30
42
36
54
42
60
48
60
48
66
54
84
84
84
84
84
84
84
84
84
84
84
84
84
84
30
36
42
48
48
54
60
66
84
84
84
84
84
41-80 lb/cu. ft
30
36
42
54
54
60
84
84
84
84
84
84
84
81-120 lb/cu. ft
24
30
36
42
48
48
84
84
84
84
84
84
84
24
30
36
42
42
48
54
60
66
84
84
84
84
41-80 lb/cu. ft
30
36
42
48
48
54
60
66
84
84
84
84
84
81-120 lb/cu. ft
24
30
36
42
42
48
54
60
84
84
84
84
84
18
24
30
36
36
42
48
54
60
66
84
84
84
35
45
ELEVATOR
Minimum Pulley Diameter
Working Tension
81-100%
16
16
18
20
24
24
30
30
30
36
42
42
42
61-80%
14
14
16
18
20
20
24
24
24
30
36
36
36
Up to 60%
12
12
14
16
18
18
20
20
20
24
30
30
30
11
11
13
13
14
15
16
Continuous Industrial
11
11
13
13
14
15
16
Note 1:These are typical values only, please consult your belt manufacturer for specific product values.
Note 2: Table 4.2 includes expanded product ratings.
26
Belt operating tension is not the only belt characteristic to be considered when selecting belt design for an application. Other important
items exist that effect how the belt will perform on a given system. The importance of these characteristics is presented below.
ELONGATION
Most new conveyor belts will exhibit some permanent stretch very early in their service life, as a result of the normal cyclic tensile
forces exerted by the conveyor system on the belt. This length change will vary among belt constructions, but it is generally much less
than one percent of the original relaxed length of the belt. The conveyor take-up system must compensate for this length change as
well as the normal belt elongations which are proportional to belt tensions in the elastic region of the stress strain curve.
Table 3-3. Recommended Minimum Take-Up Travel
(percentage of the distance between centers of the convenor*)
Type of Take-Up and
Carcass Material (warp)
75%
50% or less
Nylon
4.00%
3.00%
2.00%
Polyester
2.50%
2.00%
1.50%
Nylon
3.00%
2.50%
1.50%
Polyester
0.00%
1.00%
1.00%
Manual Take-Up**
Automatic Take-Up
*For belts installed at average empty running, take-up position 90% of the travel, and drive location at or near the high tension end of
the conveyor.
**Only short endless feeder belts and the like would normally be vulcanized on conveyors with a manual take-up.
27
LIMIT OF IDLER GAP BETWEEN CARRYING IDLERS FOR TROUGHED BELT CONVEYORS
The Association for Rubber Products Manufacturers has established the following limit for gap between carrying idlers for troughed
conveyors.(ARPM IP-1-2) The limits provided serve as a guideline for acceptable performance of conveyor belts in the idler junction
area, preventing junction failure.
Reference Document: ISO 1537 -- Continuous mechanical handling equipment for loose bulk materials -- Troughed belt conveyors
(other than portable conveyors) -- Idlers
Limit for gap between in-line positioned troughed carrying idlers:
The maximum gap between the carrying idlers will be 3/8 in (10 mm).
Figure 4-2.
Overlap and Offset Dimension for staggered (or off-set) troughed carrying idlers:
A minimum overlap between the carrying idlers will be 3/8 in (10 mm).
28
From the foregoing it is apparent that there are two extremes of lateral belt flexibility to be considered in making a belt selection, and
these are generally referred to as minimum and maximum ply design. Reference to manufacturers published tables is recommended,
especially when the belt selection will be at or near either the minimum or maximum ply extreme, because of belt design variations
and the fact that there are often two or more fabrics available with differing trough characteristics.
The ability of the belt to trough may be measured by using a standard test method (ASTM D 378). In this test, the troughability of the
belt is defined as the ratio F/L where F is the natural drop height at the center of a 6 ft (1.8 m) long belt sample freely suspended at its
edges and L is the belt sample width. Table 4-4 provides a guideline for the minimum values of F/L required to ensure that a belt will
trough correctly in the listed troughing idlers.
Table 4-4*. Three Identical Idler Rollers -- Minimum Required Values of the Ratio of Deflection (F) to the Belt Width (L)
0.08
25
0.10
30
0.12
35
0.14
40
0.16
45
0.18
50
0.20
55
0.23
60
0.26
TRANSITION DISTANCE ON THREE EQUAL LENGTH IDLER ROLLS FOR TEXTILE BELTS
A. General
In changing the troughed belt to a flat section at the head pulley or the flat belt to a troughed section at the tail pulley, edge tension is
increased as the edges are stretched between the last idler and the pulley. This tension mal-distribution can be kept within safe limits
by maintaining a proper transition distance between the last trough idler and the pulley to minimize the stretch induced into the belt
edges. At the head (high tension end), the purpose is to avoid excessively high edge tensions. At the tail (low tension end), excessive
edge tensions rarely will be encountered. If the transition is too short, however, an excessive difference between edge and center
tensions can overcome lateral belt stiffness, pull the belt down into the trough, and buckle it longitudinally along the bottom roller.
B. Recommended Terminal Pulley Location
The vertical position of the terminal pulley with respect to the troughing idlers is of great importance in determining the minimum
transition distance since this position determines the vertical drop of the belt edge. The higher the pulley location with respect to
the idlers the shorter will be the minimum required transition distance.
Figures 4-5 and 4-6 illustrate two terminal positions commonly used. Figure 4-5 usually is recommended from a belt standpoint;
it places the pulley so that the belt edge will be lowered (or raised) approximately one-half the trough depth and requires much
less transition distance than Figure 4-6 while still maintaining a troughed section across the belt width. Figure 4-6 is used
occasionally where belt tension is low, lumps are large, and belt speed is high to minimize impact forces at the discharge pulley.
29
Table 4-5. Minimum Transition Distance with Terminal Pulley at Approximately One-Half Trough Depth
Idler (deg)
Percent ofrated
tension
Fabric belts
20
More than 90
60 to 90
Less than 60
0.9w
0.8w
0.6w
2.0w
1.6w
1.0w
35
More than 90
60 to 90
Less than 60
1.6w
1.3w
1.0w
3.4w
2.6w
1.8w
45
More than 90
60 to 90
Less than 90
2.0w
1.6w
1.3w
4.0w
3.2w
2.3w
30
Table 4-6. Minimum Transition Distance with Terminal Pulley at Full Trough Depth
Idler (deg)
Percent ofrated
tension
Fabric belts
20
More than 90
60 to 90
Less than 60
1.8w
1.6w
1.2w
4.0w
3.2w
2.8w
35
More than 90
60 to 90
Less than 60
3.2w
2.4w
1.8w
6.8w
5.2w
3.6w
45
More than 90
60 to 90
Less than 90
4.0w
3.2w
2.4w
8.0w
6.4w
4.4w
Note 1: The above transition distances are conservative and have been used in service for years. Contact the belt manufacturer if
shorter distances are desired.
Note 2: Steel cord belts with their very low stretch characteristics require much greater transition distances than fabric belts. These
distances at times seem unreasonably great, but a small amount of stretch in steel cord can induce an enormous stress. In one
actual case, an 18 ft (5.5 m) steel cord belt transition was lengthened approximately eight more feet when it was shown that
the theoretically induced edge stress caused by edge stress in the 18 ft (5.5 m) distance amounted to approximately an
additional one-half of the rated belt tension.
VERTICAL CURVES
General
Vertical curves in conveyor belt systems are used to join two tangent sections with different slopes.Two different types of vertical
curves exist; a concave curve resulting from a negative change in grade; and a convex curve, resulting from a positive change in grade.
Each application needs to be evaluated to determine the correct curve radius in order to avoid problems during operation.
31
Convex curves can also be restricted by the idler pressure. When going through a convex curve, the belting is forced downward onto
the idlers.Convex curve limitations from the idler pressure standpoint are not created by the belt but by idler requirements. As a result,
the idler manufacturer should be consulted if this appears to be the limiting factor. If the manufacturer permits a greater loading, then
the radius can be reduced accordingly. Otherwise, the only other solution is to reduce idler spacing to live with the desired radius.
Short convex curves can cause idler junction failure as the belt will be forced in the idler gaps. Idler junction failure will be dependent
on the idler gaps, fabric type, belt rigidity, curve radius and edge / center belt tension.
PULLEY DIAMETERS
Pulley diameters are important to belt performance. Pulley diameters which are too small for a given belt construction, could result in
damage to the belt carcass or premature splice failure.As a belt travels around a pulley, a bending stress is induced as the outer fabric
plies must elongate and inner plies must shrink. This extra stress is dependent on the diameter of the pulley, the thickness of the belt,
and the elastic constant of the material. It is important to the integrity of the belt that this stress is kept within safe limits. Minimum
recommended pulley diameters can be obtained from the belt manufacturer for a given belt application based on the belt construction
and system tension.
IMPACT RESISTANCE
Loading bulk material on a conveyor belt creates some impacting force on the belt. This occurs since the material is dropped from
some height above the belt surface and the forward speed of the belt may be different than that of the material when it contacts the
belt.
Fine materials, regardless of weight per unit volume, do not present a problem on impacting the belt because the force is spread over a
relatively large surface area. Cover damage due to gouging is minimal and carcass bruising is normally very low in operations
involving fine materials.
Lumpy materials can cause appreciable impact on the belt. The heavier the lump, the greater height of fall, and the greater its angular
velocity when it contacts the belt, the greater will be the energy tending to rupture the belt. When the material strikes the belt directly
over a support such as an idler, damage to the carcass can result from the crushing action of the lump against the idler-supported belt.
Lumpy material having sharp corners and edges can cause cover nicks, cuts, and gouges. The heavier the lump, the greater height of
fall, and the greater its angular velocity at the time of contacting the belt, the more extensive will be the damage to the cover. Sharp,
pointed lumps can even penetrate the cover into the carcass and in rare instances completely penetrate through the belt.
To minimize impact damage, every effort should be made to provide good loading conditions for the material handled. (See Chapter
14 on loading and discharge).
Given full information regarding the material conveyed and the loading conditions, the belt manufacturer can provide a belt that will
embody the necessary elements to resist the damaging effects of impact. The selection of a cover grade and thickness, the type of
textile fiber, fabric design, and number of plies can be varied depending upon the severity of the impact conditions.
The maximum fabric ratings shown in this chapter are based on the use of impact idlers and good design of loading and transfer areas.
The impact energy equals the lump weight factor (Tables 4-7 and 4-8) times the equivalent free fall.
32
10
12
14
16
18
50
75
100
0.4
0.6
0.7
1.3
1.9
2.6
3.0
4.5
5.9
5.8
8.6
12.0
10
15
20
14
21
28
21
31
41
30
44
59
40
61
81
70
105
140
100
149
199
148
222
296
211
316
421
125
150
175
0.9
1.1
1.3
3.2
3.8
4.5
7.4
9.0
10.4
14.0
17.0
20.2
25
30
35
35
42
49
52
62
73
74
89
104
101
121
142
175
210
245
248
298
348
371
444
518
527
632
737
75
100
125
150
175
200
225
250
300
350
400
450
6812
14
21
27
26
38
53
45
68
90
62
93
124
93
137
182
133
196
263
178
271
360
312
466
622
445
613
882
657
990
1313
931
1401
1872
33
40
46
62
76
90
111
133
156
156
186
218
231
274
323
329
396
461
449
539
631
777
931
1088
1102
1323
1548
1646
1980
2303
2372
2813
3273
15
17
21
33
COEFFICIENT OF FRICTION
A coefficient of friction is the ratio of the force required to slide a belt over its supporting structure to the normal force holding the belt
to the supporting structure. The static coefficient of friction uses the force needed to start the belt into motion from rest, and the kinetic
coefficient of friction uses the force to keep the belt in motion. Where reference is made to a coefficient of friction of belting, generally
the kinetic coefficient is meant, unless specified otherwise.
This important belt characteristic affects the suitability of belting in specific applications. Generally, very low coefficients of
friction are required on the bottom surface for slider bed conveyors to minimize power requirements, and low coefficients of friction
are desired on the top surface of belting in applications involving plowing off conveyed objects toward the belt edges. A higher
coefficient of friction on the top surface is generally desired when the top surface is used to drive carrying rollers.
Very low coefficients of friction are in the range of 0.15 to 0.25 typically. Untreated textile products have a coefficient of friction
against steel of approximately 0.20. Friction surfaces of belting have coefficients of friction against steel of about 0.40 to 0.50, and
belt covers have quite high coefficients of friction, from about 0.8 to values even greater than 1.0 depending on the formulation.
34
CHAPTER 5
The width tolerances listed in Table 5-1 are the commercially accepted standards of the conveyor belt manufacturing industry. Tighter
tolerances may be specified by agreement between the individual manufacturer and his customer.
Table 5-1. Belt Width Tolerances
Molded Edge Width Tolerance
Belt Widths
in
mm
in
mm
Up to 24 in (600 mm)
1/4
3/16
3/8
10
3/16
1%
1%
1%
1%
Tolerance in (mm)
over
up to (inclusive)
--
49 (15)
2 ( 50)
49 (15)
66 (20)
3 ( 75)
66 (20)
--
Tolerance (maximum permissible difference between the delivered length and the
ordered length)
As one length
+ 2.5%, - 0.0%
In several lengths
35
CHAPTER 6
ASTM D 2228 Standard Test Method for Rubber Property - Relative Abrasion by Pico Abrader Method
ASTM International standards can be obtained at www.astm.org.
Canadian Standards Association
CAN/CSA-M422-M87 -- Fire Performance and Antistatic Requirements for Conveyor Belting
CSA standards can be obtained at www.csa.ca.
International Organization for Standardization (ISO)
ISO 251
ISO 252
ISO 282
ISO 283
Textile conveyor belts -- Full thickness tensile strength, elongation at break and elongation at the reference load -Test method
ISO 284
ISO 340
Conveyor belts -- Laboratory scale flammability characteristics -- Requirements and test method
ISO 433
ISO 433
ISO 505
Conveyor belts -- Method for the determination of the tear propagation resistance of textile conveyor belts
ISO 583
Conveyor belts with a textile carcass -- Total belt thickness and thickness of constitutive elements -- Test methods
ISO 703
ISO 1120
ISO 1537
Continuous mechanical handling equipment for loose bulk materials -- Troughed belt conveyors (other than portable
conveyors) -- Idlers
ISO 3684
ISO 3684
36
ISO 3870
Conveyor belts (fabric carcass), with length between pulley centres up to 300 m, for loose bulk materials -Adjustment of take-up device
ISO 4195
Conveyor belts with heat-resistant rubber covers -- Heat resistance of covers -- Requirements and test methods
ISO 4195
Conveyor belts with heat-resistant rubber covers -- Heat resistance of covers -- Requirements and test methods (Cor
1)
ISO 5284
ISO 5284
ISO 5285
ISO 5293
ISO 5293
Conveyor belts -- Determination of minimum transition distance on three idler rollers (Cor 1)
ISO 9856
Conveyor belts -- Determination of elastic and permanent elongation and calculation of elastic modulus
ISO 10247
ISO 10247
ISO/TR 10357
Conveyor belts -- Formula for transition distance on three equal length idler rollers (new method)
ISO 14890
Conveyor belts -- Specification for rubber or plastics covered conveyor belts of textile construction for general use
ISO 14890
Conveyor belts -- Specification for rubber or plastics covered conveyor belts of textile construction for general use
(Cor 1)
ISO 15147
Light conveyor belts -- Tolerances on widths and lengths of cut light conveyor belts
ISO 16851
Textile conveyor belts -- Determination of the net length of an endless (spliced) conveyor belt
ISO 18573
ISO 21178
ISO 21179
Light conveyor belts -- Determination of the electrostatic field generated by a running light conveyor belt
ISO 21180
ISO 21181
ISO 21182
ISO 21183-1
ISO 21183-2
ISO 22721
Conveyor belts -- Specification for rubber- or plastics-covered conveyor belts of textile construction for underground
mining
Continuous conveyors - Belt conveyors for loose bulk materials - Basis for calculation and dimensioning
22102-1
Conveyor belts with textile plies for bulk goods; dimensions, specifications, marking
22102-2
22102-3
Conveyor belts with textile plies for bulk goods; permanent joints
22109-1
Conveyor belts with textile plies for coal mining - Part 1: Mono-ply belts for underground applications; dimensions,
requirements
37
22109-2
Conveyor belts with textile plies for coal mining - Part 2: Rubber - belts with two plies underground applications;
dimensions, requirements
22109-4
Conveyor belts with textile plies for coal mining - Part 4: Rubber - belts with two plies for above applications;
dimensions, requirements
22109-5
22109-6
Conveyor belts with textile plies for coal mining - Part 6: Testing
22118
Conveyor belts with textile plies for use in coal mining; fire testing
22121
Conveyor belts with textile plies for coal mining - Permanent joints for belts with one or two plies; dimensions,
requirements, marking
1/2 D
1 1/16 D
4 1/2
Figure 6-1.
38
1/2 in Holes
3. Sample Testing
a. Testing jigs, pictured in Figure 6-2 and 6-3, are
required to both fasten and rip the sample during
testing.
b. Sample is secured using the top three holes in a moveable jaw of lab testing apparatus and top testing jig
(Figure 6-2).
Top Testing JIG
c. Bottom Testing Jig (Figure 6-3) is placed into the bottom jaw of lab testing apparatus and sample is lowered until the 1 1/16 in hole of the Jig and hole on the
bottom half of the sample line up.
Figure 6-2.
1 1/16 in Hole
4. Results
Figure 6-3.
Note: Information regarding the Impact Test Procedure will be available at a later date.
39
CHAPTER 7
INTRODUCTION
This chapter is intended to serve as an introduction to splicing methods in general use. Belt users should consult belt and fastener
manufacturers for more specific detailed information.
40
HINGED FASTENERS
Hinged fasteners are attached to each belt end separately. The ends are then brought together and joined by inserting a flexible hinge
pin, or spindle.
Hinged fasteners are of the greatest value in conveyors which must be knocked down frequently or varied in length. Joined ends may
be separated by releasing tension on the belt and removing the hinge pin. Hinged fasteners are widely used in extensible coal
conveyors.
They are not recommended for service involving rock or other service where abrasive fines are a factor because abrasive particles
cause premature failure of hinge pins and fastener loops. It is also difficult to prevent the sifting of fines through a hinged fastener
joint.
a. Bolted Double Plate Hinged Fasteners
These fasteners are attached to the belt in the same manner as double plate bolted fasteners, using templates and applicator tools
sold by fastener manufacturers.
b. Wire Hook Fasteners
These fasteners are furnished in the form of wire hooks with ground points. The hooks are supplied mounted on cardboard
combs. They must be applied to the belt with special crimping machines which are made by the fastener manufacturer. These
fasteners come in various sizes and wire diameters for belt thicknesses ranging from approximately 1/16 in (2 mm) to 5/8 in (16
mm).
c. Riveted Plate Hinged Fasteners
These consist of formed metal plates which extend from the top belt surface, around the cut end, and onto the bottom surface.
The plates are made with countersunk holes to allow passage of pointed rivets. Installation is accomplished by hammering rivets
through the plates and belt and peening the rivet ends into the countersunk holes of the plates tightly onto the belt. A hinge pin is
then inserted.
d. Drive-on-Hinged Fasteners
This type of fastener comes packaged in various lengths corresponding to common belt widths and in a range of sizes for belts
1/16 in (2 mm) to 5/8 in (16 mm) thick. The only tool needed for application is a hammer. The fastener is slipped over the end of
the belt and anchored by driving the prongs or teeth through the belt. This type of fastener is widely used for package handling,
post office belting, food processing, etc.
41
42
Pincers
Ply Lifter
Offset Knife
Rubber Knife - 6 in Long
Bevel Point Knife - 4 x 1 in
Curve V-Trim Knife - 2 1/4 x 3/4 in
Mill Knife
Single Ply Knife (cutting depth matching the fabric gauge)
Heavy Duty Scissors
Belt Clamps
Come-a-longs
H.D. C-Clamps
Screw Clamps
Edge Bars (1/16 in thinner than belt)
Fabric Belt Vulcanizing Press
Electric Handheld Thermometers with Leads
SPLICING CONDITIONS
Work Place
The quality and durability of a hot splice begins with a clean work place. The careful use and application of the splicing products are
essential. Follow the approved safety practices for the locale in which the service is being conducted.
Conveyor Belt
The belt ends to be spliced must be dry and clean to ensure a reliable splice. If necessary, dry the belt using the pre-heated lower part
of the vulcanizing press, before any further preparation work.
Ambient Conditions
The influence of humidity, e.g. formation of condensation water (due to temperature falling below the dew point), must be absolutely
avoided. Avoid loss of heat due to wind.
Extreme cold may have a negative affect on splicing materials. During extreme cold conditions a splicing tent with heating devices
may be needed.
1. Set-up a tent to protect the working area against adverse ambient conditions (sunshine, cold, rain, wind, dust).
2. It is possible to warm-up the splice area of the belt using the pre-heated lower part of the vulcanizing press. Do not to allow the
temperature to rise above 150F (66C)
Use of Thermocouples with Leads
Vulcanizing press temperatures should be verified with thermocouples allowing a minimum of one lead per heating zone (top and
bottom platens). Thermocouples allow the control of the cure temperature during the cure cycle.
Documentation
During the splicing operation all irregularities and special conditions have to be recorded. During the actual cure cycle the curing
temperature of each thermocouple and the curing pressure must be recorded at defined intervals. The heat-up and cool-down of the
vulcanizing press is also recorded.
43
GENERAL PREPARATION
Center Lining the Belt Ends On both
belt ends establish and mark
1. the belt center line;
2. the perpendicular square line;
3. the belt cover transition lines.
Establish and mark the centerline of the belt by measuring across the width of the belt at three points in length of each belt end at a
distance of approximately 12 in (304 mm). At least three center markings on each belt end must be outside the splice area.
The establishment of the centerline is easiest when done with two
rulers. The three center markings on each belt end are then
connected by means of a chalk line which represents the belt
centerline or by holding stationary the measuring tape at 0 in on
one belt edge while sliding the tape on the opposite belt edge
until an easily divided number is aligned with the belt edge.
This centerline ensures exact alignment of the belt ends, which is
indispensable for straight belt running.
The centerline outside the splice area must be durable enough to
remain evident throughout the entire splicing operation.
Destroyed or missing belt edges must be considered. The width
of the belt edge is established by measuring the width of the belt
at suitable areas of the undamaged belt ends.
Figure 7-1. Establishment of the Centerline (Step 1)
Now describe a circle with the same radius around points B and
C by means of a plumb line and a pen. The points of intersection
of both circles must still be on the belt. These intersections are
points D and E.
44
Step Lengths
The recommended step lengths vary for different types of fabric and among manufacturers. The manufacturer will provide the
specified step and overall splice length.
For precise splicing procedures contact the belt manufacturer for accurate specified splice training.
Use only the tools required.
When cutting the covers and or ply joints/seams, do not damage nick or cut the adjacent plies.
The following procedure does not represent all manufacturers preferred splicing techniques.
Step 1:
Make a bias cut on the lower belt part.
Fold back the lower part of the belt and draw a line parallel to the
bias cut on the pulley side at the belt end.
Also mark the belt rubber edges to be preserved.
45
Step 2:
Cut the rubber cover with a dull and
rounded tip Mill Knife held at an angle
(of approximately 45), without damaging
the top fabric ply.
Step 3:
Using pincers, strip the rubber cover (thus preparing the future
joint gap).
Fold back the lower part of the belt again and mark the splice
length (according to the chart), step length.
Cut the rubber cover along this line with a dull tipped Mill Knife
held at an angle of approximately 45. Avoid damaging fabric
plies!
46
Cut off the excess length of the upper part put on the lower part.
Draw a line on the carrying side from the cut.
Cut the rubber cover along the line with a Mill knife held at an angle of 45, without damaging the top fabric ply.
Strip off the rubber cover with pincers (thus preparing the joint gap).
Fold back the upper part of the belt, secure it and prepare the pulley side just as the carrying side of the lower part.
(Step the fabric plies)
47
Step 4:
For the joint gap on the pulley side cut to size an exactly fitting
filler strip consisting of a strip of uncured tie gum rubber, breaker
fabric and uncured cover rubber.
The applied filler strip must be slightly thicker than the rubber
cover of the belt.
Do overlap fabric steps which are on the same level. Stitch or roll
the whole splicing area from the center outwards.
48
49
Types of Joints
1. Lap Joints
Lap joints are one of the two most frequently used elevator belt joints. They are not generally recommended for belts having more
than about six or seven plies of fabric because of their tendency to pound on the pulley.
The belt ends are lapped over each other and secured usually with elevator bucket bolts. The length of the overlap must be at least
equal to the belt width or two bucket spacings, whichever is greater. In attaching the buckets on the lap, the bucket projection is increased by the extra thickness of belt. It is recommended that buckets with lesser projection be used in the lap area so that the
projection is the same all along the belt.
The direction of the lap is usually with the leading edge of the joint on the bucket side. The cut end of the belt on the pulley side will,
thus, trail over the pulleys rather than run against them. The ends of the laps should be cut off as closely as possible to the last row of
bolts to minimize collecting material in the joint.
2. Butt Strap Joints
This type of joint is the other most frequently used joint. It is generally recommended for thick belts. The ends of the belt are butted
together. A separate piece of belting of sufficient strength and flexibility and as wide as the elevator belt is bolted over the butted joint
on the bucket side. This separate piece of belt is the strap. The length of the strap should be sufficient to extend under at least two
buckets on each side of the joint. It may be necessary to omit a bucket at the joint to make room for a double row of bolts through the
strap where the ends of the belt meet. As in the case of the lap joint, buckets on the strap should have decreased projection equal to the
thickness of the strap. Thus the strap of course should be on the outside of the belt rounding the pulley.
3. Conventional Belt Fasteners
Conventional belt fasteners may be used for elevator belts to provide a smooth joint, but they are not recommended where the belt is
stressed beyond 50% of its rating.
4. Vulcanized Splices
Vulcanized splices in elevator belts offer the same advantages as in conveyor belts. They are recommended for large, highly stressed
belts where adequate take-up and access to the belt exists.
5. Oil Well Splices
This type of splice is illustrated in the sketch in Figure 7-17. The clamps used to bolt the belt ends come in a variety of shapes and
designs, but in all cases the belt ends are bent 90 on a relatively short radius.
Safety Factors
Conveyor belt operating tensions are chosen as a small percentage of the belts breaking strength. This provides spare strength for (1)
temporary higher transient loads such as during starting and stopping, (2) handling unusual system loads such as misalignments or
frozen idlers, and (3) loss of strength due to materials aging and other degradation factors. The ratio of original belt strength to
operating tension is called the belts Safety Factor. Traditionally, the conveyor industry has used safety factors around 10:1 for fabric
belts and around 6.7:1 for steel cord belts, however, higher and lower factors are common. It is recommended to contact the belt
manufacturer for a safety factor recommendation for a specific application.
In recent years, studies have linked a belts safety factor to its dynamic splice strength and tests have been developed to measure the
dynamic strength of the splice. There are now international standards, such as DIN 22110, that define how the dynamic splice strength
can be measured. There are also standards, such as DIN 22101, that provide a method to calculate the safety factor for a belt. A general
guideline is that fabric belt splices have a dynamic splice efficiency of 35% of the belts breaking strength and steel cord belt have
45%. In practice, many conveyor belts deteriorate due to abuse or accidental damage and historical data should always be considered
when selecting a safety factor. Other factors that should be considered when selecting a belts safety factor include the effects of a
catastrophic belt break. For example, personnel safety, loss of production, clean up cost, repair time, accessibility of the belt for repair,
and availability of repair labor and materials. There are examples where a critical conveyor belt has broken due to loss of strength
from accidental damage combined with a high peak transient load. Such events can cost millions of dollars of lost production. The
recent availability of cord monitoring systems for conveyor belts offers improved capability of accidental damage surveillance in steel
cord belts. When used correctly, such systems offer additional safeguards for the operation of belts with lower safety factors.
50
CHAPTER 8
INTRODUCTION
This chapter describes steel cord belting with references to its major components of steel cord, cover rubber, inside rubber and if
specified a breaker. This will be followed by a description of belt cover compounds, steel cord belt manufacturing methods, and
special considerations in field applications.
BELT CARCASS
Purpose
The belt carcass primarily provides resistance to tension forces that build up in the conveyor system from frictional resistance and
vertical changes in loading. Also it provides the strength to resist belt tearing and impact damage and still allow flexibility for load
support. Splicing is a critical part of the carcass design and will be discussed separately.
Steel Cord Carcass (see Figure 8-1.)
The steel cord carcass is made up of three major components: top cover, insulation gum, steel cord bottom cover and in some cases
a breaker in one or both covers. The belt strength or rating is determined by the cord diameter and pitch. The top and bottom covers
protects the steel cords, the insulation gum penetrates and adheres to the steel cords which then provide corrosion resistance.
Top Cover
Insulation Gum
Steel Cord
Bottom Cover
Figure 8-1. Steel Cord Belt Components
CARCASS PROTECTION
Breaker
Depending on the application and customer desire, some steel cord belts are specified with a breaker in the top and/or pulley cover.
The breaker aids in abuse resistance by reducing the impact, slitting and gouging of the covers and also offers some limited protection
to the cords.
51
52
CHAPTER 9
The tension rating for a belt is the recommended maximum safe working stress that can be applied to the belt.
Belt tension is commonly referred to as the force applied to the belt per unit of belt width, such as Pounds per Inch width (PIW), or
Kilo Newtons per Meter width (kN/m).
There is variation among manufacturers about the information in the following paragraphs that relates to certain system design items
such as the minimum pulley diameter, troughability, and maximum safe belt working stress to mention a few because of differences in
materials and manufacturing methods. As a direct result other belt parameters are effected such as the number of cords in a belt, belt
weight, minimum pulley diameter, troughability, belt modulus, transition distance, impact resistance, etc. Thus, it is essential to confer
with the belt manufacturer about the belt proposed for each application.
ST800
ST1000
ST1250
ST1600
ST2000
ST2500
ST3150
ST3500
ST4000
ST4500
ST5000
ST5400
PIW
4568
5710
7138
9136
11420
14275
17987
19985
22840
25695
28550
30835
kN/m
800
1000
1250
1600
2000
2500
3150
3500
4000
4500
5000
5400
Operating Tension
PIW
686
856
1070
1370
1712
2140
2697
2996
3424
3852
4280
4623
kN/m
120
150
187
240
300
375
472
525
600
675
750
810
in
0.142
0.142
0.205
0.205
0.205
0.205
0.315
0.315
0.362
0.394
0.433
0.433
mm
3.61
3.61
5.21
5.21
5.21
5.21
8.00
8.00
9.19
10.01
11.00
11.00
in
0.688
0.547
0.855
0.666
0.533
0.450
0.768
0.690
0.792
0.805
1.098
1.023
mm
17.48
13.89
21.72
16.92
13.54
11.43
19.51
17.53
20.12
20.45
27.89
25.98
Belt Modulus
PIW
329000
411000
514000
657000
822000
1030000
1290000
1440000
1640000
1850000
2050000
2220000
kN/m
57617
71977
90015
115058
143954
180381
225914
252183
287208
323985
359010
388782
Tension ratings are available in addition to those shown above. Other cord diameters may be substituted according to individual requirements.
Operating tensions are based on a 6.676:1 safety factor. Cord pitch based on 48 in belt.
IP:1 2011 Conveyor and Elevator Belt Handbook
53
Table 9-4.
Cover Compound
ARPM 1
ARPM 2
0.18
0.19
Approximate Belt Weight = Carcass Weight + Cover Weight Minimum pulley cover requirement 5/32 in
Table 9-5. Steel Cord Belt Standard Classifications
Snubs are defined as having 6 in or less belt contact and tension less than 50% of belt rating. Pulley sizes for belts are determined by
face pressure on the pulley and/or the pulley-to-cord diamteter ratio. All pulleys must be flat as crowned pulleys will cause excessive
center tension in the high modulus steel cord product. Contact belt manufacturer for belt tensions higher than 4623 PIW.
54
Table 9-6. Recommended Transition Distances, Minimum Transition Distance: One-Half Trough Depth
Idler
% of Rated
20
More than 90
60 to 90
Less than 60
2.0W
1.6W
1.0W
35
More than 90
60 to 90
Less than 60
3.4W
2.6W
1.8W
45
More than 90
60 to 90
Less than 60
4.0W
3.2W
2.2W
Table 9-7. Recommended Transition Distances, Minimum Transition Distance: Full Trough Depth
Idler
% of Rated
20
More than 90
60 to 90
Less than 60
4.0W
3.2W
2.8W
35
More than 90
60 to 90
Less than 60
6.8W
5.2W
3.6W
45
More than 90
60 to 90
Less than 60
8.0W
6.4W
4.4W
Belt operating tension is not the only belt characteristic to be considered when selecting a belt design for an application. Other
important items exist, that effect how the belt will perform on a given system. The importance of these characteristics are presented
below.
ELONGATION
Most new conveyor belts will exhibit permanent stretch very early in their service life, as a result of the normal cyclic tensile forces
exerted by the conveyor system on the belt. This length change will vary among belt constructions, but it is generally much less than
one percent of the original relaxed length of the belt. The conveyor take-up system must compensate for this length change as well as
the normal belt elongations which are proportional to belt tensions in the elastic region of the stress strain curve.
The initial take-up position is that which the take-up finds after the clamps have been removed and the belt run empty a few belt
revolutions to produce a natural tension distribution.
Table 9-8. Recommended Initial Take-Up Position
Belt Type
Steel cord
1/4
Splice length
Safety Factors
Conveyor belt operating tensions are chosen as a small percentage of the belts breaking strength. This provides spare strength for (1)
temporary higher transient loads such as during starting and stopping, (2) handling unusual system loads such as misalignments or
frozen idlers, and (3) loss of strength due to materials aging and other degradation factors. The ratio of original belt strength to
operating tension is called the belts Safety Factor. Traditionally, the conveyor industry has used safety factors around 10:1 for fabric
belts and around 6.7:1 for steel cord belts, however, higher and lower factors are common. It is recommended to contact the belt
manufacturer for a safety factor recommendation for a specific application.
In recent years, studies have linked a belts safety factor to its dynamic splice strength and tests have been developed to measure the
dynamic strength of the splice. There are now international standards, such as DIN 22110, that define how the dynamic splice strength
can be measured. There are also standards, such as DIN 22101, that provide a method to calculate the safety factor for a belt. A general
guideline is that fabric belt splices have a dynamic splice efficiency of 35% of the belts breaking strength and steel cord belt have
45%. In practice, many conveyor belts deteriorate due to abuse or accidental damage and historical data should always be considered
when selecting a safety factor. Other factors that should be considered when selecting a belts safety factor include the effects of a
catastrophic belt break. For example, personnel safety, loss of production, clean up cost, repair time, accessibility of the belt for repair,
and availability of repair labor and materials. There are examples where a critical conveyor belt has broken due to loss of strength
from accidental damage combined with a high peak transient load. Such events can cost millions of dollars of lost production. The
recent availability of cord monitoring systems for conveyor belts offers improved capability of accidental damage surveillance in steel
cord belts. When used correctly, such systems offer additional safeguards for the operation of belts with lower safety factors.
55
CHAPTER 10
Information in this chapter is referenced from ISO 15236-1, 15236-2, 15236-3, and 15236-4.
BELT THICKNESS
The belt thickness (s 1) is obtained by adding the actual cable diameter and the top cover and pulley cover thicknesses. The thickness
tolerances are shown in Table 10-1.
Table 10-1. Belt Thickness Tolerances
Belt Total Thickness
Tolerance
15 mm
10%
15 mm
+ 10%, - 5%
BELT WIDTH
The width tolerances listed in Table 10-2 are the commercially accepted standards of the conveyor belt manufacturing industry.
Tighter tolerances may be specified by agreement between the individual manufacturer and his customer.
Table 10-2. Belt Width Tolerances
Type of Belt
Unit
500
630
800 1000 1250 1400 1600 1800 2000 2250 2500 2800 3150 3500
N / mm
500
630
800 1000 1250 1400 1600 1800 2000 2250 2500 2800 3150 3500
mm
3.0
3.0
3.7
kN
7.6
7.6
10.3 12.9 18.4 20.6 26.2 25.5 25.5 26.2 39.7 39.7 50.0 55.5
4.2
4.9
5.0
5.6
5.6
5.6
5.6
7.2
7.2
8.1
8.6
8.9
9.7
10.9 11.3
Cord pitch t
mm
14.0 11.0 12.0 12.0 14.0 14.0 15.0 13.5 12.0 11.0 15.0 13.5 15.0 15.0
mm
4.0
6.5
Belt width, B in mm
Tolerance in mm
500
+10 / -5
33
42
39
39
34
34
31
650
+10 / -7
44
54
51
51
45
45
41
46
52
56
41
46
41
41
41
39
36
N/A
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
5.0
5.0
5.5
6.0
7.0
7.5
8.0
Number of cords n
N/A N/A N/A N/A N/A N/A N/A
800
+10 / -8
54
68
64
63
55
55
50
57
64
69
51
57
51
51
51
48
45
45
1000
10
68
84
80
80
68
68
63
71
80
86
63
71
63
64
63
60
56
57
1200
10
86
110
97
97
82
82
76
85
96
104
76
85
76
76
76
72
67
68
1400
12
96
124
114
113
97
97
90
100
112
122
89
99
89
89
89
84
79
79
1600
12
111
142
130
130
111
111
103
114
129
140
102
114
102
102
102
96
90
90
1800
14
125
160
147
147
125
125
116
129
145
159
116
128
116
116
116
108
102
102
2000
14
139
177
164
163
140
139
130
144
162
177
129
143
129
129
129
121
114
114
2200
15
153
195
180
180
154
154
143
159
179
195
142
158
142
142
142
133
126
126
2400
15
167
213
197
197
168
168
156
174
195
213
156
173
156
156
156
146
137
137
2600
15
181
231
214
213
182
182
170
189
212
231
169
188
169
169
169
158
149
149
2800
15
196
249
230
230
197
197
183
203
229
249
182
202
182
182
182
171
161
161
3000
15
210
267
247
247
211
211
196
218
245
268
196
217
196
196
196
183
173
173
3200
15
224
286
264
263
225
225
210
233
262
286
209
232
209
209
209
196
184
184
56
BELT LENGTH
Tolerances on Lengths
The permissible tolerances for the lengths of conveyor belts, measured loose, are given in Table 10-3.
Table 10-3. Belt Length Tolerances
Tolerance
(maximum permissible difference between delivered and ordered lengths)
+ 2.5%, 0%
5% for each single length, subject to an overall tolerance for the sum
of all lengths of + 2.5%, 0%
BELT EDGE
The edge width may not be smaller than 15 mm.
57
CHAPTER 11
ASTM D 378
ASTM D 430
ASTM D 2228 Standard Test Method for Rubber Property - Relative Abrasion by Pico Abrader Method
ASTM International standards can be obtained at www.astm.org.
Canadian Standards Association
CAN/CSA-M422-M87 -- Fire Performance and Antistatic Requirements for Conveyor Belting
CSA standards can be obtained at www.csa.ca.
International Organization for Standardization (ISO)
ISO 34-1
pieces
Rubber, vulcanized or thermoplastic -- Determination of tear strength -- Part 1: Trouser, angle and crescent test
ISO 252
ISO 282
ISO 284
ISO 340
Conveyor belts -- Laboratory scale flammability characteristics -- Requirements and test method
ISO 433
ISO 433
ISO 703
ISO 1120
ISO 1183-1
Plastics -- Methods for determining the density of non-cellular plastics -- Part 1: Immersion method, liquid
pyknometer method and titration method
ISO 1537
Continuous mechanical handling equipment for loose bulk materials -- Troughed belt conveyors (other than portable
conveyors) -- Idlers
ISO 3684
ISO 3684
58
ISO 4195
Conveyor belts with heat-resistant rubber covers -- Heat resistance of covers -- Requirements and test methods
ISO 4195
Conveyor belts with heat-resistant rubber covers -- Heat resistance of covers -- Requirements and test methods (Cor 1)
ISO 4649
Rubber, vulcanized or thermoplastic -- Determination of abrasion resistance using a rotating cylindrical drum device
ISO 5284
ISO 5284
ISO 5285
ISO 5293
ISO 5293
Conveyor belts -- Determination of minimum transition distance on three idler rollers (Cor 1)
ISO 7590
Steel cord conveyor belts -- Methods for the determination of total thickness and cover thickness
ISO 7622-1
Steel cord conveyor belts -- Longitudinal traction test -- Part 1: Measurement of elongation
ISO 7622-2
Steel cord conveyor belts -- Longitudinal traction test -- Part 2: Measurement of tensile strength
ISO 7623
Steel cord conveyor belts -- Cord-to-coating bond test -- Initial test and after thermal treatment
ISO 8094
Steel cord conveyor belts -- Adhesion strength test of the cover to the core layer
ISO 9856
Conveyor belts -- Determination of elastic and permanent elongation and calculation of elastic modulus
ISO 10247
ISO 10247
ISO/TR 10357
Conveyor belts -- Formula for transition distance on three equal length idler rollers (new method)
ISO 15236-1
Steel cord conveyor belts -- Part 1: Design, dimensions and mechanical requirements for conveyor belts for general
use
ISO 15236-2
ISO 15236-3
Steel cord conveyor belts -- Part 3: Special safety requirementsfor belts for usein underground installations
ISO 15236-4
ISO 18573
Steel cord conveyor belts -- Determination of the Lateral and Vertical Displacement of Steel Cords
DIN EN 20284
DIN 22101
Continuous conveyors - Belt conveyors for loose bulk materials - Basis for calculation and dimensioning
DIN 22131 P1
Steel cord conveyor belts for hoisting and conveying; dimensions, requirements
DIN 22131 P2
DIN 22131 P3
DIN 22131 P4
Steel cord conveyor belts for hoisting and conveying; belt joints; dimensions; requirements
DIN EN 28094
Steel cord conveyor belts -- Adhesion strength test of the cover to the core layer
DIN 53504
Testing of rubber -- Determination of tensile strength at break, tensile stress at yield, elongation at break and stress
values in a tensile test
59
DIN 53505
DIN 53509 P1
DIN 53509 P2
DIN 53515
Testing of rubber -- Determination of resistance to ozone cracking -- Part 2: Reference method for determining
ozone concentration in laboratory test chambers
Determination of tear strength of rubber, elastomers and plastic film using graves angle test piece with nick
DIN 53516
Conveyor belting of elastomeric and steel cord construction AS standards can be obtained at www.standards.org.au.
60
CHAPTER 12 - Part A
INTRODUCTION
This chapter is a brief summary for splicing Fabric Reinforced Belting. Belt users and/or splicing companies should
consult the belts manufacturer for more specific detailed splicing information and/or belt splice training.
THE FABRIC REINFORCED CONVEYOR BELT:
The conveyor belt and conveyor structure are typically matched to ensure the expected operating conditions and tensions
do not exceed the belts limitations.
The conveyor belt type and manufacturer must be known to accurately select the specified splice design, the specified cure
data and splicing materials.
Contact the belts manufacturer with any questions or concerns.
FABRIC REINFORCED CONVEYOR BELT SPLICES
Vulcanized and/or Mechanical splices are typically used to join fabric belts.
The fabric belts are generally designed with a 10:1 safety factor.
It is considered impossible to maintain the same safety factor in the splice area. However vulcanized splices are designed
Table 12:1
630 to 3150
200 to 2000
315 to 3150
800 to 3150
800 to 1600
1000 to 5400
<100 - >5400
DIN 22102-3
Finger Splice
DIN 22102-3
With intermediate tension carrier
DIN 22102-3
Stepped Splice
DIN 22121
DIN 22121
With intermediate tension carrier (B)
DIN 22129-4
Based On
DIN 22129-4
0.35
0.35
0.30
0.35
0.30
0.45
0.45
Currently, the mechanical splices provide an approximate 4:1 safety factor as advertised.
and tested to exceed the typical running tensions of the belts. DIN 22101 2002 08 Specifies the following:
The values for textile belt are reference values, most of which are derived from proven use in practice.
When determining the minimum tensile strength of a belt, the reference fatigue strength actually demonstrated for a
particular belt type and a particular splice implementation can always be used.
FABRIC REINFORCED CONVEYOR BELT SPLICE TESTING: SPLICE EFFICIENCY:
Splice efficiency can be measured in two ways, (1) Static, (2) Dynamic.
Static Splice Efficiency
Defined as the measured force required to break a splice expressed as a percentage of the theoretical breaking strength of
the belt. In addition to the peak force, the time for the splice to separate is sometimes also recorded.
This is typically performed either by clamping each belt end on either side of a splice in a suitable fixture and measuring
the force to pull the splice apart, or by making an endless belt loop with a single splice then measuring the force to pull the
loop apart using a suitable fixture.
Dynamic Splice Efficiency
Defined in DIN 22110 Part 2 for fabric belt splices
For fabric belt splices, the DIN standard describes a 6-pulley, constant speed test machine where an endless length of belt
with one or more splices and/or fastener joints is subject to a constant tension (commonly expressed as a percentage of the
nominal breaking strength of the belt). The splice is subject to multiple bend reversals on each cycle which accelerates its
failure on the test. The DIN standard only specifies that the time to failure at a given test load is recorded. However, based
on a series of tests at different loads a splice efficiency of the fabric belt splice (or fasteners) can be determined as that
IP:1 2011 Conveyor and Elevator Belt Handbook
61
maximum percentage of the nominal belt breaking strength at which the splice will achieve a pre-determined life (hours) on
the test machine. Fabric belt splices may also be tested to DIN - 22110 Part 3, as described for steel cords belt splices.
However, fabric belt testing to DIN 22110 Part 3 has proved problematic due to the relatively high extension of low tension
fabric belts and the limited allowance for belt stretch on machines primarily designed to conduct the test on steel cord belts.
Ambient Conditions during splicing
Efforts to achieve and maintain tolerant ambient temperatures and/or conditions during splicing must be made. In extreme cold
temperatures, the shelter and a portable heater may be used to maintain a warmer environment and to eliminate cold winds from
adversely affecting outer edges of the platen temperatures. Store all splice materials in a cool dry place out of direct sunlight.
Splice Work Shelter:
The quality and durability of a vulcanized splice begins with a clean work place.
A shelter may be required to protect the splice and surrounding work environment from contamination (such as dirt, dust &
moisture).
The work area consists of the lower part of the press (traverses and heating platens) and approximately 10 - 12 ft (3 - 4 m)
long work tables at either end of the press.
The heating platens must be flush with the surfaces of the work tables and be at least 4 in. (100 mm) to 6 in (152 mm)
longer than the splice on each end and at least 4 in (100 mm) wider than the belt on each side.
Storage of Splicing Materials
When unvulcanized splice materials are stored under unfavorable conditions their physical and/or chemical characteristics
change. Eventually these changes will render the unvulcanized splice materials unsuitable for use. These effects result in
changes in the curing behavior and/or in the cured physical properties of the splice materials.
The harmful effects of these factors can be minimized by a careful choice of the following storage conditions. In case of
doubt, consult the supplier of the conveyor belt splice material about the storage conditions.
a. Materials stored in non-refrigerated conditions will shorten shelf life. Materials stored in refrigerated
conditions will increase shelf life. Acceptable refrigerated storage temperature is typically 45F-55F
(12.8C-7.0C). Do not allow the materials to freeze. Allow refrigerated materials to warm before use to
allow condensation to disappear.
b. The relative humidity should preferably be below 60% for long-term storage. Damp conditions should be
avoided since long-term exposure to moisture can influence the curing and cross linking behavior of the
materials.
c. Sunlight and artificial light which has a substantial content of ultraviolet light can adversely affect the stability
of unvulcanized rubber. Depending on the grade and the time span of exposure, chain rupture and/or cross
linking may occur. In view of this, exposure to light should be restricted to a minimum. d. Where possible,
unvulcanized rubber should be protected from excessive air circulation and should not be stored near
electrical equipment (motors) that could be a source of ozone. For this reason it is advisable to keep the splice
material boxes closed and sealed.
e. Unvulcanized rubber should be stored in an area which meets the usual standards of cleanliness, even
though the rolls are individually wrapped in polyethylene sheeting. Avoided direct contact with foreign
materials of any kind. It is recommended that the material be kept in its original packaging until the
moment it is used.
f. Splice materials should not be stored longer than the specified shelf life. It is therefore recommended that
the FIFO (first in first out) stock rotation system be used.
Tools and Equipment typically used for making a Fabric Belt vulcanized splice:
1. The splicing procedure may require a number of tools and equipment which may vary with the preference of the splicer
that uses them.
2. Proper use of the needed splicing tools may be part of a designed splice training program.
3. Belt ends may be stripped by one of the following methods, which requires special individual tools:
4. The following list is considered a partial list of tools and may not include all tools used.
a. Thermocouple unit & wires
b. Buffer
c. Sharpening Stone
d. Square
e. Awl
f. Measuring Tape
g. Foxtail Brush
62
h. Stanley Knife
i. Dull rounded tip knife for cutting the rubber covers
j. Single ply knives
k. Ply Prodders
l. Porcupine roller
m. 4 Flat roller
n. 1/16 stitcher roller
o. Tuggers
p. Straight edge, squares and chalk lines
q. Ply Pullers / Pinchers
r. Ply Clamps / pulling device
5. Practice the safety requirements associated to the tools and equipment used.
6. The vulcanizer must be capable of achieving and maintaining the specified temperature and pressure during the cure
cycle and be large enough to adequately cure the splice in one cure.
7. The platens must have cool down capability. A minimum of 130o F (54.4o C) is typically required before releasing the
cure pressure.
8. Steel edge guides must be secured along the edges of the splice and adjoining belt edge. The edge bars must
approximately .063 (1.5 mm) less than the overall belt gauge and extend out each end of the bottom platen a
minimum of six inches (150 mm).
9. Use thermocouples to monitor and maintain an accurate cure temperature throughout the cure cycle. A minimum of one
thermocouple per heating element is typically specified.
Thermocouples are used to accurately maintain the specified cure temperature throughout the cure cycle. By doing so,
achieving the desired optimum cure is greatly enhanced while reducing the risk of over and/or under cured splice gums.
Most belt manufacturers typically require one thermocouple per heating zone (top & bottom platens) Thermocouple lead
wire. See fig. 12:1
Fig. 12:1
63
From the belt end, measure back into the belt the length of the splice.
Check the master line by laying the square on the opposite belt edge. See fig. 12:2.
64
Fig. 12:2
b. Triangulation
From the belt end, measure back into the belt the length of the splice. Mark the belt edge.
Measure and mark approximately 24 along the belts edge on each side of the mark.
From each of the 24 marks, measure equal diagonal lengths to the opposite belt edge and mark.
This method is common on belts 72 (1800 mm) or wider. See fig. 12:3.
Fig. 12:3
c. Swinging Arc
Measure from this point and make a mark at each edge near the belt end. These two diagonal marks must
be exactly equal
From each of the two diagonal marks measure back into the belt the total splice length.
Fig. 12:4
Drawing the Bias, Steps and/or Fingers:
The bias can typically be made to match the bias angle of most vulcanizers. The most common bias angles are 20 o and 22 o.
To get the 20 o bias, multiply the width of the belt x .036. To find the 22obias multiply the belt width x .40.
From the Master Line the Bias Line and all steps and finger can be marked and drawn. See fig. 12:5
65
Fig. 12:5
Fig. 12:6
While varied methods are necessary in making vulcanized splices on specialized types of belting, the technique normally
involves, but is not limited to, the following basic steps:
Building the Bias Step Splice:
1. Maintain a clean work area and environment
2. Properly maintain and store the splicing materials
3. Build a proper size splicing shelter (if needed)
4. Splicing dimensions are on a 220 bias
5. The top and bottom fill strips are 4 (200 mm) long
6. Top cover and bottom cover skive cuts are at an approximate 45o angle. Refer to fig 12:6
7. Cover skives and approximately 1 of the adjoining belt cover must be buffed
8. Make all step length cuts according to the specified instructions of the belts manufacturer.
66
Cover Skive
Finger
DOT
1st. Ply
Dimensions
4
2nd. Ply
Fig. 12:7
While varied methods are necessary in making vulcanized splices on specialized types of belting, the technique normally
involves, but is not limited to, the following basic steps:
Building the Bias Step Splice with fingers:
1. Maintain a clean work area and environment
2. Properly maintain and store the splicing materials
3. Build a proper size splicing shelter (if needed)
4. Refer to the belts manufacturer for specified splice dimensions. Finger length and transition lengths will
vary according to the belt type and/or the belts PIW rating. Splicing dimensions are on a 220 bias.
5. Draw out the splice on the belt ends.
6. Make the required cover skive cuts. Cover skive cuts are at an approximate 450 angle
7. Cover skives and approximately 1 of the adjoining belt cover must be buffed
8. Center line the belt ends.
9. Strip belt ends
10. Extend the center line from the belt through the full length of the exposed carcass.
11. Draw & cut out the fingers - Outside fingers must point opposite the belts direction of travel.
12. Dry fit the belt ends and make stationary.
13. Apply one even coat of cement to the carcass / exposed fabric of each belt end. Allow the cement to dry
completely before proceeding.
14. Install the bottom cover fill strip composite
15. Clean all splicing materials with the specified solvent during installation.
16. Build the splice as specified by the belts manufacturer. See Dos and Donts of Splicing in this document.
67
Fig. 12:8
While varied methods are necessary in making vulcanized splices on specialized types of belting, the technique normally
involves, but is not limited to, the following basic steps:
Building the Full Carcass Finger Splice:
This picture shows the centerline on the carcass and the fingers marked to be cut. The opposite belt end to be spliced to this
belt end will have the opposite fingers removed.
Outside finger point opposite the belts direction of travel. See fig. 12:9
Fig. 12:9
1.
2.
3.
4.
68
14. Build the bottom cover composite. The composite will consist of:
a. Bottom cover
b. Breaker fabric. The breaker fabric must be long and wide enough to completely wrap the carcass.
c. Inside gum
15. Clean all splicing materials with the specified solvent during installation.
16. Use the porcupine roller after each laminate to remove all possible trapped air.
17. Position the bottom cover composite
18. Build the splice as specified by the belts manufacturer. See Dos and Donts of Splicing in this document.
GENERAL SPLICE PREPARATION
Center Lining the Belt Ends On both
belt ends establish and mark
1. Establish and mark the centerline of the belt ends to be spliced by measuring across the width of the belt at three
points in length of each belt end and outside the splice area at a distance of approximately 12 in (304 mm).
2. The centerline ensures exact alignment of the belt ends, which is indispensable for straight belt running.
3. The perpendicular square line;
This square line will be the starting point from which the splice will be laid out.
4. The following three methods are general used to achieve a true straight line: a. Square
& Straight Edge Typically used on new belt with straight edges
b. Triangulation This method is typically used on the wider belts (72 and greater)
c. Swing Arch Can be used on any belt
5. The belts cover transition lines.
The transition distance is typically defined by the belts manufacturer and is a line drawn perpendicular to the
square line.
Aligning the belt ends
Accurate belt end alignment is required to ensure the belt runs straight on the conveyor system.
Misaligned splices can also create additional stress on the cords and or fill rubber within the splice.
Align the lower part of the vulcanizing press (traverses and heating platens). Accurately count the number of cables of
each belt end and mark the center cable. Align the belt ends under consideration of:
a. splice length,
b. the belts center cables and the carcass center line on each belt end
c. mark correct alignment with a chalk line. Now the center lines on both belt ends must form one straight
line.
d. The distance of the reference lines on both belt edges must be equal distances approximately the overall
splice length.
e. Secure both belt ends with clamps. See fig. 12:10
Fig. 12:10
Best practices generally used to build a bias step fabric belt vulcanized splice or the bias step fabric belt vulcanized
splice with fingers: Refer to the belts manufacturer for specific detailed splicing instructions a. Determine the appropriate
splice design.
69
a. Determine the appropriate splice design. The appropriate splice design will match the belt, the conveyor
system, and expected dynamic operating parameters. Refer to the belts manufacturer for proper splice
design and materials.
b. Lay out the splice and strip each belt end.
c. If the splice is the bias step fabric belt vulcanized splice, the bottom fill strip will lead in the belts direction
of travel. If the splice is the bias step fabric belt vulcanized splice with fingers, the bottom fill strip will
lead and the outside fingers must point opposite the belts direction of travel.
d. Strip the belt ends. Use caution and DO NOT damage the adjacent plies when cutting. If the adjacent plies
are damaged the splice must be stepped back or redone. The damaged area must be removed from the
splice.
e. Buff the 45o cover skives and one inch of the adjoining cover
f. Apply one even coat of cement to the fabric only
g. Allow all cement and solvent applications to dry completely before continuing.
h. Install thermocouples on bottom platen (minimum of one per heating zone)
i. Cover the bottom platen with release paper
j. Center line and stabilize belt ends
k. Dry Fit belt ends. Make necessary adjustments. Each ply seam / joint must have an approximate 0.031
(0.8mm) gap. Do not fit the ply seams/joints tightly together or allow them to overlap.
l. Verify the belts center line and stabilize belt ends
m. Install inside gum to the bottom of the splice carcass section
n. Place noodles over each ply seam joint and or around each finger
o. Install bottom cover fill composite
p. Position top side of the splice
q. Install top cover fill composite
r. Install thermocouples on top cover (minimum of one per heating zone)
s. Install steel edge guides and balance guides
t. Install release paper over the splice
u. Install top of press
v. Secure edge guides and wedges if necessary
w. Cure the splice following the manufacturers recommended curing specifications.
x. Document cure (cure temperature and pressure of each thermocouple at defined intervals)
y. After the cure cycle has been completed - Cool the platens to at least 130o F. while maintaining the cure
pressure.
z. Release pressure and remove the top platen of the press after the press has cooled to a minimum of 130o F.
aa. Inspect and trim the splice
bb. Buff any flash from the splice located on the adjacent belt covers. A smooth and even transition from the
belt to the splice is required.
Best practices generally used to build a bias full carcass finger fabric belt vulcanized splice:
Best practices for the traditional full carcass finger splice typically include:
a. Mark out the specified dimensional fingers at each belt end.
b. Install Thermocouples on the bottom platen at each heating element used.
c. Install the bottom cover composite on the bottom section of the vulcanizing press;
d. Cut the specified dimensional fingers to length and width.
e. Apply one even coat of the specified cement to the bare fabric carcass and fingers to promote adhesion to
the rubber;
f. Lay down the fingers in the defined direction of travel. Outside fingers will point opposite the direction of
travel.
g. Fill all voids between and around each finger and within the splice with noodles.
h. Wrap the complete carcass fingers with the specified breaker fabric.
i. Install the top cover gum followed by completion of the press assembly;
j. Install thermocouples on the top cover composite of the splice at each heating element location used.
k. Install and stabilizing the proper edge guides
l. Vulcaniz the splice.
Curing the Fabric Belt Splices:
1. Use a minimum of one thermocouple per heating element/zone.
2. The vulcanizer must be large enough to cure the splice in one cook. The platens are to be at a minimum
4 6 longer each end and 4 6 wider each side of the splice.
3. The vulcanizer must be capable of achieving and maintaining the specified curing pressure throughout the
cure and cool down cycles.
70
4. The vulcanizer should have cool down capability. Water cool down is preferred. The platens are cooled to
at least 1300 F. after the cure cycle has completed. The curing pressure is not released until the platens
have reached the desired cool down temperature. Do not leave the belt on a hot platen for an extended
period of time.
5. Refer to the belts manufacturer for the specified cure time, cure temperature and cure pressure. However,
the typical cure temperature is 2900 F +/- 50 F and the typical cure pressure is 100 psi.
6. Steel or aluminum edge guides are to be positioned along the entire length of the splice length. The
edgeguides should extend past the ends of the bottom platen by a minimum of 6 (152mm). The edge
guides are positioned tightly against the splice and belts edges and held in place with come-a-longs or
some other clamping device.
Fig. 12:11
Fig. 12:12
71
Hook types:
The Hook Type fasteners attach to the belt ends by means of hooks formed from wire or sheet steel. They are applied by
forcing the hooks through the belt and clinching on the opposite side. They have a hinge pin or rocker pin joint and can be
taken apart easily. They will permit leakage of material. These types are particularly suited for package conveying where
there relative smoothness may be an advantage. See fig. 12:14
Fig. 12:14
Extensive testing has proven the necessity for tightening the fasteners on a periodic schedule, usually after a few hours
operation, after a few days of operation and at intervals of two or three months. Inspections may indicate the necessity to
re-tighten at more frequent intervals. Failure to inspect the fasteners may result to severe belt damage and or mechanical
splice failure. Fasteners are available in a variety of different metals designed for special applications, which may include
non-sparking, non-magnetic, and abrasion and chemical resistance. The manufacturer should be consulted for the proper
recommended use of specific applications.
ELEVATOR BELT SPLICING
The type of splice is more critical on elevator belts than on conveyors because of limited take up travel for belt stretch plus
extreme dangers and difficulties generated if a splice separates and the belt falls into the boot. The confined space makes
the belt splicing difficult. Vulcanized splice: This is the most desirable splice yet the least used due to lack of available
space for the vulcanizing equipment. Consult the belt manufacturer for specific installation and/or splicing procedures.
There are several customary methods of joining elevator belt. They are listed below in order of preference:
Butt Strap Splice:
A properly designed Butt Strap Splice utilizes the bucket bolts and plate fasteners to join the belt ends. The butt strap should
be an all nylon construction equal to the elevator rating and compound and should be long enough to overlap 2 to 4 buckets
on each side of the belt joint. See fig 12:15.
72
Fig. 12:15
Lap Splice:
Only the bucket bolts join the belt ends. The ends of the belts are overlapped a minimum of four
buckets and fastened with the top row of the bucket bolts passing through both pieces of the belt.
This method should not be used for belts over 5/8 (15 mm) thick. See fig. 12:16.
Fig. 12:16
73
Fig. 12:17
74
CHAPTER 12 - Part B
INTRODUCTION
This chapter is a brief summary for splicing Steel Cord Belting. Belt users and/or splicing companies should consult the belts
manufacturer for more specific detailed splicing information.
12b:1 THE STEEL CORD CONVEYOR BELT:
The conveyor belt and conveyor structure are typically matched to ensure the expected operating conditions and tensions do not
exceed the belts limitations.
The conveyor belt type and manufacturer must be known to accurately select the specified splice design, the specified cure data and
splicing materials.
Contact the belts manufacturer with any questions or concerns.
12 b:2 STEEL CORD CONVEYOR BELT SPLICES
Vulcanized splices are typically used for steel cord belts.
Currently, mechanical fasteners do not provide the needed dynamic strength to reliably join steel cord belts.
12b:3 STEEL CABLE CONVEYOR BELT VULCANIZED SPLICES
An individual splice drawing for each steel cord belt construction can generally be obtained from the belt manufacturer. Splice
drawings typically detail the proper cutting dimensions, cord step lengths, and the correct rubber and cement to use.
Specific instructions for tearing down the belt ends and building up the uncured splice will vary with the technician. Contact the
belts manufacturer for specific splicing details and / or possible splice training.
12b:4 Construction and Dimensions of Steel Cable Belt Splices
12b:4.1 Splicing methods:
Splices on steel cable belts in accordance with DIN 22131 can be 1-step or multi-step splices in rhombic (belt width x .4) or
rectangular shape. The load ability of both the rectangular and the rhombic shaped splice is
similar.
12b:4.2 Splice Construction:
Cable diameter and cable pitch as well as the minimum breaking strength of a cable and the dynamic cable tear-out strength in the
splice area dictate length and geometrical construction of a splice.
The geometrical construction is determined by:
a. number of steps;
b. length of steps;
c. length of transitions;
d. cyclic cable laying sequence (including cut cables);
e. cable pitch in the splice area (noodle thickness).
The construction is also influenced by:
f. distance between butted cables;
g. stepping of cable ends;
The gap between butted cables shall be a min. 3 times and max. 4 times the cable diameter.
The cable ends are typically staggered to reduce the flexing load as the belt runs over the pulleys. Cables on the belt edges should be
laid in full length in opposite running direction of the belt. Cables within the dimensions of the splice must not be cut to allow room
in the splice. Using the specified splicing materials, following the specified splicing procedures and splice diagram will ensure a
straight splice and will allow all cords to fit in the splice.
If a steel cable belt is equipped with a breaker, a breaker should be applied in the splice area corresponding to the belt construction.
75
The breaker will be positioned approximately 2 inches (50 mm) from each cover skive.
12b:4.3 The splice length includes:
a. deflection zones of cables:
b. staggering of cable ends:
c. minimum step length:
d. distance of butted cables:
12b:5 SPLICE EFFICIENCY
Splice efficiency can be measured in two ways, (1) Static, (2) Dynamic.
12b:5.1 Static Splice Efficiency: Reference the ASTM testing method
Defined as the measured force required to break a splice expressed as a percentage of the theoretical breaking strength of the belt. In
addition to the peak force, the time for the splice to separate is sometimes also recorded.
This is typically performed either by clamping each belt end on either side of a splice in a suitable fixture and measuring the force to
pull the splice apart, or by making an endless belt loop with a single splice then measuring the force to pull the loop apart using a
suitable fixture.
12b:5.2 Dynamic Splice Efficiency
Defined in DIN 22110 Part 2 for fabric belt splices, and Part 3 for steel cord belt splices.
For steel cord belt splices DIN 22110 Part 3 describes a 2-pulley, constant speed test machine where an endless loop of belt with one
splice is subjected to a cyclic tension every 50 seconds. The tension cycle is intended to approximately simulate a real life belt tension
cycle but at elevated peak tensions to accelerate the test. The cycle ramps from low tension to high tension then down to the low
tension again with a ramp time ratio of 5:1 for the two segments (i.e. approximately 42 seconds up, 8 seconds down). The low test
tension is defined as 6.67% of the nominal breaking strength of the belt. The high test tension is defined as one of a series of at least
four different maximum test loads, at least one of which is typically 50% of the nominal belt breaking strength or higher. The four
test loads are used to determine four test lives, each measured in terms of the number of test cycles completed at splice failure. These
points are then plotted on a type of fatigue curve, known as a Wohler curve. The Wohler curve displays, test load (y-axis), in percent
of nominal belt break strength, against load cycles to failure (x-axis). The so-called relative reference fatigue strength of the splice,
which is expressed as a percentage of the nominal breaking strength of the belt, is defined as the test load on the Wohler curve at which
10,000 load cycles are achieved.
12b:6 Ambient Conditions during splicing
Efforts to achieve and maintain tolerant ambient temperatures and/or conditions during splicing must be made.
In extreme cold temperatures, the shelter and a portable heater may be used to maintain a warmer environment and to eliminate cold
winds from adversely affecting outer edges of the platen temperatures. Store all splice materials in a cool dry place out of direct
sunlight.
12b:7 Splice Work Shelter:
Due to the need for cleanliness and the need to protect the splice from contamination (such as dirt and dust) where possible, the splice
should be made in a sheltered area. The quality and durability of a hot splice begins with a clean work place. The splicer
should eliminate the possibility of contaminants entering the splice and/or the splicing materials and adhere to all local and other
associated safety requirements.
The entire work area should be adequately protected by the shelter from environmental influences.
The work area consists of the lower part of the press (traverses and heating platens) and approximately 10 - 12 ft (3 - 4 m) long work
tables at either end of the press. The splicer should install a work table and the bottom of the vulcanizing press.
The heating platens must be flush with the surfaces of the work tables and be at least 4 in. (100 mm) to 6 in (152 mm) longer than the
splice on each end and at least 4 in (100 mm) wider than the belt on each side.
12b:8 Storage of Splicing Materials
When unvulcanized splice materials are stored under unfavorable conditions their physical and/or chemical characteristics change.
Eventually these changes will render the unvulcanized splice materials unsuitable for use. These effects result in changes in the curing
behavior and/or in the cured physical properties of the splice materials.
76
The harmful effects of these factors can be minimized by a careful choice of the following storage conditions. In case of doubt,
consult the supplier of the conveyor belt splice material about the storage conditions.
a. Materials stored in non-refrigerated conditions will shorten shelf life. Materials stored in refrigerated conditions will
increase shelf life. Acceptable refrigerated storage temperature is at 45F-55F (12.8C-7.0C). Do not allow the materials
to freeze. Allow refrigerated materials to warm before use to allow condensation to disappear.
b. The relative humidity should preferably be below 60% for long-term storage. Damp conditions should be avoided since
long-term exposure to moisture can influence the curing and cross linking behavior of the materials.
c. Sunlight and artificial light which has a substantial content of ultraviolet light can adversely affect the stability of
unvulcanized rubber. Depending on the grade and the time span of exposure, chain rupture and/or cross linking may
occur. In view of this, exposure to light should be restricted to a minimum.
d. Where possible, unvulcanized rubber should be protected from excessive air circulation and should not be stored near
electrical equipment (motors) that could be a source of ozone. For this reason it is advisable to keep the splice material
boxes closed and sealed.
e. Unvulcanized rubber should be stored in an area which meets the usual standards of cleanliness, even though the rolls are
individually wrapped in polyethylene sheeting. Avoided direct contact with foreign materials of any kind. It is
recommended that the material be kept in its original packaging until the moment it is used.
f. Splice materials should not be stored for any longer than the specified shelf life. It is therefore recommended that the FIFO
(first in first out) stock rotation system be used.
12b:9 Tools and Equipment (Splicing Steel Cable Belt)
1. Instructions for the proper use of the needed splicing tools may be part of a designed splice training program. Practice the
safety requirements associated to the tools and equipment used.
2. Belt ends may be stripped by one of the following methods which requires special individual tools:
a. Hook Knife: Requires hook knives
b. Piano Wire: Requires piano wire and a tugger / pulling device pulling device
c. REMA Strip: Requires a REMA Strip machine and a tugger / pulling device
3. Practice the safety requirements associated to the tools and equipment used.
4. The vulcanizer must be capable of achieving and maintaining the specified temperature and pressure during the cure cycle
and be large enough to adequately cure the splice in one cure.
5. The platens must have cool down capability. A minimum of 130o F (54.4o C) is typically required before releasing the
cure pressure.
6. Steel edge guides must be secured along the edges of the splice and adjoining belt edge. The edge bars must
approximately .063 less than the overall belt gauge and extend out each end of the bottom platen a minimum of six
inches.
7. The vulcanizer must be capable of achieving and maintaining the specified temperature and pressure during the cure
cycle and be large enough to adequately cure the splice in one cure. Typical specified cure temperature is 290 +/- 50 and
the specified cure pressure is 150 psi 200 psi. Consult the belts manufacturer for accurate cure specifications.
8. Steel edge guides must be secured along the edges of the splice and adjoining belt edge. The edge bars must
approximately .063 (1.5 mm) less than the overall belt gauge and extend out each end of the bottom platen a minimum
of six inches (150 mm).
9. Use thermocouples to monitor and maintain an accurate cure temperature throughout the cure cycle. A minimum of one
thermocouple per heating element is typically specified.
Thermocouples are used to accurately maintain the specified cure temperature throughout the cure cycle. By doing so, achieving
the desired optimum cure is greatly enhanced while reducing the risk of over and/or under cured splice gums.
Most belt manufacturers typically require one thermocouple per heating zone (top & bottom platens) Thermocouple lead wire.
See fig. 12b:1
Fig. 12b:1
77
78
g.
h.
i.
j.
uring the cord and noodle assembly. Cord alignment and spacing should be checked regularly during cord assembly to ensure
width accumulations are not occurring. Corrective measures typically involve stretching noodles longitudinally, which
reduces their width, to ensure cords are aligned correctly.
Laying down the top cover composite followed by completion of the press assembly;
Installing Thermocouples on the top cover composite of the splice at each heating element location used.
Installing and wedging the proper edge guides
Vulcanizing the splice.
As the number of cords is increased in the belt, there comes a point where it is impossible to fit all cords into the splice while
maintaining the required gap between cables. In order to accommodate the extra cables it is necessary to cut and butt some of them, as
in Fig 12b:3. A splice pattern is chosen such that the rubber gap between all cords is at least 35% of the cord diameter.
79
Figure 12b:3
80
2. The centerline ensures exact alignment of the belt ends, which is indispensable for straight belt running.
3. The perpendicular square line;
This square line will be the starting point from which the splice will be laid out.
4. The following three methods are general used to achieve a true straight line:
a. Square & Straight Edge Typically used on new belt with straight edges
b. Triangulation This method is typically used on the wider belts (72 and greater)
c. Swing Arch Can be used on any belt
5. The belts cover transition lines.
The transition distance is typically defined by the belts manufacturer and is a line drawn perpendicular to the square line.
12b:15 Prepare tools, equipment and splicing materials: Be Certain that:
a. all the required tools are available and in working order
b. the vulcanizer is capable of achieving and maintaining the specified cure temperature and cure pressure.
c. the vulcanizer has cooling capabilities
d. the specified splicing materials are available and meet manufacturing requirements
e. the required curing specifications and splice design are available from the belts manufacturer before beginning the splice
12b:16.1 Draw the splice Dimensions on each belt end:
Figure 12b:4
12b:16.2 Cut off the rubber edges along the outer steel cables from belt transition lines to belt ends.
Figure 12b:5
12b:16.3 Cut the cover skives completely across the belts width and down to the cables at an angle of approximately 30o to 45o.
Figure 12b:6
IP:1 2011 Conveyor and Elevator Belt Handbook
81
12b:16.4 Remove the top cover and stripping of steel cables / Conventional manual procedure
Remove the top cover from the cover skive to the belt end.
The method of removing the cover may vary with individual splicing groups.
It may be necessary to remove the cover in longitudinal strips approximately 8 (203mm) 12 (305) wide.
Figure 12b:7
12b:16.5 The cables can be stripped by:
a. Hook Knife Usually preferred method for small diameter cables and/or short splice lengths consisting of one stage and
perhaps two stages. Cables should be cleaned of excess rubber prior to installation.
Figure 12b:8
12b:16.6 Piano Wire Usually used on cords 5.2mm or greater diameter. Remove as many/much of the rubber tips from the stripped
cables.
Figure 12b:9
82
12b:16.7 The bottom cover can be removed after the hook knife or piano wire cord removal procedure is completed.
12b:16.8 Coated Cords for Pre-Mold Splices: Cords will have approximately .5mm of the belts cured inside gum attached. This
allows rubber to rubber adhesions for greater bonding and dynamic performance. Pre-Mold splices are typically used in cases where
many of the same splices will be applied and or on the larger diameter cords.
a. Make sure to use cutting blades corresponding to the cable diameter.
b. After stripping, the result should be a nearly round cable, with rubber embedded on the cable. Stripped cables should be
handled with clean gloves only and placed onto a clean surface (PE film).
c. Requires buffing the cords no more than twenty four hours prior to installation.
d. Carefully buff the rubber embedded cables with a grooved wire brush. Avoid overheating, shiny spots and scorching of the
rubber. Buffing will automatically break the edges of cubed cable rubber.
e. Cementing the cables is not necessary when using the Pre-mold Belt Splice Method
f. Stripped cables should be handled with clean gloves only and placed onto a clean surface.
12b:17 Aligning the belt ends
Accurate belt end alignment is required to ensure the belt runs straight on the conveyor system. Misaligned splices can also create
additional stress on the cords and or fill rubber within the splice. Align the lower part of the vulcanizing press (traverses and heating
platens). Accurately count the number of cables of each belt end and mark the center cable.
Align the belt ends under consideration of:
a. splice length,
b. the belts center cables and the carcass center line on each belt end
c. mark correct alignment with a chalk line. Now the center lines on both belt ends must form one straight line.
d. The distance of the reference lines on both belt edges must be equal distances approximately the overall splice length.
e. Secure both belt ends with clamps.
Figure 12b:10
83
84
c. Cover gum
It is not necessary to use cements between the layers of the cover pads. It is recommended to strike / wipe the surfaces with
the specified solvent Allow the solvent to dry completely then laminate. After each laminate remove all possible trapped air
using the Porcupine / stitcher roller.
12b:23 Installing the bottom cover pad
a. Measure and cut a bottom cover approximately 16 longer and 6 wider than the splice.
b. Wipe it clean with solvent.
c. Cut an equal size inside gum / tie gum and wipe it clean with solvent
d. Install the inside gum / tie gum to the cover gum matching the cleaned sides to each other
e. Remove all possible trapped air using the porcupine / pricker roller.
f. Carefully place the bottom cover pad in position between the belt ends and mark the location of the cover skives.
g. Make a 450 skive cut along the freshly made cover skive marks on the bottom cover composite
h. Position the bottom cover in place matching the cover skives of both belt ends and the bottom cover pad skive cuts.
12b:24 Matching and Laying Cables:
a. Splices with odd number of cables at each belt end will generally have a butt gap joining the center cables.
b. Splices with even number of cables at each belt end will generally have two long center cables.
c. The center cords must be center lined and placed in the splice
d. Lay the cables from the center cords to the outside cords as explained in the corresponding splice drawing.
e. Check for proper cord alignment during the process of laying the cables.
f. Outside cables must point opposite the belts direction of travel.
g. It is very important to follow the specified splice dimensions and design when laying cables. Do not cut additional cables to
allow room if cables begin to bow.
h. The top and bottom covers must be stitched tightly against the top and bottom cover skives. The cover skives as well as the
adjoining cover pad interface must be cut at approximately 450 angles.
i. The belts cover skives must be buffed and cleaned.
j. Strike / wipe the belts cover skives and the top and bottom cover pads skives with solvent before mating them together.
k. Scribe / mark the step lines for laying the cables according to the specified laying scheme of the splice diagram on the tie gum
of the bottom cover composite.
l. The step lines can also be marked by placing noodle rubber strips onto the established lines.
12b:25 Laying the cables:
The following steps are guidelines which are generally true: However it is strongly recommended to refer to and follow the instructions as detailed on the splice drawing for the particular splice being applied.
a. The belts manufacturer will generally supply a splice drawing when requested.
b. Always start in the center of the splice by accurately positioning the center cables. Continue laying cables from the center to
the splice edges.
c. Lay an equal number of cables at each side of the center cords checking the alignment often.
d. Carefully clean all surfaces with the specified solvent to remove possible contaminants and create better green tack.
e. The specified noodle rubber strip is placed edgewise between the cables. The dimensions of the noodle rubber strips are to
ensure that the cables are laying straight and maintain the correct gap between them.
f. Correctly using the noodle tie rubber strips will help to maintain a uniform distance between the cables, especially at the
cable ends, which are exposed to the maximum rubber shearing force within the splice.
g. During the laying operation continuously check that the cables are laying straight.
h. When the last cables are laid, there should be sufficient space for the rubber edge.
12b:25.1 One step splices: Splices with odd number of cables in them generally will have a butt gap joining the center cables of each
belt end.
12b:25.2 Two step and multi-step splices: In both cases start with the center cable of the first belt end, which, in case of a multistep
splice is a long cable. This cable is deflected by half the cable pitch towards the belt center line.
On the second belt end also start with the center cable, which then is deflected towards the other side of the belt center line by half
the cable pitch and laid in the matching length in accordance with the cable cycle. All further cables are laid according to cable laying
scheme proceeding to the edge on both sides.
12b:25.3 Even number of cables
On each belt end start with the left cable of the two center cables, which are staggered towards the marked belt center line.
85
86
87
Section 12b:7
Tool &
Equipment
Section 12b:9
Section 12b:4
Section 12b:14
Section 12b:14
Section 12b:14
Section 12b:14
Section 12b:21
Section 12b:16.5
Section 12b:16.6
Section 12b:16.8
88
Section 11.0
Section
12b:11
Page: #11
& Cementing
Section
Section
16.3 12b:16.3
Page: #9
Section 12b:19
19.0
Section
Page: #12
Section
12b:20
Section 20.0
Page: #12
Bottom Cover
Composite
Bottom Thermocouple
Installation
Section
9.012b:9
Section
Page: #4
Section 10.3
Page: #13
Bottom Cover
Installation
Cord
Lay - Up
Top Cover
Installation
Top Thermocouple
Installation
Section 23.0
Section
Page: #1312b:23
Section 24.0
Section 12b:24
Page: #14
Section
26.012b:26
Section
Page: #15
Section 27.1.0
Section
12b:27.1
Page: #13
Section
Section9 12b:9
Page: #4
89
Final Press
Assembly
Cure
Start-up
Final Press
Assembly
Section 27.0
Section 12b:27
Page: #15 & #16
Splice
Vulcanization
Monitor
Cure Time
& Pressure
Cool Platens
To at least
130o 54oC
Vulcanizer
Removal
Section27.0
12b:27
Section
Page: #15
Section27.5
12b:27.5
Section
Page: #16
Section 27.0
Section
12b:27
Page: #15
Document Cure
Temperature &
Pressure
Section
12b:10
Section
10.0
Page: #5
Section 27.5
Section
12b:27.5
Page: #16
Section
Section27.5
12b:27.5
Page: #16
Section 27.5
Section
12b:27.5
Page: #16
Splice Completion
90
CHAPTER 13
BELT MONITORING
INTRODUCTION
Conveyor belts are a critical component of many mining and processing operations. The loss of a conveyor belt on a
critical conveyor line will result in significant downtime and cost the operation significantly due to lost productivity. There
are a number of methods that can be utilized by operations to monitor their belt in order to maximize the belts productivity.
Operation monitoring sensors continually monitor the interaction between the material being conveyed, the conveyor belt and
the conveyor system in order to detect situations that are considered to be out of the normal operating conditions. Included
in these sensors are belt slip sensors, belt tracking or misalignment sensors, plugged chute sensors and metal detectors, to
name a few. By monitoring the operation for potentially catastrophic events it is possible to minimize or avoid damage to the
conveyor belt that would result in prolong downtime of the mining operation.
13:1 Operation-Based Sensors
Slip Sensors
Slip Sensors monitor for belts running on a frozen pulley or a pulley driving a belt that is not moving. In either case,
this type of event will result is a large amount of heat from frictional forces between the pulley and the belt that can
result in fire and potentially a broken belt. The slip sensors monitor the rotation of two different pulleys on the
system and compare the speed differential between the two pulleys. This is typically accomplished using encoders or
proximity sensors mounted on two different pulleys, normally a drive and a separate non-drive pulley. Assuming the
system is functioning properly, the speed of the belt should be the same in both locations.
Alignment Switches
Alignment Switches are used to measure when a belt tracks off of the conveyor structure. These are used to trigger a
belt stop when the belt pushes a bar attached to a limit switch beyond the limit setting for that switch. Belt tracking
could also be tracked by an ultrasonic sensor; however, the fail safe characteristics of the alignment switches are the
most common methodology implemented in mines.
Figure 13:1: Misalignment Switch Mounted Near Edge of Conveyor Belt
Infrared Technology
Infrared Technology in the form of spot, line and camera sensors are often used in the coal industry to monitor the
temperature of the material being carried; however, in some cases, IR cameras are also being used as a means to
detect heat build in pulleys or idler rolls.
91
Metal Detectors
Metal Detectors are often utilized to detect metal debris on the belt that may result in belt damage or a longitudinal
rip. If a large enough piece of metallic debris is detected, the unit will shut the conveyor down to enable operations
to remove the metal. In high risk areas, mines will implement electromagnets to remove as much of this metallic
debris as possible out of the material being conveyed before it causes damage.
Speed Monitors
Speed Monitors are used to monitor the belt speed in order to ensure the belt drives are controlling the belt speed
properly. Speed sensors can either be encoders that make physical contact with pulley or a non-contact proximity
sensor that detects a target system mounted to the pulley (Figure 13:2). In either case, the revolution of the pulley is
converted to a belt speed and this speed is used to verify that the conveyor is functioning properly.
Figure 13:2 Encoder and Proximity Sensor Speed Sensors
92
93
94
or under the magnet. Once magnetized, a single steel cord will have a north polarity on one end and a south
polarity on the opposite end. The magnetic flux lines that are emitted from these cord ends will be more per
pendicular to the belt surface and hence magnetically distinct from the magnetic field of the rest of the belt.
These distinct magnetic flux lines can be detected using inductive coils or solid state sensor technologies, both
of which generate voltages proportional to the magnetic field strength in the region of the cord ends. With
this technology, it is possible to map any cord damages that occur along any given length of belt. The fact that
this sensor technology is not restrictive and can be used to monitor the conveyor belt continuously, these
sensors are starting to find their way into the mainline sensor arsenal of mines. The ability to detect and
minimize the risk of a transverse tear event and the ability to detect longitudinal rips is expected to become a
standard in steel cord conveyor belt monitoring.
Splice Monitoring
Splice monitoring in textile belts has always been a challenge. Historically, the two most common systems for splice
monitoring in textile belting utilize optical or magnetic markers near the edges of the splice. By comparing subsequent
images of the splice to a baseline image, the quality of the splice can be determined. Primarily, the analysis is looking at
splice deformation compared to the baseline image in the form of de-linearization of the splice along designed
construction lines and/or the elongation of the overall splice length.
X-Ray Based Splice Scanning
Periodic X-Ray scanning of textile and steel cord splices has also been a method of checking the integrity
of the conveyor belt splices. Like in the conveyor belt, damage to the fabric or steel cords will be visible as
density changes in the belt. Variation in splice lengths and deformations can also be determined by
analyzing the X-ray images and comparing them to a benchmark image of the belt.
Magnetic Based Splice Scanning
Steel cord splice monitoring has historically been done as part of the belt analysis on a periodic basis. Once a
magnetic scan was completed the magnetic signal is reviewed for evidence of change or degradation of the
magnetic intensities. In some cases, once a magnetic anomaly has been identified X-Ray images are
completed to verify the magnetic results. This type of analysis has been automated more recently in order to
continually monitor changes to a splice over time and to alarm if the splice quality is degrading.
For the best combination of conveyor belt design and applicable sensor systems for a given application, it is recommended that
the belt manufacturer is consulted.
95
CHAPTER 14
Belting ready for installation should be mounted on a shaft for unrolling and threading onto the conveyor. Conveyor belting can be
rolled with top cover either in or out, and this should be considered when positioning the roll for threading.
In some cases, such as in mines where head room does not permit maneuvering a roll, the belt may have to be pulled off the roll and
reefed. Extreme care must be exercised to see that the loops have large bends to avoid kinking or placing undue strain on the belt. No
weight should ever be placed on the belt when it is in a reefed position. Ideally, supports should be placed at each end where the bends
occur. Another method of handling belting under such conditions is to lay the roll on a turntable with a vertical spindle. The belt must
make a 90-degree twist as it comes off the turntable.
New belting can be pulled onto the conveyor either by attaching it to the trailing end of the old belt which has been cut or, in the
case of a new installation, by attaching it to a rope or cable which has been threaded around the idlers and pulleys. It is important to
prevent damage to the new belt. It should be attached to the old belt or cable with a clamp or other device so as to distribute the pull
evenly over its entire width.
IDLERS
Diameter
The diameter of carrying idlers should conform to the following:
Table 14-1. Idler Recommendations
Diameter of Idler
up to 4 in (100 mm)
Conditions of Use
Portable underground equipment for coal.
4 in (100 mm)
Materials 40 lb/ft3(640 kg/m3) or less. Speeds 300 ft/min (1.5 m/s) or less.
5 in (125 mm)
Materials of 100 lb/ft3(1600 kg/m3) or less. Speeds 600 ft/min (3 m/s) or less. Lumps notover 12
in (300 mm).
6 in (150 mm)
Materials over 100 lb/ft3(1600 kg/m3). Speeds 800 ft/min (4 m/s) or less. Lumps up to 18 in
(450 mm).
7 in (175 mm)
Materials over 100 lb/ft3(1600 kg/m3). Speeds up to 1000 ft/min (5 m/s). Lumps over 18 in
(450 mm).
Note: Idlers are also categorized by their load carrying ability. The Conveyor Equipment Manufacturers Association (CEMA) defines
a range of standard idlers.
IP:1 2011 Conveyor and Elevator Belt Handbook
96
Width
The length of the idlers must be greater than the width of the belt to allow for transverse movement of the belt. In general, the length
of the idlers shall not be less than:
Table 14-2. Width
Belt Width
+ 3 in (75 mm)
+ 4 in (100 mm)
+ 5 in (125 mm)
Note: For information on idler gaps see Chapter 5, Troughability and Load Support.
Structural Clearance
The conveyor belt must have the ability to move transversely to prevent damage to the belt edges due to structural misalignment,
foundation shifting, temperature changes, weather conditions, belt tolerances, etc.
These conditions become more severe as the conveyor length increases. Therefore the following belt clearance must be observed:
Table 14-3. Belt Structural Clearance
Structural Clearance (Minimum Each Edge)
Belt Width
6 in (152 mm)
4 in (102 mm)
6 in (152 mm)
6 in (152 mm)
8 in (203 mm)
Training Influence
Comments
2 Roll V
Positive
Flat
None
None
Less desirable than flat but acceptable with training idlers as needed.
(Cluster of 8 in (203 mm) min.)
None
Not recommended
A belt is basically trained by the effect of contact between the belt surface and the face of the idlers. Misalignment in a conveyor
system, misaligned idlers, or a crooked belt, will cause off-center operation, but as long as the belt surface contacts the idlers and
there is not a restricting edge force, training can be controlled by adjusting idler alignment and/or use of training idlers. Usually, these
adjustments are sufficient to permit acceptable belt training.
Narrow disc type return idlers can cause conveyor belt training problems because they violate the basic concepts for belt training in
two respects, as follows:
1. The belt edges may extend beyond the end discs on the idlers. Any degree of off-center operation due either to idler misalignment or
belt crookedness results in an edge extending well beyond the end disc, sometimes to the extent that the cantilever effect eliminates
or reduces belt surface contact on the face of the idler to the point that training effect is lost. At this point, the belt tends to move off
the pulley until it contacts some stationary part of the conveyor structure, thus damaging the belt and/or the structure. This effect
will be exaggerated with belts in which some degree of cupping or curl is present.
2. When a belt moves off-center on narrow disc type return idlers to the extent that one edge is inside the end disc, that edge may drop
down enough that corrective training action will be restricted because the belt edge is trapped inside the end disc. This effect will
also be exaggerated by any degree of cupping or curl in the belt (see Figure 14-1).
97
Figure 14-1.
Table 14-5. Minimum Face Width of Pulleys
Conveyor Centers
Examples:
1. A belt 42 in (1050 mm) wide on centers of 450 ft (135 m) will use pulleys with a minimum face width of 44 in (1110 mm).
2. A belt 48 in (1200 mm) wide on centers of 450 ft (135 m) will use pulleys with a minimum face width of 51 in (1275 mm).
3. A belt 42 in (1050 mm) wide on centers of 500 ft (150 m) will use pulleys with a minimum face width of 46 in (1150 mm) since a
46 in (1150 mm) face is the next standard face width above 44 in (1100 mm).
4. A belt 48 in (1200 mm) wide on centers of 500 ft (150 m) will use pulleys with a minimum face width of 54 in (1400 mm) since a
54 in (1400 mm) face is the next standard face width above 51 in (1275 mm).
BELT TRAINING
The basic rule of tracking is that the belt moves toward the end of the roll/idler that it contacts first. All conveyors require a positive
training influence on the belt to maintain a centered position. This is particularly true on conveyor centers over 500 ft (150 m) where
structural tolerances, weather conditions and multi-ply belt roll variations can accumulate.
Usually the troughing idlers on the carrying side exert a training influence and are generally sufficient to maintain belt position. The
addition of carrying side training idlers can be installed if needed for the more difficult conveyor.
The return side presents the most serious condition for belt damage due to its confined position within the conveyor structure or idler
hanger brackets. The typical flat return idler exerts no positive centering influence on the belt.
Table 15-4 outlines the effectiveness of the different types of return idlers as to belt training.
Training a belt is the procedure required to make a belt run straight when empty and also when fully loaded. If a conveyor belt is off
center in the loading zone the belt will not track well down the carry side of the conveyor. It is therefore critical to have the belt centered as it goes through the areas where material is loaded on the belt.
Pulleys
All pulleys must be set at right angles to the direction of belt travel.
Manual Take-Up
This device must be such that when tension is applied to the pulley, the pulley will remain at right angles to the direction of belt travel.
98
Automatic Take-Up
The track alignment must be such that the pulley(s) are maintained at right angles to the direction of belt travel. In a gravity take-up
the carriage must be guided to maintain the pulley on a horizontal axis.
Idlers
The troughing and return idlers should be initially installed at right angles to the direction of belt travel. All tilted wing idlers must
be installed with the tilt in the direction of the belt travel. Tilting of idlers should not be done on reversing conveyors as the positive
training influence in one direction can cause negative training influence when the belt is run in the opposite direction.
Conveyor Structure
The conveyor structure must be straight and level.
Side Guide Idlers
Side guide idlers are not recommended for constant use in forcing belts to run straight. They may be used to assist in training a belt
initially or for protection in an emergency.
Reversible Belts
In reversible belts all idlers should be kept at right angles to the direction of belt travel and any correction necessary made with
self-aligning idlers designed for reversing operation. (See Tilted Troughing Idlers below.)
Procedure for Training a Belt
The normal sequence of training a belt is to start with the return run, working toward the tail pulley, and then to follow with the top
run in the direction of belt travel. Start with the belt empty. For stiff belts it may be desirable to load the belt after the return run is
corrected to complete the training.
Adjustment is made while the belt is running and should be spread over some length of the conveyor preceding the region of trouble.
The result of an adjustment may not be immediately apparent, so permit the belt to run for several minutes after the idlers have been
adjusted to determine if additional adjustment is required.
If the belt is over-corrected after adjustment, it should be restored by moving the same idler back and not by shifting additional idlers.
If the entire belt runs to one side at a particular point(s) on the conveyor structure, the cause will probably be due to the alignment or
leveling of the structure or to the idlers and pulleys in that particular area or a combination of these factors.
If a section(s) of the belt runs off at all points along the conveyor, the cause is most likely in the belt itself, in the belt not being joined
squarely, or in the loading of the belt. If it is in the belt, this will be due to bow, and it should correct itself after it is operated under
fully loaded tension. A bowed belt rarely needs to be replaced.
If a belt is not joined squarely, it is necessary to cut away the faulty joint and make a new one properly squared.
Tilted Troughing Idlers
Tilting the troughing idlers forward, not over 2, in the direction of belt travel produces good alignment. If the angle of tilt exceeds 2,
excessive wear may occur on the pulley side of the belt and on the troughing idler itself due to rotation of these rolls on an axis not at
right angles to the direction of belt travel. Tilted troughing idlers must not be used on reversible belts.
Centering a belt as it approaches the tail pulley can be further assisted by slightly advanced and raising the alternate ends of the return
idlers nearest the tail pulley.
Self-Aligning Idlers
Both troughing and return idlers are usually mounted on center pivots. An off-center belt causes the idlers to rotate about these center
vertical pivots in such a direction as to bring the belt back to center. These should only be used on problem systems and should ideally
be up to 50 ft from any terminal or bend pulleys to achieve maximum benefit. Do not use training idlers in either concave or convex
vertical curves.
1. Unidirectional Self-Aligning Idlers
This type of idler depends on pressure from the belt edge on a side roller mounted on an arm extended in the front of the idler. It
will function only for belts running in one direction.
99
PULLEY CROWNS
The purpose of a pulley crown is to create a centering force on the belt so that the belt tends to train toward the center of the pulley
thereby holding the belt centrally on the conveyor. The crowned pulley is most effective when it has a long unsupported span of belt
approaching the pulley. The lateral position of the belt can be influenced by the crown more easily when there is a minimum of
resistance being offered by a supporting slider bed or supporting idlers.
Crown-faced pulleys should never be used on systems with steel cord belting, or high modulus ply type belting.
When a crowned pulley is used, the recommended amount and configuration of crown used is dependent upon the belt type and belt
tension applied.
PULLEY LAGGING
Drive Pulleys
Drive pulleys should be lagged for the following reasons:
1. Improved coefficient of friction. This permits a belt to be driven by lower slack slide tension, resulting in lower total tension in
many cases.
2. Reduction of slippage in wet conditions if grooved lagging is used.
3. Increased life for pulley and belt covers.
Non-Driving Pulleys
Non-driving pulleys, especially those contacting the carrying cover, should be lagged for the following reasons:
1. Partial self-cleaning. Rubber deflection minimizes material build up on pulleys. Grooving generally improves the deflection and
cleaning action of lagging.
2. Increased life for pulley and belt covers.
Quality of Pulley Lagging
Various polymers are used for lagging, but the most common are natural rubber, SBR, neoprene and urethane. Except in very light
service, the level of quality is generally equal to or greater than Grade 2 conveyor belting.
Hardness recommendations for lagging are generally as follows:
Drive and High Tension Pulleys* 60 5 Shore A Durometer
Non-Driving, Low Tension Pulleys 45 5 Shore A Durometer
*With some high tension steel cord belts, pulley lagging on high tension pulleys of 70 5 Shore A Durometer is recommended.
Types of Pulley Lagging
1. Vulcanized-on Lagging
This is a material generally 1/2 in (13 mm) thick cured directly to the metal surface. Fabric reinforcement is not required. It is longer
wearing with better and more uniform adhesion to the pulley than bolted-on lagging.
2. Cemented-on Lagging
This is similar to vulcanized-on lagging except that the rubber is cured and supplied in sheet form. Field application using the proper
self-curing cement is its big advantage over the vulcanized-on type. When properly applied, the results are comparable to
vulcanized-on lagging.
3. Sprayed-on Lagging
This type of lagging is applied from an airless spray gun supplied with suitable material.
100
4. Bolted-on Lagging
This comes in strip or sheet form and is fabric backed with two or more plies of belt duck to hold bolts. The thickness is generally 1/8
in (3 mm) for smooth lagging and 1/4 in (6 mm) for grooved. When installed, the bolt heads must be sunk below the level of the
surrounding lagging to prevent damage to the belt cover.
5. Spiral Lagging
This is a lagging with a special adhesive backing which may be spiraled onto the pulley for low tension service.
6. Stretch on Sleeve Lagging
This lagging is previously made as a curved sleeve and is stretched onto the pulley.
7. Grooved Pulley Lagging
A grooved lagging is usually required to maintain a sufficient coefficient of friction between a drive pulley and a wet belt. The pattern
of grooving most commonly used is a chevron or herringbone design with the apex at the pulley center pointing in the direction of belt
travel so the pulley cover engages the groove progressively from the center to the belt edge, driving out water or slimy materials.
Groove depth should leave at least 1/16 in (2 mm) or more material at the bottom on fabric-backed lagging and 1/8 in (3 mm) or more
at the bottom on non-reinforced lagging.
Groove widths generally range from 1/4 in (6 mm) to 3/4 in (19 mm).
Center spacing of grooves is usually from 1 in (25 mm) to 2 in (50 mm) but sometimes is as little as 1/2 in (13 mm).
Note: For further information on pulley lagging please refer to the current ARPM Roll Covering Handbook (ARPM IP-5).
TAKE-UP
Introduction
A take-up device in a conveyor belt system has three major functions:
1. To establish and maintain a minimum slack-side operating tension in the belt that will enable the drive pulley(s) to impart the
necessary tractive force to the belt and will prevent excessive sag of the loaded belt between idlers.
2. To remove the accumulation of slack (elastic elongation) in the belt occurring at start-up or during momentary overloads, in
addition to maintaining the correct operating tension.
3. To provide sufficient reserve belt length to permit resplicing if necessary.
Types
1. Screw Take-Up (Manual)
This type of take-up consists of tension pulley, usually the tail, which can be moved to tighten the belt by means of threaded rods or
by steel cables which can be wound on a winch. They give no indication of the tension they establish and are adjusted by trial and
error until slippage is avoided. They are unable to automatically compensate for any length changes in the belt between adjustments
and they permit wide variations in belt tension. Use is generally restricted to short and lightly stressed conveyor belts up to 200 ft (60
m) center-to-center in length.
2. Automatic Take-Up
This type depends on suspension of a predetermined weight (gravity) or by activation of a torque motor or by hydraulic pressure.
These devices maintain a predetermined tension at the point of take-up regardless of changes in belt length resulting from load
change, start-up, stretch, etc. They allow the belt to be run under the minimum operating tension and should be used on all long
conveyors and moderate to highly stressed conveyors.
ASSOCIATED EQUIPMENT
Decking
Decking between the top and return runs will prevent spillage of excess material from falling on the return. Even though it might not
be considered for the entire length, such decking is especially desirable in the loading region.
101
Plows
Plows should be placed on the return run immediately in front of the tail pulley or other pulleys so material which has fallen on the
return run is not carried between the belt and pulley. Plows are generally held against the belt by gravity and set at an angle of about
45 to the direction of belt travel.
Screen Bars
When dealing with lumpy material mixed with fines, incorporation of screen bars into the back plate of the chute allows the fines to
fall through first and form a bed or cushion to help absorb the impacting force of the lumps and minimize cutting and gouging of the
cover. A V slot cut in the bottom of the chute is another satisfactory method of allowing fines to fall on the belt before the lumps.
Skirt Boards
Skirt boards assist in centering and settling the load on the belt as it leaves the loading point. They are vertical or inclined slightly
outward at the top and are set in from each edge by approximately one-sixth of the width of the belt. Thus, at the start, the opening
is two-thirds of the width of the belt, tapering out in the direction of belt travel. The length, which should be sufficient to center and
settle the load properly, is generally four to five times the width of the belt. The solid structure of the skirt board is never brought
down tightly against the belt surface, but is left with a substantial clearance [approximately 1 in (25 mm) minimum] which is then
closed with a sealing strip. The clearance between the skirt boards and the belt should increase in the direction of belt travel to permit
freeing any trapped material. To further ensure against trapping material here, the sealing strip should be on the inside of the skirt
board. Skirt boards are what may be termed necessary evils and, if not kept properly set and sealed, can do more damage to the belt
than any other single source of abrasion or cover cutting.
Vertical Take-Up Protection Plates
The use of a metal plate is recommended to keep material which would have fallen into the loop from dropping down between the
belt and the take-up pulley.
Belt Cleaning Devices
Adequate means must be provided for belt cleaning, particularly where materials are damp and/or sticky and have a tendency to build
up on the pulley or idlers. Build-up of material on snub pulleys and return idlers as well as on other pulleys will cause the belt to run
out of line.
1. Brushes
Dry materials may be cleaned off the belt with rotating bristle or vane brushes driven at a fairly high surface speed. These brushes
wear rapidly, require considerable maintenance, and are likely to fill up and solidify if used with moist, wet, or sticky materials.
2. Scrapers
These are generally mounted adjacent to the head pulley. Care should be taken that they are held against the belt with only sufficient
pressure to remove the material without causing damage. With sticky materials it is generally necessary to apply a scraper to the snub
pulley also.
3. Water Sprays
Water sprays before wiping with a scraper will do a good cleaning job on almost any material.
MAINTENANCE
Lubrication of Metal Parts
Provision must be made for lubrication of the driving gear, bearings, and idlers of a conveyor system, and a program of periodic
checking should be adopted and followed. All lubrication should be according to the recommendations of the manufacturer of the
equipment.
1. Idlers
Idlers should be lubricated as frequently as is needed to keep them in good running condition. A frozen idler will cause excessive
cover wear and may lead to crooked running resulting in edge wear or even igniting the belt when it is stopped.
2. Self-Aligned Idlers
These idlers must have freedom to move and good lubrication is essential.
102
3. Excessive Lubrication
Excessive lubrication should be avoided and extreme care must be taken in lubrication that oil or grease does not get on the belt and
that no excess can drop or otherwise come into contact with the covers of the belt.
Belt
The belt itself should be checked periodically for cover cuts, gouges, abraded areas, edge wear, and carcass breaks. Both the top
and bottom of the belt should be inspected. The frequency of inspection will depend on the type and severity of service. Field-made
repairs of belting are discussed in detail below.
Cause A:
Solutions:
Cause B:
Solutions:
Sticking idlers
Free idlers and improve maintenance and lubrication
Cause C:
Solutions:
Cause D:
Solutions:
Cause E:
Solutions:
Cause F:
Solutions:
Problem 2:
Particular section of belt runs to one side at all points on the conveyor.
Cause A:
Solutions:
Cause B:
Solutions:
Bowed belt
For a new belt, this condition should disappear during break-in; in rare instances, belt must be straightened or
replaced; check storage and handling of the belt rolls.
Problem 3:
Belt runs to one side for long distance or entire length of the conveyor.
Cause A:
Solutions:
Belt running off-center around the tail pulley and through the loading area
Install training idlers on the return side prior to the tail pulley
Cause B:
Solutions:
Cause C:
Solutions:
Cause D:
Solutions:
Cause E:
Solutions:
Cause F:
Solutions:
103
Problem 4:
Cause A:
Solutions:
Problem 5:
Cause A:
Solutions:
Belt running off-center around the tail pulley and through the loading area
Install training idlers on the return side prior to the tail pulley
Cause B:
Solutions:
Cause C:
Solutions:
Problem 6:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Cause D:
Solutions:
Problem 7:
Belt slip
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Cause D:
Solutions:
Cause E:
Solutions:
Sticking idlers
Free idlers and improve maintenance and lubrication
Problem 8:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Problem 9:
Cause A:
Solutions:
104
Cause B:
Solutions:
Improper initial positioning of the counterweight in its carriage, causing apparent excessive belt stretch
Consult conveyor belt manufacturer for the recommended initial position
Cause C:
Solutions:
Cause D:
Solutions:
Cause E:
Solutions:
Cause F:
Solutions:
Problem 10:
Cause A:
Solutions:
Problem 11:
Belt shrinks
Belt absorbing moisture
Put in extra piece of belt; increase tension if belt construction permits - contact conveyor belt manufacturer before
increasing tension
Grooving, gouging or stripping of the top cover
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Cause D:
Solutions:
Cause E:
Solutions:
Excessive sag between idlers causing the load to work and shuffle on the belt as it passes over idlers
Increase tension if unnecessarily low; reduce idler spacing
Problem 13:
Cause A:
Solutions:
Sticking idlers
Free idlers, improve maintenance and lubrication
Cause B:
Solutions:
Cause C:
Solutions:
105
Cause D:
Solutions:
Cause E:
Solutions:
Cause F:
Solutions:
Cause G:
Solutions:
Problem 14:
Cause A:
Solutions:
Sticking idlers
Free idlers and improve maintenance and lubrication
Cause B:
Solutions:
Cause C:
Solutions:
Cause D:
Solutions:
Problem 15:
Cause A:
Solutions:
Cause B:
Solutions:
Problem 16:
Cause A:
Solutions:
Problem 17:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Cause D:
Solutions:
Problem 18:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
106
Cause D:
Solutions:
Cause E:
Solutions:
Problem 19:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Cause D:
Solutions:
Bowed belt
For a new belt, this condition should disappear during break-in; in rare instances, the belt must be straightened or
replaced; check storage and handling of belt rolls
Problem 20:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Problem 21:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Problem 22:
Ply separation
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
Problem 23:
Cause A:
Solutions:
Cause B:
Solutions:
Cause C:
Solutions:
107
Problem 24:
Cause A:
Solutions:
Cause B:
Solutions:
ELEVATOR BELTS
The general rules set forth in Chapter 15, Storage of Belting, and in the preceding pages of this chapter are to be observed in storing,
installing, maintaining, repairing, and inspecting elevator belts. The following comments apply to elevator belts only:
Punching
Elevator belts should be punched with the aid of a template to ensure correct location of the holes.
Tension
Apply only enough tension to avoid:
a. Slippage at the drive pulley and;
b. Belt slack at the boot pulley.
Joints
1. Fastened
Lap and butt joints are most frequently used. Lap joints are generally not recommended for belts having more than six or seven plies
of fabric because they tend to pound considerably on the pulley. A butt strap joint is generally recommended for thick belts, in which
case a separate piece of belting is laid over the joint extending under at least two buckets on each side of the joint. Plate fasteners are
not recommended where the belting is stressed beyond 50% of its rating.
2. Vulcanized
Vulcanized splices are recommended on large, highly stressed belts and often are the most economical when adequate take-up is
available.
3. Oil Well Splice
The oil well splice is sometimes used for light-duty applications where the belt gauge is thin and the tensions are low. Some users
have successfully developed oil well splices that are tailored to their equipment and type of belt. The following guidelines should be
adhered to:
a. Do not use oil well splices on any elevators running at more than 50 percent of rated belt tension.
b. Clamps should extend to within 1/2 in of belt edges. If they are too much shorter than the belt width, the belt may tend to
crease around clamp ends and tear.
c. Plates used to make the clamps should be heavy enough to spread the clamp pressure over as mucg belt area as possible.
Thickness of 1/4 in for light belts and service to 1/2 in for heavy belts and service are generally acceptable.
d. Bend as large a radius as possible. Radii more than 1in are probably rarely used but even a 1 in radius can induce enormous
bending stresses in the belt.
e. Form the clamps by bending steel plate rather than rounding one edge of a steel angle bar.
f. Keep bolt holes as far from the ends of the clamps as possible; twice the thickness of the belt with a 1 in minimum. Less
than 1 in is no doubt frequently used with success, especially in light service, but it could lead to reduced splice life.
g. Install clamps tightly and then retighten at frequent intervals. The more the rubber in the belt construction, the greater the
possibility of some compression set early in the splice life which could cause the clamp to loosen. This is the same
procedure commonly recommended with mechanical conveyor belt fasteners.
108
Flaps
Flaps made of transmission belting or conveyor belting (new or used) are useful on continuous bucket elevators to keep material from
getting under the buckets as they discharge.
Hot Material
Where hot material is being carried, washers made from belting placed under each bucket are recommended. These washers will
protect the belt from the heat of the bucket.
Clearance
The elevator system must be designed to provide the necessary clearance for the belt and buckets.
Inspection
1. Splices
Splices should be inspected frequently to see that there is no immediate danger of a failure that would allow the whole belt to fall into
the boot. Such an occurrence could result in serious damage to the belt.
2. Buckets
The buckets and bolts should be inspected frequently. Badly worn buckets should be replaced. Loose bolts should be retightened to
seat the head in the cover properly. Badly worn bolts should be replaced.
3. Boot
When handling hard, coarse materials, an accumulation of lumps in the boot should be avoided. Pieces of material not picked up by
the normal passage of buckets may become jammed and tear off buckets or damage the belt. Decking installation just above the boot
pulley will prevent any large particles from falling between the pulley and the belt. The take-up mechanism on a boot take-up should
be kept clean to permit the required adjustment.
109
advantage of centrifugal force acting at the center of gravity of the material in the bucket.
Continuous bucket elevators have buckets installed close together and shaped so that discharge can be accomplished by gravity alone
at fairly slow speeds. The discharge from one bucket slides over the flanged back of the preceding bucket.
Elevator Loading
Spaced centrifugal elevators are usually vertical and, when inclined, are not more than 20 to 25 from the vertical. Loading is
accomplished by digging in the boot or a combination of digging and fly-feed from a chute feeding directly into buckets on the
ascending leg.
Centrifugal discharge elevators are preferred for handling fine, free flowing, or small lump material such as grain, sand, gravel, coal,
finely crushed ore, sugar, or any other material which may be loaded into the spaced buckets by digging at the boot pulley and which
leaves the bucket easily in discharging. Easy digging and discharge materials such as grain are handled at higher speeds and with
closer bucket spacing, whereas sluggish, sticky, and large lumpy materials require lower speeds and wider bucket spacing.
Continuous bucket elevators may be vertical or inclined but are normally vertical for best pick-up and discharge of materials. Loading
is fly-fed directly from a chute into the first, second, or third bucket above the boot pulley. The belt is supported from behind and
guided laterally at the loading point to ensure accurate loading from the chute. Any digging is only small amounts of spill in the boot.
The speed of continuous bucket elevators is slower than that of spaced centrifugal elevators. The V bucket is shaped and spaced to
handle abrasive materials such as coarse crushed ore, stone, or other large lumpy materials. The slow speed is also excellent for very
fine, dusty materials that tend to trap air.
Elevator Discharge
Discharge of spaced centrifugal bucket elevators is directly affected by the shape of the bucket; the weight, size, and cohesiveness of
the material; the speed of the belt; and the diameter of the head pulley. All of these factors must be related and the discharge opening
located so that little or no material can spill down the back leg.
Continuous bucket elevators, particularly inclined elevators, are not as critically affected by discharge variations as are spaced bucket
elevators, but the same factors must be considered.
110
It is important that repairs be made under good working conditions, moisture and dust or dirt should be prevented from contacting the
area being repaired because either can cause poor adhesion or blistering of the repaired area. Work should be scheduled so that once
the repair spot is cleaned, cementing, drying, and applying the new cover are done promptly to prevent contamination.
3. Major Vulcanization Repairs
These repairs involve replacing at least a portion of the carcass. The severity of the injury to the carcass determines whether the belt
can be allowed to run in regular service until a scheduled shutdown occurs or whether the operation should be shut down immediately
to avoid drastic damage to the belt.
In either case, the repair requires stepping back one or more of the carcass plies to remove the damaged area. Coated fabric is then laid
into the area under repair, and finally the whole area is covered with new cover compound. Finally, the entire repaired area is finished
in a heated press.
Manufacturers supply proper instructions for stripping down the damaged area and inserting the new carcass members and the new
cover. The necessary repair materials are available from the belt manufacturers, who will also supply in detail the proper conditions
for making repairs.
As with minor repairs, it is doubly important that moisture, dust and dirt be prevented from getting in or on the surface being repaired.
The timing of the repair work should permit cementing, drying, and application of the repair materials in rapid sequence to prevent
contamination of the clean surfaces before the whole area is sealed with new cover compound.
With extensive carcass damage it is generally considered good practice to remove the damaged section and make a splice, inserting a
length of new belting if required.
111
CHAPTER 15
STORAGE OF BELTING
STORAGE
Preferably a roll of belting should be stored suspended off the floor on a bar pushed through the center of the roll. Where suspension is
not possible, the roll should be stored on a dry surface, and rotated 90 every 6 months. It is particularly advisable to rotate a large roll
of belting (over 25 tons) to prevent flat spotting (cold flow). This flow under pressure, creates a thinner belt. Although this condition
may correct itself after several months of operation, it is advisable to take steps for its prevention.
Belts in storage should be protected against excessive temperature and humidity, ozone, sunlight, oils, solvents, corrosive liquids and
fumes, insects and rodents. Whenever possible, belts should be stored in their original shipping containers until ready for use,
especially
when such containers are wooden crates or are protected with cardboard and/or black polyethylene film. These containers will provide
protection against the deteriorating effects of oils, solvents, and corrosive liquids, and some protection against ozone and sunlight.
Even if the precautions outlined in this section are followed, it is still possible that the outside wrap of each roll may suffer excessive hardening or cracking during long-term storage. If this situation occurs, remove the outer turn of the roll to assure that optimum
cover/carcass quality material is used for splicing.
In the case of neoprene belting, the 40F (4C) minimum recommended temperature must be respected, since unlike other belting,
excessive hardening and stiffening may result at temperatures even slightly below 40F (4C). Since this characteristic is
time-temperature dependent, short-term exposure to ambient winter temperatures during normal shipment can be tolerated. Particular
care should be taken to warm neoprene belting thoroughly before installation and splicing.
112
CHAPTER 16
113
-Bbackstop:a mechanical device for preventing a loaded, inclined conveyor or elevator belt from running backwards after the belt has
been stopped.
Banbury mixer:a specific type of internal mixer used to incorporate fillers and other ingredients in rubber or plastic operations.
bare pulley:a pulley whose face surface is not covered or lagged.
bareback surface:a belt surface where the textile surface is without any coating.
basic tension bearing yarns:one of the two warp systems in a straight warp fabric where the warp yarns are substantially without
crimp and provide the tensile strength for the belt.
basket weave: a fabric with ends of yarn side by side in both the warp and filling in a plain weave construction.
bead rubber:an extruded polymeric compound used to fill the void between a butted joint of two pieces of fabric.
bed:a continuous surface over which a conveyor belt may slide.
belt:a flexible reinforced band placed around two or more pulleys to carry materials from one place to another.
belt clamp:beams or metal plates secured transversely on both sides of belt ends to hold the ends in a desired position.
belt conveyor:a mechanical system composed of suitable head, tail, bend pulleys and belt idlers or a slider bed to handle bulk
materials, packages, or other objects placed directly upon it.
belt cleaning device:a scraper or rotating device pressed against the belt surface to remove material stuck to the belt.
belt drive:an assembly of power-driven pulley(s) used to transmit motion to a conveyor or elevator belt.
belt fastener: a device for holding belt ends together.
belt grade:a classification of belting according to the quality and properties of the belt cover.
belt modulus:the ratio of stress to strain.
belt sag:the amount of vertical deflection of a conveyor belt from a straight line between idlers, usually expressed as a percentage of
the center to center spacing of the idlers.
belt sag factor: a constant used to determine the amount of tension required to limit to a prescribed amount the sag of a belt between
the idlers.
belt slip: the action that takes place, causing a differential movement between the pulley surface and the belt.
belt slope tension:see tension, slope.
belt tracking switch:a limit switch actuated by the edge of a conveyor belt when the belt moves abnormally to either side of its centered path.
belt turnover/twist:a system of pulleys arranged to turn a belt over. It prevents sticky material on the carrying side from building up
on the return idlers.
bending force:the force required to bend a belt under prescribed conditions.
bend pulley:a pulley used to change direction of belt run.
bias angle:the smaller included angle between the warp yarns of a fabric and the diagonal line across the warp yarns.
bias laid:material laid on or wrapped around so the warp yarns are at an angle less then 90 to the longitudinal direction.
binder warp yarn:one of the warp systems in a straight warp fabric interlaced with the filling yarn to provide the strength to hold
mechanical fasteners.
bolted plate hinge fastener:steel plates both sides and both ends of two belt ends to be fastened together (secured to the belt with
bolts) with the ends of the plates constructed into a circular hole for accepting a hinge pin to secure the two ends of the belt(s) together.
boot:enclosure for the loading end of a bucket elevator belt.
114
115
cemented end:a belt end sealed with the application of elastomeric cement.
center roll:the horizontal roll between the side troughing rolls.
center-to-center:the distance between the center of two pulleys or idlers. Also called centers or center distance.
centrifugal bucket elevator: a type of bucket elevator having a belt which travels at sufficient speed to discharge material from the
buckets by centrifugal force.
checking:the short shallow fissures on the surface of a belt cover caused by action of environmental conditions.
chevron:a ridge or profile arranged in a Vee shaped configuration on a belt carrying cover to stabilize material carried up an incline.
chute lining:highly abrasion resistant elastomeric lining in a chute to protect the metal chute from abrasion wear.
chute slope:angle relative to the horizontal a chute is inclined.
cleated belt:transverse raised sections on a conveyor belt to stabilize material carried up an incline.
closed belt conveyor:a moving, endless conveyor belt formed into a tubular shape by joining its edges while carrying material, and
opening the edges while in motion to receive and discharge material.
cluster end:a flat disc idler with several discs adjacent to each other at the ends of the idler.
cohesive:tendency of a material to stick to itself.
cold flexibility:the relative ease of bending following exposure to low temperature.
cold flow:continued deformation under stress.
compound:a mixture of a polymer(s) and other materials to give the desired chemical and physical properties in the elastomeric
components of a belt.
compression member:the portion of a belt beneath the pitch line as the belt bends around a pulley.
compression set:the deformation in a material remaining after it has been subjected to and released from a compressive force.
conductivity: the ability of a material to conduct heat, electricity, and particularly static electricity.
continuous bucket elevator:a bucket elevator belt that discharges by gravity over the inverted bottom of the preceding bucket on the
descending side of the elevator.
control:a material or a product of known characteristics included in a series of tests to provide a basis for evaluation of other products.
conveyor:a system for the continuous movement or transport of bulk materials, packages or objects along a predetermined path.
conveyor belt:a belt that carries materials from one place to another.
conveyor belt stretch:the increase in belt length which takes place when tension is imposed. Stretch is either elastic or permanent.
Elastic stretch is a temporary change in length which varies directly with the pull. Permanent stretch is the residual change in length
after tension has been removed; it generally accumulates over a period of time.
cord belt: a belt with textile or steel cords for the longitudinal tension-bearing member.
cord fabric:a fabric with plied or cabled yarns in the warp direction and a light weight filling yarn spaced only sufficiently to process
the fabric.
cotton:a natural fiber of high cellulosic content.
count:in fabric, the number of warp ends, the number of filling picks, or both in a square inch of fabric.
counter weight:in conveyor belting, the weight applied to the take-up assembly to maintain proper belt tension.
cover:the outer component of a belt.
cover splice:the transverse joint formed by connecting two lengths of cover stock.
cover wear:the loss of material during use due to abrasion, cutting, or gouging.
crack:a sharp break or fissure in a surface. Usually caused by strain and/or environmental conditions.
116
-Ddate code:any combination of numbers, letters, symbols, or other methods used by a manufacturer to identify the date of manufacture.
decking:a protective covering over the return run of a belt conveyor.
deflector:a board or plate at an angle across the path of a belt traveling over a flat surface to transfer material off the belt.
denier:a yarn sizing system for continuous filament synthetic fibers on the basis of the weight in grams of 9000 meters of the yarn.
dip coat:a thin film formed on a surface by immersing the material in a suitable coating solution.
dipped fabric:a cloth coated by passing it through a solution and drying.
discharge:removal of material from a belt.
dog leg:the abrupt deviation of belt from a straight line.
double plate bolt fastener:two ends of belting joined together with a plate on both sides across both ends of the joint.
drive:an assembly of electrical and mechanical parts that provide motive power to a belt.
drive factor:a numerical factor used for calculating the belt minimum slack side tension required for a given driving condition and or
configuration.
drive-on plate fastener:two ends of belting joined with a single plate, across the top cover joint, with rivets or sharp teeth clinched
over on the bottom cover side of the belting.
drive-on hinged fastener: two ends of belting joined together with a pre-packaged fastener assembly having prongs for driving
through the belt end.
drive pulley: a pulley mounted on a drive shaft which transmits power to the belt.
drive snubbed pulley:an undriven pulley located close to the drive pulley to provide a greater arc of contact around the drive pulley.
drop ply:the omission of a reinforcing ply, usually the bottom or next to bottom ply, for a specified distance from both edges to
improve the troughability of the belt.
duck:a term applied to a wide range of medium and heavyweight woven fabrics made from cotton or synthetic fibers or a
combination of both. Duck is also identified as canvas, army duck, belt duck, harvest duck, hose duck, and shoe duck.
dumbbell:a test specimen with lesser width at the middle of its length than at its ends.
117
durometer:an
d
t
iinstrument
t
t ffor measuring
i th
the hhardness
d
off an elastomer.
l t
durometer hardness:a numerical value which measures the resistance to indentation of the blunt indentor point of a durometer.
dutchman:a short section of belting mechanically spliced into a length of belting and removed when the take-up allowance is
exceeded.
dynamometer:an apparatus capable of inducing various loads for evaluation of dynamic belting properties.
dynamic fatigue:loss in properties of a material when continually subjected to flexing and or cyclic stress.
118
filler seam:extruded polymeric compound used to fill the void between two pieces of belt cover or fabric.
filling yarns:the transverse yarns in a fabric.
finger splice:belt ends cut into mating fingers.
flanged edge:in conveyor belting, an edge built up to prevent spillage.
flame performance:the manner in which belting after being ignited will burn and/or self extinguish.
flame test:a means, under specific conditions, for establishing the flame performance of a belt. This will not indicate the performance
of the belt in any fire in which the belt may be involved.
flanged pulley: a pulley with a raised rim at the edges for the purpose of keeping the belt on the pulley.
flash:excess material protruding from the surface of a molded article at a parting line.
flat belt:(1) a belt the cross section of which is in the general form of a rectangle; (2) a belt which operates on a smooth flat bed or
straight idlers or rollers.
flat press:a belt finishing press with flat platens, between which the belt is heated and compressed.
flat spots:thin spots on a conveyor belt surface stored on a flat surface for a long time.
flat wire braid:flattened braided wire, frequently used for armoring the belt.
fleet:the lateral movement of a conveyor belt to either side of its intended path.
flex cracking:a surface cracking induced by repeated bending and straightening.
flexing:the bending of a belt.
flex life:the relative ability of a belt to withstand cyclical bending stress.
flight:(1) one of a series of belt conveyors discharging one to another. (2) a series of cleats or profiles on a belt.
floating breaker:a leno or cord breaker embedded in a belt cover with a distinct layer of elastomer separating the breaker from the
carcass.
folded belt edge:a belt construction with the inner carcass enclosed in an envelope of a ply or plies of fabric.
frequency factor:the duration of time in minutes required for one complete cycle of a conveyor belt.
friction surface:the duration of time in minutes required for one complete cycle of a conveyor belt.
friction:(1) the resistance to motion of a belt due to the contact between two surfaces. (2) improperly used to indicate the bond
between two surfaces.
friction coating:a polymeric compound applied to the surface of a fabric when the fabric interstices are filled with the polymeric
compound.
frictioned fabric:a fabric impregnated and lightly surface coated with a polymeric compound.
fusion:an irreversible process during which a PVC compound or platisol undergoes a physical change and becomes a homogeneous
mixture by the mutual solvation of the PVC resin and the plasticizers in the compound, as a result of heating to an appropriate
temperature.
-Ggauge:(1) an instrument for making measurements (2) a term used to indicate a measure of thickness.
glass fiber:glass extruded through a die with many fine holes into continuous filaments.
gouging:the effect of sharp heavy material falling onto a conveyor belt cover to loosen or tear out pieces of the cover.
grade:the ratio of incline or decline of a conveyor expressed as a percent of the vertical height to the horizontal distance.
grade of belting:the quality of belting cover on the basis of gouge, cut, and abrasion resistance.
119
gravity take-up:a mechanical system that adjusts for the stretch or shrinking of a conveyor belt automatically by a weighted pulley in
the system.
grooved lagging:lagging with round or angular grooves to minimize material buildup on the pulley.
ground finish:a surface produced by grinding or buffing.
120
impregnation:filling the interstices of and partial absorption into the yarns of a fabric with a polymeric compound.
impulse:an application of force in a manner to produce sudden strain or motion.
indentation:(1) the extent of deformation by the indentor point of any one of a number of standard hardness testing instruments; (2)
a recess in the surface of a belt cover.
inside length:a belt length measured along its inside circumference.
installation allowance:the amount by which the center distance can be adjusted so a belt can be installed without damaging.
instantaneous modulus:the ratio of stress to strain at a single point on the stress-strain curve.
interstice:a small opening, such as between fibers in a cord or threads in a woven or braided fabric.
interwoven conveyor belt:a type of conveyor belt construction similar to that of a solid woven belt, with plies interwoven such that it
is impossible to separate them.
irons:strips of metal at the edges of a belt in a flat press to confine the edge elastomer for making a molded edge or to obtain uniform
thickness of the edges of a slit edge belt near its edges.
ISO:International Organization for Standardization. (www.iso.org)
-Jjaws:clamps to hold a specimen when applying stress to the specimen for certain tests.
joint:the location where two belt ends are fastened together by either mechanical means or a vulcanized splice.
-Kkinking:a temporary or permanent distortion of belting caused by doubling the belt on itself.
121
load support:the ability of a fully loaded conveyor belt to bridge the idler gap without creasing into the idler gap and carry material
without excessive sag between the carrying idler pulleys.
load weight:the weight of material per unit of time.
loading angle:the angle to the horizontal at which material is loaded onto a conveyor belt.
loading impact:the energy with which material is loaded onto a conveyor belt.
longitudinal:a lengthwise direction.
longitudinal seam:a joint butting two materials lengthwise in the finished product.
low temperature flexibility:the ability of belting to be bent or flexed at low temperatures without loss of serviceability.
lump size:the size of larger material on a conveyor belt.
-Nnarrow disc idler:a flat pulley with discs attached around the pulley at certain intervals across the pulley.
necking down:a localized decrease in the cross-sectional area of a product.
needle punched:non-woven fabric punched with a hack latched needle to improve its strength and stability.
122
net endless length:the manufactured length necessary to provide proper initial fit and tensioning of a belt on a specified drive.
nicks:cuts in the surface or edge of belting.
nitrile:common name for nitrile-butadiene polymer.
nominal:an approximate amount.
nonwoven fabric:a mat of nonaligned fiber bonded together.
Norway type elevator bolt:flat top, squared shoulder bolt for attaching elevator buckets to elevator belts.
NR:abbreviation for isoprene polymer.
numbered duck:fabric weight designated by numbers based on linear yard of cloth 22 in in width.
nylon:common name for polyamide fiber.
-Ooffset idler:the center carrying roller which is offset and transversely lapping the troughing idlers.
oil swell:the change in volume of an elastomer resulting from contact with oil.
oil well splice:two ends of a belt each bent 90 around a steel form and bolted together through the belt and steel form.
operating tensions:the tension of longitudinal sections of a belt system (tight side and slack side) when moving material, as
distinguished from tension when the belt is running empty.
optimum cure:the time, temperature and compression of vulcanization or of fusion at which a desired combination of properties is
attained in an elastomer.
outside diameter eccentricity:the degree a pulley is out-of-round with respect to its central axis.
oxidation:the reaction of oxygen on a rubber product, usually evidenced by a change in the appearance or feel of the surface or by a
change in other physical properties.
oxygen bomb:a chamber capable of holding oxygen at an elevated pressure
oxygen bomb:a chamber capable of holding oxygen at an elevated pressure which can be heated to an elevated temperature. Used for
an accelerated aging test.
oxygen bomb aging:a means of accelerating change in the physical properties of rubber compounds by exposing them to the action
of oxygen at an elevated temperature and pressure.
ozone cracking:belt cover cracks or crazing caused by exposure to ozone in the atmosphere.
123
plasticity:(1) a measure of the resistance to shear of an unvulcanized elastomer; (2) a measurement of resistance to shear with heat
history.
plasticizer:a compounding ingredient which can change the physical and chemical properties and processibility of a polymeric
compound.
plastisol:a dispersion of a powderous polymer in a plasticizer.
plied yarn:a yarn made by twisting together two or more single yarns.
plows:plates across a belt to remove material lying on or sticking to the belt.
ply:a layer of fabric, multiple strands of textile cord, or steel cord.
ply adhesion:the force required to separate two adjoining reinforcing members of a belt.
ply tensile:the ultimate breaking strength of a belt expressed in force per inch width per ply.
polymer:a macromolecular material formed by the chemical combination of monomers having either the same or different chemical
composition.
polymerization:the process that converts monomers into polymers.
porosity:the condition of containing numerous small holes or voids.
portable conveyor:a conveyor system readily moved from one place to another.
portable vulcanizer:a vulcanizer readily moved from one place to another, usually used for making field splices and repairs.
pot life:the period of time during which a reacting polymeric compound remains suitable for its intended use after having been mixed
with a reaction-initiating agent.
press:a machine consisting of two or more heated plates which can be brought together and separated by hydraulic pressure or
mechanical action.
press cold ends:the area of reduced temperature at the press platen end.
press lap:the area of overlap of one press cure length on the next.
press length:the length of a belt which can be pressed at one time.
press marks:irregularities in the surface of a vulcanized product caused by the press ends or by corresponding irregularities in the
press surface.
pricker marks:small marks in the cover of a vulcanized belt where a roll with sharp needles had penetrated the uncured belt to allow
trapped air in the uncured belt composite to escape.
processing:the operations in the manufacture of a belt.
prong:the sharp point of a mechanical fastener that penetrates the belt.
pulley:a cylinder, mounted on a central axis rod.
pulley cover:(1) a covering on a drive pulley; (2) the bottom cover of a belt that contacts the drive pulley.
pulley wear cover:(1) elastomeric material attached to the pulley to minimize pulley surface wear; (2) additional belt bottom cover
thickness where extraordinary wear is anticipated.
pulley projection:the amount a pulley face width extends beyond belt edge.
pure gum compound:a natural rubber or isoprene compound containing only the ingredients necessary to process it, to protect it
from aging, and to cause vulcanization.
-Qqualification inspection test:the examination of samples from a typical production run to determine conformance to a given
specification for approval to become a supplier.
qualification conformance inspection:the examination of samples from a production run to determine conformance to a given
specification.
124
quarter turn drive:a belt system in which the axes of the adjacent pulleys are at right angles to each other to cause a 90 twist in the
belt about its longitudinal axis.
125
sag belt tension:the minimum tension in any portion of the carrying run of a belt necessary to prevent excessive sag of the belt
between idlers.
sample:a piece of material removed for evaluation. scraper:a device for cleaning the surface of belting.
screw take-up:a take-up for a conveyor system in which movement of a pulley-bearing block is accomplished by means of a screw.
See also take-up.
seam:the place where two edges of fabric or elastomer are adjacent to each other to form a single ply or layer.
seaming strip:a strip of polymeric material laid over and/or in a seam to fill any voids between the adjacent plies of material.
self-aligning idler:an idler having a belt-activated swivel mechanism to control the side movement of an operating conveyor belt.
selvage:the lengthwise woven edge of a fabric. Also called selvedge.
semi-cure:a partial or incomplete cure.
service condition:all the conditions of operation to which a conveyor or elevator belt is exposed.
service factor:the amount by which the normal rating of a unit is altered to compensate for specific service requirements.
service test:a test in which the product is evaluated under actual service conditions.
set:the amount of deformation remaining after complete release of the load producing the deformation.
shadowing:a bas-relief or outline of a reinforcement which appears on a cover after vulcanization.
shelf storage life:the period of time prior to use during which a product retains its intended performance capability.
singles yarn:the product from aligning and twisting together fibers or twisting together filament fibers.
skim:a thin layer of polymeric compound applied to a fabric.
skirt board:in a conveyor system, the vertical or inclined plates located longitudinally and closely above the belt to confine the
conveyed material.
skive:a cut made on an angle to the surface of a material to produce a tapered or feathered edge.
slab belting:belting made in wide widths and long lengths for later slitting into narrower widths and cutting into shorter lengths.
slack side tension:the lessor of the tensions in a belt on an operating conveyor. Usually immediately following the drive pulley.
slider bed:a stationary surface on which a belt slides.
slip:the action that takes place, causing a differential movement between the pulley surface and the belt.
slip and sequence system:an interlocking belt conveyor system that stops the system when the speed of the conveyor belt drive
ulley exceeds a certain speed of the conveyor belt.
slit edge:the square finished edge of a belt after trimming to width.
slope belt:a conveyor belt used to carry material along an inclined flight.
snub pulley:a pulley adjacent to a drive pulley that increases the arc of contact on the drive pulley to increase the effectiveness of the
drive.
solid woven belt:a type of conveyor belt wherein the carcass is a single ply consisting of multiple layers of warp and filling yarns
interwoven. The carcass usually is impregnated and/or coated with polymeric compound.
specification:detail description of specific requirements.
specimen:a piece cut from a sample of belting to test.
splice:methods for joining the ends of belting together without using a mechanical fastener.
splice angle:the angle at which belting is spliced.
spread coat:to apply a thin coat of material over a surface determined by means of a knife, bar, or doctor blade.
126
spring take-up:a mechanical device on both sides of the conveyor system where a variable force spring is secured to the conveyor
structure and to the tail pulley block for the purpose of maintaining a uniform tension in the belt.
spun yarn:a yarn produced from short fibers by aligning and twisting them together.
stacker:a conveyor adapted to piling or stacking bulk material, packages, or objects.
stamped metal:perforated metal sheet used for making a rough top design on a conveyor belt.
standard:a quality level set for the results from a belt test.
staple fiber:the short fibers from which a spun yarn is made.
starting tension:the tension necessary to accelerate a belt from rest to normal operating speed.
127
textile:a general term applied to yarn, cord, non-woven, or woven fabric made from a fibrous material.
tie gum:a thin sheet of unvulcanized rubber inserted between plies in vulcanized repairs of splices.
tilted troughing idlers:used for belt training.
time cycle:the duration of time, in minutes, required for one complete cycle of a conveyor belt.
tire bead wire:steel wire placed in or beneath the top cover to minimize rips in the belt by objects that penetrate the belt.
tolerances:the limiting values for a dimension.
top cover:the material conveying surface of a conveyor belt.
top cover wear:loss of the elastomer due to abrasion.
traction:the friction between a drive pulley and the conveyor belt.
training:the process of adjusting idlers, pulleys, and loading conditions to insure the belt runs straight.
training idler:an idler mounted on a mechanical device, actuated by the belt moving sidewise to make the belt run straight.
trajectory:the arc made by material freely discharged from a conveyor system.
transition distance:the distance between the last fully troughed idler and the flat driving or discharge pulley.
transition idler:a troughed belt idler having a lesser degree of trough than the previous carrying idlers.
transverse:a crosswise direction of a belt.
transverse cord breaker:a cord fabric laid in the top cover at right angles to the belt edges.
transverse seam:the joint, across the belt, of two ends of a fabric ply in the belt or cover material.
tripper:a fixed or moveable mechanism at some intermediate place in the conveyor system to discharge material from the belt.
troughability:the property of a belt that permits it to conform to the contour of troughing idlers.
troughability index:the ratio of the deflection of a freely supported transverse section of a belt to the distance between the freely
supported ends.
troughed belt:a belt operating in a conveyor system with inclined side idlers to cause the belt edges to turn up and increase the
amount of material carried while minimizing side spillage of the material.
troughing angle:the angle troughing idlers are to the horizontal extension of the flat carrying idler.
troughing idlers:an idler system which supports a belt in a troughed configuration. Usually it consists of a center horizontal roll with
an inclined roll on each side. See also catenary idler.
twill weave:a fabric woven with the appearance of diagonal lines.
twist:the rotation of a belt on its longitudinal axis. A 180 twist is used as a means of inverting a belt through the zone of the twist.
-Vvertical curve:the portion of a conveyor belt where the angle of incline increases.
viscosity:the flow property of a material.
vulcanization:a process over a range in temperature during which a polymeric compound, through a change in molecular structure
(e.g., crosslinking) becomes less plastic and causes changes in the physical and chemical properties of the resulting elastomer.
128
129
CHAPTER 17
USEFUL TABLES
Belt
Width
10
20
25
30
in
mm
TPH
t/h
TPH
t/h
TPH
t/h
TPH
t/h
TPH
t/h
TPH
t/h
14
16
18
20
350
400
450
500
15
21
27
34
13.6
19.0
25.4
30.8
18
25
33
42
16.3
22.7
29.9
38.1
22
29
38
49
20.0
26.3
34.5
44.5
28
38
50
64
25.4
34.5
45.4
58.2
32
43
56
72
29.0
39.0
50.8
65.3
34
48
63
80
30.8
43.6
57.2
72.5
24
30
36
600
750
900
52
86
125
47.2
78.0
113.0
63
105
155
57.2
95.3
141.0
74
120
180
67.2
109.0
164.0
96 87.2
155 141.0
230 209.0
110
176
260
99.8
160.0
236.0
120
195
290
109
177
263
42
48
54
60
66
72
1050
1200
1350
1500
1650
1800
175
235
300
375
455
550
159
213
272
340
413
499
210
280
360
450
550
655
191
254
327
408
499
594
250
330
420
525
640
770
227
300
381
476
581
700
360
480
610
760
930
1115
327
435
554
690
845
1011
400
530
680
845
1030
1230
363
482
617
767
935
1115
320
425
545
680
830
995
290
386
494
617
753
902
20 Idlers
35 Idlers
45 Idlers
Flat Rolls
1.00
1.59
1.87
0
1.000
1.470
1.690
0.185
1.00
1.39
1.55
0.32
1.00
1.27
1.37
0.53
1.00
1.22
1.30
0.56
1.00
1.19
1.25
0.62
*Surcharge angle is that angle which the material makes with the horizontal while being conveyed.
Example:
Width
Trough Angle
Speed
English Units
48 in
45
500 fpm
Material
Surcharge Angle
130 lb/ft3
25
SI Units
1200 mm
45 Belt
2.5 m/s
2080 kg/m3
25
130
16
(400)
0.91
18
(450)
0.96
20
(500)
1.0
24
(600)
1.05
30
(750)
1.095
36
42
48
54
60
66
72
(900) (1050) (1200) (1350) (1500) (1600) (1800)
1.13 1.155 1.175
1.19 1.195 1.205 1.215
Belt
Width
0
in
24
30
36
42
48
mm
600
750
900
1050
1200
TPH t/h
TPH t/h
82
74.5
95
86.2
105 95.2
130 118.0
130 118.0 165 150.0
150 136.0 200 182.0
160 145.0 220 200.0
TPH
125
195
260
330
405
30
t/h
113
177
236
300
368
TPH
140
210
290
370
450
t/h
127
191
263
336
408
Belt
Width
0
in
24
30
36
42
mm
600
750
900
1050
TPH
97
130
160
180
t/h
88
118
145
163
10
TPH t/h TPH t/h
104
110 99.9 115
150
150 136.0 165
191
190 173.0 210
227
225 204.0 250
48
54
60
1200
1350
1500
200
360
390
182
327
354
260
430
485
Example:
25
Width
Trough Angle
Belt Speed
Material
Surcharge Angle
236
390
440
295
475
540
268
432
490
English Units
48 in
45 LC
500 fpm
130 lb/ft3
25
20
TPH t/h
130 118
190 172
255 232
300 272
TPH
140
210
280
355
t/h
127
191
254
322
TPH
150
225
305
395
t/h
136
204
277
358
345
526
617
430
640
755
390
582
685
485
700
830
440
635
752
380
580
680
25
30
SI Units
1200 mm
45 LC
2.5 m/s
2080 kg/m3
25
131
SI Units
English Units
mm
mm
in
10
12
14
250
300
350
300
400
500
12
16
20
16
18
20
400
450
500
600
650
800
24
26
32
24
26
30
600
650
750
1000
1200
1400
40
48
56
36
42
48
900
1050
1200
1600
1800
2000
64
72
80
54
60
72
1350
1500
1800
84
2100
mm
1
2
2
3
4
5
6
8
10
13
16
20
25
SI Units
mm
1
2
3
4
5
6
Fractional in
1/32
1/16
1/8
8
10
13
5/32
3/16
1/4
5/16
3/8
1/2
16
20
25
5/8
3/4
1
132
SI Units
Specified lengths of conveyor belting are rounded to the next highest whole number of meters.
For conversion to English units:
Divide belt length in meters by 0.304 8;
Round to the next highest whole number;
The result is belt length in feet.
Factors for Test Data and Application Engineering
Conversion factors which are exact are in bold type; the other factors given are much more than sufficiently accurate for conveyor
belting work.
All factors may therefore be rounded off at a level which provides sufficient accuracy for the data involved, or full factors may be
used and the converted results rounded as outlined under Rounding of Converted Values on page 135.
CONVERSION UNITS
To Convert FROM English units TO SI units MULTIPLY by the Factor.
To convert TO English units FROM SI units DIVIDE by the Factor.
Quantity
English Unit
Acceleration
SI Unit
Metric Symbol
Factor
m/s2
0.304 8
Area
m2cm2
0.092 903 04
6.451 6
Capacity
dm3
dm3
dm3
dm3
35.239 07
36.368 72
3.785 412
4.546 09
Density
kg/m3
16.018 46
Energy
foot pound-force
horsepower hour
kilowatt hour
joule
megajoule
megajoule
J
MJ
MJ
1.355 818
2.684 52
3.6
Force
pound-force
pound-force
newton*
kilogram-force
N
kgf
4.448 222
0.453 592 37
kN/m
kgf/cm
0.175 127 8
0.178 58
Length
foot
inch
inch
milemil (0.001 inch)
yard
meter
millimeter
centimeter
kilometer
millimete
rmeter
m
mm
cm
km
mm
m
0.304 8
25.4
2.54
1.609 344
0.025 4
0.914 4
133
English Unit
SI Unit
Mass
ounce (avoirdupois)
pound (avoirdupois)
slug
ton, short (2000 lb.)
ton, long (2240 lb. UK)
gram
kilgram
kiogram
**metric tonne (1000 kg)
**metric tonne (1000 kg)
g
kg
kg
t
t
g/m2
tex
tex
Momentum
Power
Pressure or Stress
(Force Per Unit Area)
Torque
(Moment of Force)
Velocity
(Speed)
Volume
horsepower
28.349 523
0.453 592 37
14.593 9
0.907 184 74
1.016 046 908
33.905 7
4.882 43
703.069 6
kg/m
kg/m2
1.000
1.000
mg/m
g/km
kg.m2
kg.cm
0.042 140 1
2.926 4
kg.m/s
0.138 255
horsepower,
horsepower, metric
(cheval vapeur)
kilowatt
kilowatt
kW
kW
0.746
0.735 499
pound-force per
square inch (psi)
pound-force per
square inch (psi)
pound-force per
square inch (psi)
kilopascal
(kilonewton per square meter)
megapascal
*kilogram-force per
square centimeter
kPa
MPa
6.894 757
0.006 895
0.070 307
pound-force foot
pound-force inch
foot per minute
foot per second
mile per hour
mile per hour
cubic foot
cubic foot
cubic yard
newton meter
newton meter
meter per second
meter per second
meter per second
kilometer per hour
cubic meter
cubic decimeter (liter)
cubic meter
kgf/cm2
N.m
N.m
m/s
m/s
m/s
km/h
1.355 818
0.112 985
0.005 08
0.304 8
0.447 04
1.609 344
m3
0.0283
28.31685
0.764555
dm
m3
134
0.0050
0.0250
0.0001
0.0250
0.0500
0.0005
0.050
0.250
0.001
0.250
0.500
0.005
0.50
2.50
0.01
2.50
5.00
0.05
5.0
25.0
0.1
25.0
50.0
0.5
50
250
250
500
500
2 500
10
2 500
5 000
50
5 000
25 000
100
25 000
50 000
500
50 000
250 000
1 000
135
APPENDIX
Conveyor Analysis Data Sheets provide a standardized format for the orderly collection of data which best characterize a particular
conveyor installation. These data can then be used to develop a specific recommendation with regard to the conveyor belt construction
deemed to be most suitable for the application described.
The following pages show a typical Conveyor Analysis Data Sheet for both English and Metric units.
136
Discharge: End
Plow
Tripper, Lift__________ft
Other (Describe)____________________________________ To ________________________________________
Previous Conveyor Belt:
Width__________in
Fabric______________________________________Plies ____________
Quality__________Top Cover___________in
Pulley Cover________________________in
Manufacturer________________________________________Life __________________________
Pattern of Belt Failure:
Ply Separation
Carcass Breaks
Cover Worn Off
Other, Specify __________________________________________
137
Diagram No.
138
__________kg.
Max. Lump Size ____mm % Fines __________________________
Max. Temp. ______ C Avg. Temp. ______ C
Oil Condition ______________________
Abrasion:
Slight
Moderate Extreme Other Conditions _____
___________________________________________
Discharge: End
Plow
Tripper, Lift__________m
Other (Describe)____________________________________ To ________________________________________
Previous Conveyor Belt:
Width__________mm
Fabric______________________________________Plies ____________
Quality__________Top Cover___________mm
Pulley Cover_______________________mm
Manufacturer________________________________________Life __________________________
Pattern of Belt Failure:
Ply Separation
Carcass Breaks
Cover Worn Off
Other, Specify __________________________________________
139
Diagram No.
140