CONVEYOR

HANDBOOK

UPDATE February 2002

Foreword

This “CONVEYOR HANDBOOK” is provided by APEX FENNER to allow designers to select the
correct specification belting for any particular installation

Properties of fabrics used in Polyester Nylon multi-ply belting constructions are given in detail,
while the general properties and application areas of special multi-ply constructions, solid woven,
Aramid and steel belting are also shown.

The use of various natural and synthetic rubbers with these reinforcements for handling different
service conditions is set out for the designer.

Design considerations affecting power demands, belt curves, transitions etc., are provided.

Whilst users are vitally interested in these design considerations for conveyors, there is a special
section on fault diagnosis to enable users to identify causes of troubles which may occur and
correct them before belt damage either occurs or becomes extended.

The layout of this manual and it’s easy approach to belt design will be readily followed by belt
design engineers. Should problems arise, the services of APEX FENNER are always available to
help with any problems in the design, application or operation of conveyor belts.
Index

1. Materials of construction

Reinforcements ………………………………………………………………………… 1-1

General Properties …………………………………………………………………….. 1-3

2. Belt Capacities

Capacity Calculations …………………………………………………………………. 2-1

Properties of Materials …………………………………………………………………. 2-2

3. Belt Power and Tensions

Belt Power Calculations Formulae …………………………………………………. 3-1

Calculation of Maximum Tensions ….……………………………………………….. 3-5
Graduated Idler Spacings ……………………………………………………………... 3-7
Feeder Belt Calculations ………………………………………………………………. 3-9
Acceleration and Deceleration ……………………………………………………….. 3 - 10
Application of Forces ………………………………………………………………….. 3 - 14
Algebraic Signs of Conveyor Forces ……………………………………………….. 3 - 15
Coasting ………………………………………………………………………………….. 3 - 16
Check List for Large Conveyor Systems …………………………………………... 3 - 17

4. Belt Carcass Selection

Belt Construction Requirements ………………………………………………….… 4-1

Considerations ….……………………………………………………………………… 4-1
Procedure ………..……………………………………………………………………… 4-2

5. Cover Gauges and Qualities

Considerations…………………………………………………………………………… 5-1
Selection……………….………………………………………………………………….. 5-1
Pulley side cover………………………………………………………………………… 5-1

6. Pulley Diameters

Parallel face pulleys…………………………………………………………………….. 6-1

Crown face pulleys……………………………………………………………………… 6-2
Pulley face width………………………………………………………………………… 6-2
7. Design Considerations

Multiple Slope and Vertical Curve Conveyors ……………………………………... 7-1

Terminal Troughing Idler Arrangements ……………………………………………. 7-4
Transitions …………………………………………………………………..……………. 7-4
Take - Up Arrangements ……………………………………………………………….. 7-5

8. General Data

Belt Mass and thickness………………………..………………………………………. 8-1

Shipping dimensions and roll sizes…………………………….………………...….. 8-1
Length of belt on a roll…………………………………………………………...…… . 8-2
Belt transport guidelines……………………………………………………….………. 8-3

9. Solid Woven Belting

Belt construction…………………………………………………………………………. 9-1

Belt and cover thickness……………………………………………………………….. 9-2
Operating temperature range………………………………………………………….. 9-2
Operating factor of safety………………………………………………………………. 9-2
Safety………………………………………………………………………………………. 9-2

10. Trouble Shooting

General Maintenance .…………………..……………………………………………… 10 - 1

Loading point considerations……………………………………………….. ………. 10 - 2
Random events …………………………………………………………………………. 10 - 4
Troubleshooting ………………….………………………………………….…………. 10 - 5
1. Materials of construction

Reinforcements ………………………………………………………………………….. 1–1

General Properties ……………………………………………………………………… 1–3

Table 1 Reinforcement Fabrics ………………………………………………… 1–2

Table 2A Cover Compounds ……………………………………………………... 1–4
Table 2B Heat Resistant Belts …………………………………………………… 1–5
Table 2C Oil & Chemical Resistant ……………………………………………… 1–6
Table 2D Fire Resistant & Anti Static Belts …………………………………….. 1–7

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1. Materials of construction

The composition of a conveyor belt can be considered in two parts:

A. The Carcass, whether ply type (textile) or steel cord construction, which must have sufficient
strength to handle the operating tensions and to support the load.

B. The Covers, which must have the required physical properties and chemical resistance to
protect the carcass and give the conveyor belt an economical life span.

The general properties and the application usage of the more economical available reinforcement
fabrics and rubber compounds are discussed in this section.

REINFORCEMENTS

Fabrics

Fabrics that are commonly used as reinforcement in conveyor belts are shown in Table 1 of this
section

The fabric designation indicates the material used in both warp and weft, e.g. PN signifies that
the fabric has Polyester warp fibres and Nylon weft fibres.

The ultimate strength of the belt in kilonewtons per metre width is shown along with the number
of plies. PN1000/4 designates a belt with four plies of polyester warp, nylon weft fabric and an
ultimate full-belt tensile strength of 1000kN/m. Alternatively the belt can be often described as 4
ply PN250 where the strength of the individual plies is shown.

The allowable working tensions allocated are shown in tables 1 and 2 in section 4.

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TABLE 1.
REINFORCEMENT FABRICS

STRENGTH
CARCASS CARCASS MATERIALS RANGE FEATURES AND APPLICATIONS
TYPE

WARP WEFT kilonewtons per

(longitudinal) (transverse) metre width

PN Polyester Nylon 315 to 2000 kN/m Low elongation.

plain weave (150 to 400 Very good impact resistance
(DIN code EP) kN/m/ply) Good fastener holding
An excellent general purpose fabric.

PN Polyester Nylon 630 to 2500 kN/m Low elongation

crow's foot (315 to 500 Good impact resistance
weave kN/m/ply) Very good fastener holding.
Excellent rip resistance.
For high abuse installations

PN Polyester Nylon 900 & 1350 kN/m Low elongation.

double weave (450 kN/m/ply) Excellent impact resistance.
Excellent fastener holding.
For high abuse installations.

PP Polyester Polyester Up to 900 kN/m Used in special applications where

Plain weave (120 & 150 acid resistance is needed.
kN/m/ply) Contact us for information.

NN Nylon Nylon Up to 2000 kN/m High elongation, mostly replaced by

Plain weave (150 to 450 polyester-nylon.
kN/m/ply) Used in special applications where
low modulus needed or in high pH
environment

CC Cotton Cotton Up to 400 kN/m Used in special applications such as

Plain weave (65 & 70 kN/m/ply) plasterboard belting and hot pellet
handling.

SW Nylon/cotton Nylon/cotton 600 to 1800kN/m Main use in underground coal

Solid woven or mining.
Polyester/cotton Good fastener holding and impact
resistance.
Used for bucket elevators.

ST Steel cord None 500 to 7000 kN/m Very low elongation and high
Steel cord (special strength Used for long haul and high-
reinforcement tension applications.
available)

AN Polyaramide Nylon 630 to 2000 kN/m Low elongation, high strength, low-
Aramid nylon weight.
(Kevlar) Used on high-tension applications
and on equipment conveyors.

PN belting comprises the vast majority of plied fabric belting in service and is referred to throughout
this handbook. For information advice on other belting types consult APEX FENNER.

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GENERAL PROPERTIES OF
BELT COVERS AND GRADES

The following tables give a comparison of general characteristics of polymers used in belting compounds.

Special compounding can result in substantial changes to these general polymer properties.

Generally conveyor belts are supplied with electrical resistance in the anti-static range and should not be
used for electrical insulation. Special non-conductive grades are available on request.

There are four separate tables:

Belts for Mining, Quarrying and General Service

Heat Resistant belts

Oil and Chemical Resistant grades

Fire Resistant and Anti-static belts

Notes referred to in these tables are:

1. Available with extended ozone resistance capabilities on special request.

2. The low temperature performance figures given in the table are representative of general
purpose compounds in each classification. Belts for operation at lower temperatures than
those given are available on request.

3. The high temperature performance figures given in the table are representative of situations
where the belt is subject to relatively long exposures of blanketing heat. Considerably higher
temperature bulk material can often be carried in ventilated situations or where the belt surface
can be shielded to some extent by a protective layer of cooled fines.

4. Resist most acids except concentrated strongly oxidising ie., Sulphuric, Nitric and their
derivatives. Contact APEX FENNER for specific applications.

5. Fire resistant and anti-static grades:

GRADE S meets AS4606 for UNDERGROUND COAL MINING.
GRADE E, F fire resistant and anti-static - mostly for ENCLOSED ABOVE GROUND USE
GRADE K fire retardant and anti-static - meets MSHA 2G and ISO433 requirements

6. Resists most oils however resistance may vary greatly depending on the type of oil.

7. May have poor resistance to oils with low aniline points.

If in doubt, contact APEX FENNER

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 TABLE 2A – GENERAL PROPERTIES
Mining, Quarrying and General Service

APEX FENNER GRADE Super M Grade A

Grade M, Grade N XCG QuarryMaster
(Common description) MA (SAR)

Natural Rubber Natural Rubber

GENERIC TYPE Natural rubber Natural rubber Natural Rubber
Polybutadiene Styrene Butadiene
(Description) (NR) (NR) (NR)
(NR / BR) (NR / SBR)

Heavy to extreme
Medium to heavy duty Abrasion resistant for Cut and gouge resistant Medium to heavy duty
APPLICATION mining service with
mining and quarrying fine materials for heavy service mining and quarrying
lumps & abrasion

M Z – SUPER M
AS1332 BRANDING A Z – XCG Z – QUARRYMASTER
N Z – MA

CO-EFFICIENT OF
GOOD GOOD GOOD GOOD GOOD
FRICTION (drive)

WEATHERING/OZONE
GOOD (1) GOOD (1) GOOD (1) VERY GOOD GOOD (1)
RESISTANCE

CUT/TEAR RESISTANCE GOOD to EXCELLENT GOOD to EXCELLENT GOOD GOUGE RESISTANT GOOD to EXCELLENT

ABRASION RESISTANCE GOOD / VERY GOOD GOOD EXCELLENT VERY GOOD GOOD / VERY GOOD

ACID RESISTANCE GOOD (4) GOOD (4) GOOD (4) GOOD (4) GOOD (4)

MINERAL/OILS POOR POOR POOR POOR POOR

SERVICE TEMP RANGE

- 30 to 70 - 30 to 70 - 30 to 70 - 30 to 70 - 30 to 70
( ºC ) See notes (2) & (3)

FLAME RESISTANCE POOR POOR POOR POOR POOR

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 TABLE 2B – GENERAL PROPERTIES
Heat resistant belts

APEX FENNER GRADE CRHR Apex EPT-GP EPT-Super HRNR Hi Temp Nitrile
(Common description)

GENERIC TYPE Styrene Butadiene Ethylene Propylene Ethylene Propylene Natural rubber Nitrile rubber
(Description) (SBR) Terpoymer (EPT) Terpolymer (EPT) (NR) (NBR)
Heat resistant for fine
Maximum heat resistance Medium heat resistance.
Heat resistant for lumpy materials.
APPLICATION for fine materials. Resists Resists hardening and Oil and heat resistant
and abrasive materials Resists hardening
hardening and cracking cracking
and cracking

AS1332 BRANDING Z – CRHR Z – EPT GP Z – EPT SUPER Z – HRNR Z – NITRILE

CO-EFFICIENT OF
GOOD GOOD GOOD GOOD GOOD
FRICTION (drive)

WEATHERING/OZONE
FAIR EXCELLENT EXCELLENT GOOD FAIR
RESISTANCE

CUT/TEAR RESISTANCE VERY GOOD FAIR FAIR EXCELLENT VERY GOOD

ABRASION RESISTANCE VERY GOOD GOOD GOOD GOOD VERY GOOD

ACID RESISTANCE GOOD (4) VERY GOOD VERY GOOD GOOD (4) GOOD (4)

VERY GOOD to
MINERAL/OILS POOR POOR POOR POOR
EXCELLENT (7)

SERVICE TEMP RANGE

- 10 to 125 (3) - 2o to 170 (3) - 20 to 210 (3) - 20 to 100 (3) - 10 to 125 (3)
( ºC ) See notes (2) & (3)

FLAME RESISTANCE POOR POOR POOR POOR POOR

1-5
 TABLE 2C – GENERAL PROPERTIES
Oil and Chemical Resistant grades

APEX FENNER GRADE Hi Temp

ORS Neoprene PVC Nitrile SOR K, SOR EPT-GP
(Common description) Nitrile

Nitrile rubber Nitrile rubber Ethylene Propylene

GENERIC TYPE Nitrile rubber Neoprene Nitrile PVC
Styrene Butadiene Styrene Butadiene Terpolymer
(Description) (NBR) (CR) (NBR / PVC)
(NBR/SBR) (NBR / SBR) (EPT)
Oil resistant mostly for Medium oil resistance Medium oil & fire
Oil and heat Heat, weathering and
APPLICATION Oil resistant grain handling and mostly for grain & resistance used for
resistant acid resistant
fertilizer production wood chip handling grain and wood chip

AS1332 BRANDING Z – NITRILE Z – ORS Z – PVC NITRILE Z – SOR K, Z – SOR Z – EPT GP

CO-EFFICIENT OF
GOOD GOOD FAIR GOOD FAIR GOOD
FRICTION (drive)

WEATHERING/OZONE
FAIR GOOD VERY GOOD FAIR / GOOD FAIR EXCELLENT
RESISTANCE

CUT/TEAR RESISTANCE VERY GOOD GOOD GOOD GOOD GOOD FAIR

ABRASION RESISTANCE VERY GOOD GOOD VERY GOOD GOOD GOOD GOOD

ACID RESISTANCE GOOD (4) GOOD (4) GOOD (4) GOOD (4) GOOD (4) VERY GOOD

VERY GOOD TO
MINERAL/OILS VERY GOOD (6) VERY GOOD (7) GOOD (6) GOOD (6) POOR
EXCELLENT (7)

SERVICE TEMP RANGE

- 10 to 125 - 10 to 110 - 10 to 120 - 20 to 70 - 20 to 70 - 20 to 170
( ºC ) See notes (2) & (3)

FLAME RESISTANCE POOR GOOD POOR POOR MODERATE POOR

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 TABLE 2D – GENERAL PROPERTIES
Fire Resistant and Anti-static belts

Underground FRAS S,D Grade K K-SOR

APEX FENNER GRADE Grade E
Above ground FRAS D,E,F MSHA Oil Resistant FRAS PVC
(Common description) Anti-Static
Above ground FRAS K,D Sugar FRAS Grade K

Natural rubber
Nitrile rubber
GENERIC TYPE Neoprene Styrene Butadiene Natural Rubber
Styrene Butadiene PVC
(Description) (CR) Polybutadiene (NR)
(NBR / SBR)
(NR / SBR / BR)
Generally for enclosed Sugar and grain Medium oil & fire Solid woven belt for
APPLICATION hazardous environs – coal, industries, coal resistance used for grain coal mining Grain handling
grain etc. handling and wood chips underground
S,D D,E,F, K,D K, L K, Z-SOR S
AS1332 BRANDING E
(See Note 5) (See Note 5) (See Note 5) (See Note 5)

CO-EFFICIENT OF
GOOD GOOD FAIR FAIR GOOD
FRICTION (drive)

WEATHERING/OZONE
VERY GOOD GOOD (1) FAIR FAIR GOOD (1)
RESISTANCE

CUT/TEAR RESISTANCE VERY GOOD GOOD GOOD FAIR GOOD to EXCELLENT

ABRASION RESISTANCE EXCELLENT FAIR GOOD VERY GOOD GOOD / VERY GOOD

ACID RESISTANCE GOOD (4) GOOD (4) GOOD (4) GOOD (4) GOOD (4)

MINERAL/OILS GOOD (6) POOR GOOD (6) GOOD POOR

SERVICE TEMP RANGE

- 10 to 100 - 30 to 70 - 20 to 70 - 15 to 90 - 30 to 70
( ºC ) See notes (2) & (3)

FLAME RESISTANCE EXCELLENT EXCELLENT MODERATE EXCELLENT POOR

1-7
2. Belt Capacities

Capacity Calculations …………………………………………………………………. 2–1

Properties of Materials …………………………………………………………………. 2–2

Table 1 Cross Sectional Areas of Load on Belt …………………………….… 2–3

Table 2 Capacity Factor ………………………………………………………… 2–3
Table 3 Typical Belt Speeds in General Use ……………………………….… 2–4
Table 4 Maximum Lump Size Recommended for Various Belt Widths…….. 2–4

Capacity of Troughed Belts for Common Materials

Table 5 Material Weight 480 kg/m3 ………………………………………….… 2–5
Table 6 Material Weight 800 kg/m3 ………………………………………….… 2–6
Table 7 Material Weight 1200 kg/m3 ………………………………………….. 2–7
Table 8 Material Weight 1600 kg/m3 ………………………………………….. 2–8
Table 9 Material Weight 2000 kg/m3 ………………………………………….. 2–9
Table 10 Material Weight 2400 kg/m3 ………………………………………….. 2 – 10

Table 11 Properties of Materials ………………………………………………… 2 – 11

Table 12 Conveyor Maximum Slope Angles With Various Materials ……….. 2 – 13
3. Belt Power and Tensions

Belt Power Calculations Formulae …………………………………………………. 3–1

Calculation of Maximum Tensions ….………………………………………………. 3–5

Graduated Idler Spacings ……………………………………………………………... 3-7

Feeder Belt Calculations ………………………………………………………………. 3-9

Acceleration and Deceleration ……………………………………………………….. 3 - 10

Application of Forces ………………………………………………………………….. 3 - 14

Algebraic Signs of Conveyor Forces ……………………………………………….. 3 - 15

Coasting ………………………………………………………………………………….. 3 - 16

Check List for Large Conveyor Systems …………………………………………... 3 - 17

Table 1 Standard Drive Factor ‘K’ Values …………………………………….. 3-3

Table 2 Special Drive Factor ‘K’ Values …………………………………….… 3-4
Table 3 Average Values for ‘Q’ for Fabric Belts (Mass of Moving Parts) ….. 3-4
Table 4 Recommended Average Carrying Idler Spacing ………………….… 3-7
Table 5 Belt Tensions Required at Low Tension Zones to Restrict
Sag to 2% of Idler Spacing ………………………………………….… 3-8
Table 6 Graduated Carrying Idler Spacing Guide ………………………….… 3-8
Table 7 Conveyor Starting Methods and Their Classifications …………….. 3 - 10
Table 8 Recommended Drive and Take-up Locations With
Counterweight Reaction ……………………………………………….. 3 - 12
Table 9 Requirement for Brake or Anti-Roll Back Devices ………………….. 3 - 13
Table 10 Typical Acceleration Values …………………………………………… 3 - 15
4. Belt Carcass Selection

Belt Construction Requirements ……………………………………………………….. 4-1

Considerations ….……………………………………………………………………….. 4-1

Procedure ………..……………………………………………………………………….. 4-2

Table 1A Allowable Working Tensions – Standard constructions…………….. 4-3

Table 1B Allowable Working Tensions – CoalMaster series………………….. 4-4
Table 2A Load support table – Standard constructions……………………….. 4-5
Table 2B Load support table – CoalMaster series……………………………… 4-6
Table 3 Belt troughability –………………………………………………………. 4-7

4-0
4. Belt Carcass Selection

BELT CONSTRUCTION REQUIREMENTS.

To select the optimum plied belt carcass, five properties must be considered:

♦ The belt width.

♦ The service conditions under which the belt will operate.

♦ The maximum operating tension (Tmax) – both steady state condition and peak (see table 1).

♦ The minimum number of plies required to support the load (see tables 2).

♦ The maximum number of plies beyond which transverse flexibility is reduced and the
troughing efficiency is affected. This varies with the belt width, trough angle and the idler roll
arrangement (see table 3)

CONSIDERATIONS:

Operating conditions

The allowable working tensions shown on Table 1 that follow are applicable for reasonably well
maintained conveyors operating with moderate impact, infrequent starts and good loading. Peak tension
– on starting or braking, should not exceed 140% of the allowable working tension.

For more severe operating conditions, moderate maintenance, short time cycles, frequent DOL or loaded
starts, poor loading or severe impact, hot materials handling etc., reduce the tabled figures by 15%.
Tension on starting or braking should not exceed 150% of the resulting rated tension.

For severe service conditions, poor maintenance, very hot materials, chemically aggressive
environment, severe impact and short time cycles etc., reduce the tabled figures by 30%. Tension on
starting or braking should not exceed 160% of the resulting rated tension.

Safety factors

The working tensions shown on these tables are based on the application of a safety factor of 6.7:1 on
the strength of the belt at the splice or fastened join. The safety factor is increased for more difficult
operating conditions with further restrictions applying for starting and braking.

Starting and braking tensions

A check should always be made comparing the acceleration or braking tension with the allowable peak
tension for the belt, i.e. 140% of rated working tension. If the peak tension exceeds the latter figure, a
stronger belt can be selected or the choice of control must be changed to reduce peak tension.

4-1
Mechanical fasteners

APEX FENNER always recommend hot vulcanised splices for plain weave plied belting. Other
constructions including the Crows Foot Weave, Double Weave and Solid Woven PVC can be
successfully operated at close to vulcanised joint tensions for long periods of time whereas plain weave
constructions generally operate at reduced tensions when fitted with mechanical fasteners

Recommended precautions including frequent inspection and monitoring, any Local Authority restrictions
and greater than normal care should always be observed when using Mechanical Fasteners. Belt
cleaners should only be fitted if specifically suited to operation with mechanical fasteners

If a conveyor belt is to be operated for any length of time with mechanical fasteners then the selected
combination of belt and fastener should be statically tensile tested and a working tension of not more
than 15% of that result. Table 1 lists APEX FENNER recommendations for its common range of belts.

Troughability and load support

This table provides a guide to the maximum width of belt that will support the load when carrying material
with the bulk density shown.
This table provides a guide to the minimum width of belt that will trough satisfactorily at the trough angle
shown. The widths shown above are a guide only and experience may dictate the selection of a ply more
or a ply less.

Some factors that may influence the choice are:

♦ Partially filled belt.

♦ Idler trough angle
♦ Convex or concave curve radius and idler pitch
♦ Lump size of material
♦ Installed pulley diameters

PROCEDURE:

Consider the possible belt constructions.

1. Calculate working tension needed for the both steady state and peak (accelerating or braking).

Required Working Tension (kN/m) = Tmax (kN)

Belt width (m)

Where: Tmax. = Peak or Steady State tension in conveyor (kN).

2. Considering operating conditions and starting and braking tensions and determine suitable belt
constructions from tables 1A and 1B. Working tensions shown in tables 1A and 1B are applicable
for reasonably well-maintained conveyors with moderate impact, infrequent starts and good
loading and are reduced where operating conditions are less favourable - see discussion below

3. Consider special needs and the use of special fabrics such as Crow’s foot or Double weaves.

4. Establish the various practical carcass/ ply number combinations to support the load for the
conveyor working conditions under review - (Tables). Load support requirements may dictate that
the selected belt is operating at a fraction of it’s allowable working tension.

5. Check that the selected construction(s) are acceptable for troughing - (Table 3)

6. Check that the installed pulley diameters are adequate – (refer section 6)

The final selection should be checked with APEX FENNER since cost, availability and service
criteria can be additional factors for consideration.

4-2
 Table 1A – ALLOWABLE WORKING TENSION

Standard Constructions
(other than CoalMaster series)

RECOMMENDED ALLOWABLE WORKING TENSION

For reasonably well maintained conveyors with moderate impact, infrequent starts and good loading.

Number of plies 2 3 4 5 6

PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6

plain weave Spliced 24 kN/m 50 kN/m 72 kN/m 90 kN/m 112 kN/m
Fastened 27 kN/m 40 kN/m 53 kN/m 66 kN/m 79 kN/m

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6

plain weave Spliced 30 kN/m 63 kN/m 90 kN/m 120 kN/m 150 kN/m
Fastened 34 kN/m 51 kN/m 68 kN/m 85 kN/m 102 kN/m

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Spliced 37 kN/m 75 kN/m 112 kN/m 150 kN/m 187 kN/m
Fastened See below See below See below See below See below

PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6

plain weave Spliced 48 kN/m 90 kN/m 140 kN/m 180 kN/m 225 kN/m
Fastened See below See below See below See below See below

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5

plain weave Spliced 100 kN/m 157 kN/m 192 kN/m
Fastened See below See below See below

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

plain weave Spliced 60 kN/m 120 kN/m 168 kN/m 216 kN/m
Fastened See below See below See below See below

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5

Crow's foot Spliced 56 kN/m 100 kN/m 140 kN/m 192 kN/m
weave Fastened 56 kN/m 84 kN/m 112 kN/m 140 kN/m

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

Crow's foot Spliced 60 kN/m 120 kN/m 168 kN/m 216 kN/m
weave Fastened 70 kN/m 105 kN/m 140 kN/m 175 kN/m

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5

Crow's foot Spliced 150 kN/m 202 kN/m 270 kN/m
weave Fastened See below See below See below

PN 450 PN900 /2 PN1350 /3

Double weave Spliced 67.5 kN/m 135 kN/m
Fastened 90 kN/m 135 kN/m

Not generally recommended for permanent use with mechanical fasteners, but may be used with
fasteners either temporarily or permanently under certain conditions.

4-3
 Table 1B – ALLOWABLE WORKING TENSION

CoalMaster series
(For underground coal mining)

RECOMMENDED ALLOWABLE WORKING TENSION

For reasonably well maintained conveyors with moderate impact, infrequent starts and good loading.

Number of plies 2 3 4 5 6

PN 150 - 160 PN630 /4 PN800 /5

plain weave Spliced 72 kN/m 96 kN/m
Fastened 53 kN/m 66 kN/m

PN 200 - 220 PN800 /4 PN1000 /5 PN1200 /6

plain weave Spliced 90 kN/m 120 kN/m 150 kN/m
Fastened 68 kN/m 85 kN/m 102 kN/m

PN 250 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Spliced 112 kN/m 150 kN/m 187 kN/m
Fastened See below See below See below

PN 300 - 315 PN1250 /4 PN1500 /5

plain weave Spliced 140 kN/m 180 kN/m
Fastened See below See below

PN 320 - 350 PN1400 /4 PN1750 /5

plain weave Spliced 157 kN/m 210 kN/m
Fastened See below See below

PN 360 - 400 PN1600 /4 PN2000 /5

plain weave Spliced 180 kN/m 240 kN/m
Fastened See below See below

PN 315 - 375 PN1120 /3 PN1400 /4 PN1600 /5

Crow's foot Spliced 100 kN/m 157 kN/m 192 kN/m
weave Fastened 90 kN/m 115 kN/m 140 kN/m

PN 360 - 400 PN1200 /3 PN1600 /4 PN1875 /5

Crow's foot Spliced 120 kN/m 180 kN/m 225 kN/m
weave Fastened 105 kN/m 140 kN/m 175 kN/m

PN 450 - 500 PN1500 /3 PN2000 /4 PN2500 /5

Crow's foot Spliced 150 kN/m 225 kN/m 300 kN/m
weave Fastened See below See below See below

PN 450 PN1350 /3
Double weave Spliced 135 kN/m
Fastened 135 kN/m

Not generally recommended for permanent use with mechanical fasteners, but may be used
with fasteners either temporarily or permanently under certain conditions.

4-4
 Table 2A - LOAD SUPPORT

Plain Weave Fabrics

(with standard thickness skim)

MAXIMUM WIDTH TO SUPPORT THE LOAD

For conventional troughed conveyors

Number of plies 2 3 4 5 6

PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6

plain weave 800 kg/m3 900 mm 1100 mm 1600 mm 2100 mm 2500 mm
Load 1200 kg/m3 700 mm 1000 mm 1500 mm 1900 mm 2400 mm
Bulk density: 1800 kg/m3 600 mm 800 mm 1300 mm 1700 mm 2200 mm
2600 kg/m3 - 500 mm 1000 mm 1500 mm 1900 mm

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6

plain weave 800 kg/m3 1100 mm 1300 mm 1800 mm 2400 mm -
Load 1200 kg/m3 1000 mm 1200 mm 1700 mm 2300 mm -
Bulk density: 1800 kg/m3 800 mm 1000 mm 1500 mm 2100 mm -
2600 kg/m3 500 mm 800 mm 1300 mm 1800 mm 2300 mm

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6

plain weave 800 kg/m3 1200 mm 1500 mm 2100 mm - mm -
Load 1200 kg/m3 1100 mm 1400 mm 2000 mm - mm -
Bulk density: 1800 kg/m3 900 mm 1200 mm 1800 mm 2500 mm -
2600 kg/m3 700 mm 1100 mm 1600 mm 2200 mm -

PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6

plain weave 800 kg/m3 1400 mm 1800 mm - mm - -
Load 1200 kg/m3 1300 mm 1600 mm 2500 mm - -
Bulk density: 1800 kg/m3 1100 mm 1500 mm 2300 mm - -
2600 kg/m3 800 mm 1200 mm 2100 mm - -

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5

plain weave 800 kg/m3 2000 mm - -
Load 1200 kg/m3 1800 mm - -
Bulk density: 1800 kg/m3 1600 mm 2400 mm -
2600 kg/m3 1400 mm 2200 mm -

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

plain weave 800 kg/m3 1600 mm 2100 mm 2400 mm -
Load 1200 kg/m3 1500 mm 2000 mm - -
Bulk density: 1800 kg/m3 1300 mm 1800 mm - -
2600 kg/m3 1000 mm 1600 mm - -

4-5
 Table 2B - LOAD SUPPORT

Special Weave Fabrics

(with standard thickness skim)

MAXIMUM WIDTH TO SUPPORT THE LOAD

For conventional troughed conveyors

Number of plies 2 3 4 5 6

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5

Crow's foot 800 kg/m3 1600 mm 2100 mm - -
weave 1200 kg/m3 1500 mm 2000 mm - -
Bulk density: 1800 kg/m3 1300 mm 1800 mm - -
2600 kg/m3 1000 mm 1600 mm 2400 mm -

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

Crow's foot 800 kg/m3 1700 mm 2400 mm - -
weave 1200 kg/m3 1600 mm 2200 mm - -
Bulk density: 1800 kg/m3 1400 mm 2000 mm - -
2600 kg/m3 1200 mm 1800 mm - -

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5

Crow's foot 800 kg/m3 - - -
weave 1200 kg/m3 - - -
Bulk density: 1800 kg/m3 2400 mm - -
2600 kg/m3 2200 mm - -

PN 450 PN900 /2 PN1350 /3

Double weave 800 kg/m3 1900 mm -
1200 kg/m3 1800 mm -
Bulk density: 1800 kg/m3 1600 mm -
2600 kg/m3 1300 mm -

4-6
 Table 3 – TROUGHABILITY

Plain Weave Fabrics

(with standard thickness skim)

MINIMUM WIDTH TO TROUGH THE BELT

(For conventional troughed conveyors)

Number of plies 2 3 4 5 6

PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6

plain weave 20 to 30º mm 400 mm 450 mm 500 mm 600 mm
30 to 40º mm 450 mm 500 mm 600 mm 750 mm
up to 45º 400 mm 500 mm 600 mm 650 mm 800 mm

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6

plain weave 20 to 30º mm 450 mm 500 mm 650 mm 800 mm
30 to 40º 450 mm 500 mm 650 mm 750 mm 900 mm
up to 45º 500 mm 650 mm 800 mm 900 mm 1050 mm

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6

plain weave 20 to 30º 400 mm 450 mm 650 mm 800 mm 900 mm
30 to 40º 450 mm 600 mm 800 mm 900 mm 1000 mm
up to 45º 600 mm 750 mm 900 mm 1050 mm 1350 mm

PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6

plain weave 20 to 30º 400 mm 600 mm 750 mm 800 mm 1000 mm
30 to 40º 500 mm 650 mm 800 mm 900 mm 1050 mm
up to 45º 600 mm 800 mm 1000 mm 1050 mm 1200 mm

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5

plain weave 20 to 30º 600 mm 750 mm 900 mm
30 to 40º 750 mm 900 mm 1050 mm
up to 45º 800 mm 1000 mm 1200 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

plain weave 20 to 30º 500 mm 650 mm 800 mm 1050 mm
30 to 40º 600 mm 750 mm 900 mm 1200 mm
up to 45º 650 mm 900 mm 1050 mm 1400 mm

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5

Crow's foot 20 to 30º 500 mm 650 mm 750 mm 900 mm
weave 30 to 40º 600 mm 750 mm 900 mm 1050 mm
up to 45º 750 mm 900 mm 1050 mm 1350 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

Crow's foot 20 to 30º 500 mm 650 mm 800 mm 1050 mm
weave 30 to 40º 650 mm 750 mm 900 mm 1200 mm
up to 45º 750 mm 900 mm 1050 mm 1500 mm

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5

Crow's foot 20 to 30º - - -
weave 30 to 40º - - -
up to 45º 2200 mm - -

PN 450 PN900 /2 PN1350 /3

Double weave 20 to 30º 1300 mm -
30 to 40º 1800 mm -
up to 45º 1900 mm -

4-7
5. Cover Gauges and Qualities

Considerations…………………………………………………………………………… 5-1

Selection……………….………………………………………………………………….. 5-1

Pulley side cover………………………………………………………………………… 5-1

Table 1 Top Cover Thickness ………………………………………………… 5–2

5-1
5. Cover gauges and qualities

CONSIDERATIONS

There are a number of factors that must be taken into account when selecting the belt grade or
cover material, such as:

♦ Fire resistance or anti-static properties

♦ Resistance to oils or chemicals
♦ Temperature of the operating environment or conveyed material
♦ Resistance to ageing, weathering and ozone.
♦ The type of material being conveyed
♦ The lump size and shape of the material being conveyed
♦ The mix of lumps and fines in the material
♦ The abrasiveness of the material
♦ The method of loading the belt
♦ The fall height of material to the belt
♦ The cycle time of the conveyor for a single revolution of the belt
♦ Performance or experience in a similar application
♦ For replacement belts – the performance of previous belts on the same installation
♦ Availability and cost

SELECTION

Previous experience will always be the best guide to the optimum selection of both the type and
thickness of belt cover, however if this information is not available as will be the case for new
installations, the following steps should be followed.

♦ From table 1 – 2 select the most suitable cover types of cover or belt grades for the
application. In some cases statutory requirements or the operating conditions will limit
selections to one or two possibilities.
♦ Calculate the time cycle of the conveyor = (2 x L)
S
Where:L = conveyor centres (m)
S = belt speed (m/s)

♦ Use table 1 as a guide to select the appropriate thickness of top cover. Consideration
should be given to the applicable properties of the cover in making this selection.

For difficult applications such as belt feeders, or impact belts, heavier covers may be required.

PULLEY SIDE COVER

As a guide, pulley side cover should generally be not less than 1/4 of carry side cover for covers up
to 9mm and about 1/3 of carry cover thickness for covers heavier than 9mm. Operating conditions
can dictate that heavier pulley side covers are required.
For long centre, long time cycle conveyors, pulley side cover can be up to 1/2 of carry side cover.

5-2
TABLE 1
BELT COVER THICKNESS

Lightly abrasive Moderately abrasive Heavily abrasive Extremely abrasive

Time cycle materials materials materials materials
seconds

(2 x L)
S
Lump size Lump size Lump size Lump size
Cycle time for (mm) (mm) (mm) (mm)
complete belt
revolution.
10 50 125 200 300 10 50 125 200 300 10 50 125 200 300 10 50 125 200 300

15 seconds 1-2 3-5 6-7 8-10 10-12 1-2 4-5 7-10 9-12 11-15 2-4 4-7 7-10 10-15 12-19 3-6 4-10 8-15 10-19 13-23

30 seconds 1-2 3-4 5-6 6-8 8-10 1-2 3-4 5-8 7-10 9-12 2-3 3-6 6-10 8-12 10-15 2-5 4-8 6-12 8-15 10-18

60 seconds 1-2 2-3 4-5 5-6 7-8 1-2 3-4 5-6 6-8 7-10 1-3 3-5 5-8 6-10 8-13 2-4 3-6 5-10 7-13 9-15

120 seconds 1-2 2-3 3-4 5-6 6-7 1-2 2-3 4-6 5-7 6-9 1-2 2-4 4-7 6-9 7-11 2-4 3-6 5-7 6-11 8-13

180 seconds
1-2 1-2 3-4 4-5 5-6 1-2 2-3 4-5 5-6 6-8 1-2 2-4 4-6 5-8 6-10 2-3 2-5 4-8 5-10 7-12
and over

Wood chips - bituminous coal - grains - Basalt - sand - anthracite coal - crushed Limestone - ores - phosphate - slag -
Typical materials Glass cullet - granite - quartz ores etc.
round river gravel etc. gravel etc. cement clinker etc.

5-3
6. Pulley Diameters

Parallel face pulleys…………………………………………………………………….. 6-1

Crown face pulleys……………………………………………………………………… 6-2

Pulley face width………………………………………………………………………… 6-2

Table 1A Standard constructions

– operating at over 60% of allowable working tension ……………… 6-3
Table 1B CoalMaster series
– operating at over 60% of allowable working tension ……………… 6-4
Table 2A Standard constructions
– operating at 30 - 60% of allowable working tension ….…………… 6-5
Table 2B CoalMaster series
– operating at 30 - 60% of allowable working tension …….………… 6-6

6-0
6. Pulley diameters

The minimum pulley diameter recommended for a particular belt depends upon three factors:

• Carcass Thickness – The wire rope diameter in the case of Steel Cord belts.
– The overall thickness of all plies plus the rubber skims
between plies in the case of Ply Type belts.
– The overall thickness of the thick woven fabric separating
the top and bottom covers in the case of Solid-woven belts.

• Operating Tension – The relationship of the operating tension of the belt at the
particular pulley to the belt’s Allowable Working Tension.

• Carcass modulus – The relationship between elongation of the carcass and

the resulting stress.

Whatever the carcass type, Steel Cord, Ply Type or Solid Woven, when the belt is bent around a
small radius, tension stresses are developed in the outer fibres while compression stresses are built
up in the inner fibres. At a given tension, if the radius is too small the elastic limit of the outer fibres
may be exceeded and fracture, and at the same time, the compression of the inner fibres may cause
severe crinkling and eventual ply separation.

Since the elastic properties of the rubber or PVC cover material is so much greater than the carcass
material, the cover thickness of the belting is not a factor in determining minimum pulley size, and
may be ignored.

The tables of recommended pulley diameters in the APEX FENNER handbook for Ply Type belting
are based on the three classes of pulleys defined in ISO 3684. viz.;

• Type “A” – High tension / tight side pulleys (T1) e.g. head, drive, tripper and shuttle pulleys
• Type “B” – Low tension or slack side pulleys (T2) such as tail and take up pulleys
• Type “C" – Low tension snub or bend pulleys with wrap angle of less than 30 degrees

Two sets of Pulley Diameter tables follow:

• For belts operating at over 60% of allowable working tension

Table 1 A - for standard belt constructions
Table 1 B – for CoalMaster series belts

• For belts operating at 30 – 60% of allowable working tension

Table 2 A - for standard belt constructions
Table 2 B – for CoalMaster series belts

For belts operating at less than 30% of the allowable working tension, the diameter of Type “A”
pulleys can be reduced to the same as Type “B”.

PARALLEL FACE PULLEYS

With just a few special exceptions, all pulleys used with modern high strength, high modulus fabric
belts should be parallel face types. It is absolutely mandatory that all pulleys used in conveyors fitted
with Steel Cord belting be parallel face type. One notable exception to this rule is in the case of
Bucket Elevators which, lacking any other means of tracking the belt centrally, may benefit from
Crown Faced Pulleys.

6-1
CROWN FACE PULLEYS

A Crown Faced pulley can have the effect of centering the tracking of the belt, but only in the case
where there is a long unsupported length of belt leading into the pulley, as the belt must be able to
bend longitudinally along its centreline to benefit from the crown. High modulus Ply Type belts have
very little ability to bend longitudinally and Steel Cord belts have virtually no ability at all. Solid Woven
belts are not quite so rigid but still need an unsupported distance of something like 4 to 6 times the
belt width to be able to react.

Apart from not serving much purpose in troughed conveyor systems, Crowned pulleys can seriously
damage the belt by severely overstressing the carcass in the centre of the belt, particularly in the case
of Steel Cord belts.

The few special cases where Crowned pulleys are useful include, Bucket Elevators, the Take- up
pulley in long gravity Take-up arrangements and for some short centre - wide belt, reversing
conveyors. In cases like this where there are no supporting idlers to train the belt, some benefit may
be obtained from the installation of Crowned pulleys.

Face Width W
Taper
1 in 100

W/4 W/4
W/2

d D

It is fairly common practice to crown a pulley by machining a taper of 1 in 100 from each pulley edge
towards the centre over a distance of 1/4 pulley face. It is more correct to relate the amount of pulley
crown to the pulley diameter, not to its face width. Viz.; d = D - 0.008 x D

PULLEY FACE WIDTH

As all belts tend to wander a bit in operation, the overall face width of the pulleys should exceed the
belt width by the following minimum amounts, if serious edge damage is to be avoided;

• Belts up to 650mm wide …. …. …. …. …. …. …. …. 100mm

• Belts 750 to 1400mm wide …. …. …. …. …. …. …. …. 150mm
• Belts over 1400mm wide …. …. …. …. …. …. …. …. 200mm

For conveyors built on unstable ground, as in underground coal mines and very long overland
conveyors, the above allowances should be increased by 50mm.

6-2
TABLE 1A
STANDARD CONSTRUCTIONS
(other than CoalMaster series)

RECOMMENDED MINIMUM PULLEY DIAMETERS

For belts operating at over 60% of maximum allowable working tension

Number of plies 2 3 4 5 6

PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6

plain weave Type “A” 315 mm 400 mm 560 mm 710 mm 800 mm
Type “B” 250 mm 315 mm 450 mm 560 mm 630 mm
Type “C” 200 mm 250 mm 360 mm 450 mm 500 mm

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6

plain weave Type “A” 400 mm 450 mm 630 mm 800 mm 900 mm
Type “B” 315 mm 360 mm 500 mm 630 mm 710 mm
Type “C” 250 mm 280 mm 400 mm 500 mm 560 mm

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Type “A” 450 mm 500 mm 710 mm 900 mm 1120 mm
Type “B” 360 mm 400 mm 560 mm 710 mm 900 mm
Type “C” 280 mm 315 mm 450 mm 560 mm 710 mm

PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6

plain weave Type “A” 500 mm 560 mm 800 mm 1120 mm 1400 mm
Type “B” 400 mm 450 mm 630 mm 900 mm 1120 mm
Type “C” 315 mm 360 mm 500 mm 710 mm 900 mm

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5

plain weave Type “A” 630 mm 900 mm 1120 mm
Type “B” 500 mm 710 mm 900 mm
Type “C” 400 mm 560 mm 710 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

plain weave Type “A” 560 mm 710 mm 1000 mm 1250 mm
Type “B” 450 mm 560 mm 800 mm 1000 mm
Type “C” 360 mm 450 mm 630 mm 800 mm

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5

Crow's foot Type “A” 560 mm 710 mm 1000 mm 1250 mm
weave Type “B” 450 mm 560 mm 800 mm 1000 mm
Type “C” 360 mm 450 mm 630 mm 800 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

Crow's foot Type “A” 560 mm 800 mm 1000 mm 1250 mm
weave Type “B” 450 mm 630 mm 800 mm 1000 mm
Type “C” 360 mm 500 mm 630 mm 800 mm

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5

Crow's foot Type “A” 900 mm 1250 mm 1600 mm
weave Type “B” 710 mm 1000 mm 1250 mm
Type “C” 560 mm 800 mm 1000 mm

PN 450 PN900 /2 PN1350 /3

Double weave Type “A” 630 mm 1000 mm
Type “B” 500 mm 800 mm
Type “C” 400 mm 630 mm

6-3
TABLE 1B
COALMASTER SERIES
( For underground coal mining)

RECOMMENDED MINIMUM PULLEY DIAMETERS

For belts operating at over 60% of maximum allowable working tension

Number of plies 2 3 4 5 6

PN 150 - 160 PN630 /4 PN800 /5

plain weave Type “A” 500 mm 710 mm
Type “B” 400 mm 560 mm
Type “C” 315 mm 450 mm

PN 200 - 220 PN800 /4 PN1000 /5 PN1200 /6

plain weave Type “A” 630 mm 800 mm 1000 mm
Type “B” 500 mm 630 mm 800 mm
Type “C” 400 mm 500 mm 630 mm

PN 250 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Type “A” 800 mm 1000 mm 1250 mm
Type “B” 630 mm 800 mm 1000 mm
Type “C” 500 mm 630 mm 800 mm

PN 300 - 315 PN1250 /4 PN1500 /5

plain weave Type “A” 800 mm 1000 mm
Type “B” 630 mm 800 mm
Type “C” 500 mm 630 mm

PN 320 - 350 PN1400 /4 PN1750 /5

plain weave Type “A” 900 mm 1120 mm
Type “B” 710 mm 900 mm
Type “C” 560 mm 710 mm

PN 360 - 400 PN1600 /4 PN2000 /5

plain weave Type “A” 1000 mm 1250 mm
Type “B” 800 mm 1000 mm
Type “C” 630 mm 800 mm

PN 315 - 375 PN1120 /3 PN1400 /4 PN1600 /5

Crow's foot Type “A” 710 mm 1000 mm 1250 mm
weave Type “B” 560 mm 800 mm 1000 mm
Type “C” 450 mm 630 mm 800 mm

PN 360 - 400 PN1200 /3 PN1600 /4 PN1875 /5

Crow's foot Type “A” 800 mm 1000 mm 1250 mm
weave Type “B” 630 mm 800 mm 1000 mm
Type “C” 500 mm 630 mm 800 mm

PN 450 - 500 PN1500 /3 PN2000 /4 PN2500 /5

Crow's foot Type “A” 900 mm 1250 mm 1600 mm
weave Type “B” 710 mm 1000 mm 1250 mm
Type “C” 560 mm 800 mm 1000 mm

PN 450 PN1350 /3
Double weave Type “A” 1000 mm
Type “B” 800 mm
Type “C” 630 mm

6-4
TABLE 2A
STANDARD CONSTRUCTIONS
(other than CoalMaster series)

RECOMMENDED MINIMUM PULLEY DIAMETERS

For belts operating at over 30 to 60% of maximum allowable working tension
(for belts operating at less than 30% of allowable working tension,
type “B” diameters can be used for Type “A” pulleys)
Number of plies 2 3 4 5 6

PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6

plain weave Type “A” 250 mm 315 mm 450 mm 560 mm 630 mm
Type “B” 200 mm 250 mm 360 mm 450 mm 500 mm
Type “C” 160 mm 200 mm 280 mm 360 mm 400 mm

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6

plain weave Type “A” 315 mm 360 mm 500 mm 630 mm 710 mm
Type “B” 250 mm 280 mm 400 mm 500 mm 560 mm
Type “C” 200 mm 225 mm 315 mm 400 mm 450 mm

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Type “A” 360 mm 400 mm 560 mm 710 mm 900 mm
Type “B” 280 mm 315 mm 450 mm 560 mm 710 mm
Type “C” 225 mm 250 mm 360 mm 450 mm 560 mm

PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6

plain weave Type “A” 400 mm 450 mm 630 mm 900 mm 1120 mm
Type “B” 315 mm 360 mm 500 mm 710 mm 900 mm
Type “C” 250 mm 280 mm 400 mm 560 mm 710 mm

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5

plain weave Type “A” 500 mm 710 mm 900 mm
Type “B” 400 mm 560 mm 710 mm
Type “C” 315 mm 450 mm 560 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

plain weave Type “A” 450 mm 560 mm 800 mm 1000 mm
Type “B” 360 mm 450 mm 630 mm 800 mm
Type “C” 280 mm 360 mm 500 mm 630 mm

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5

Crow's foot Type “A” 450 mm 560 mm 800 mm 1000 mm
weave Type “B” 360 mm 450 mm 630 mm 800 mm
Type “C” 280 mm 360 mm 500 mm 630 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

Crow's foot Type “A” 450 mm 630 mm 800 mm 1000 mm
weave Type “B” 360 mm 500 mm 630 mm 800 mm
Type “C” 280 mm 400 mm 500 mm 630 mm

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5

Crow's foot Type “A” 710 mm 1000 mm 1250 mm
weave Type “B” 560 mm 800 mm 1000 mm
Type “C” 450 mm 630 mm 800 mm

PN 450 PN900 /2 PN1350 /3

Double weave Type “A” 500 mm 800 mm
Type “B” 400 mm 630 mm
Type “C” 315 mm 500 mm

6-5
TABLE 2B
COALMASTER SERIES
(For underground coal mining)

RECOMMENDED MINIMUM PULLEY DIAMETERS

For belts operating at over 30 to 60% of maximum allowable working tension
(for belts operating at less than 30% of allowable working tension,
type “B” diameters can be used for Type “A” pulleys)
Number of plies 2 3 4 5 6

PN 150 - 160 PN630 /4 PN800 /5

plain weave Type “A” 400 mm 560 mm
Type “B” 315 mm 450 mm
Type “C” 250 mm 360 mm

PN 200 - 220 PN800 /4 PN1000 /5 PN1200 /6

plain weave Type “A” 500 mm 630 mm 800 mm
Type “B” 400 mm 500 mm 630 mm
Type “C” 315 mm 400 mm 500 mm

PN 250 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Type “A” 630 mm 800 mm 1000 mm
Type “B” 500 mm 630 mm 800 mm
Type “C” 400 mm 500 mm 630 mm

PN 300 - 315 PN1250 /4 PN1500 /5

plain weave Type “A” 630 mm 800 mm
Type “B” 500 mm 630 mm
Type “C” 400 mm 500 mm

PN 320 - 350 PN1400 /4 PN1750 /5

plain weave Type “A” 710 mm 900 mm
Type “B” 560 mm 710 mm
Type “C” 450 mm 560 mm

PN 360 - 400 PN1600 /4 PN2000 /5

plain weave Type “A” 800 mm 1000 mm
Type “B” 630 mm 800 mm
Type “C” 500 mm 630 mm

PN 315 - 375 PN1120 /3 PN1400 /4 PN1600 /5

Crow's foot Type “A” 560 mm 800 mm 1000 mm
weave Type “B” 450 mm 630 mm 800 mm
Type “C” 360 mm 500 mm 630 mm

PN 360 - 400 PN1200 /3 PN1600 /4 PN1875 /5

Crow's foot Type “A” 630 mm 800 mm 1000 mm
weave Type “B” 500 mm 630 mm 800 mm
Type “C” 400 mm 500 mm 630 mm

PN 450 - 500 PN1500 /3 PN2000 /4 PN2500 /5

Crow's foot Type “A” 710 mm 1000 mm 1250 mm
weave Type “B” 560 mm 800 mm 1000 mm
Type “C” 450 mm 630 mm 800 mm

PN 450 PN1350 /3
Double weave Type “A” 800 mm
Type “B” 630 mm
Type “C” 500 mm

6-6
7. Design Considerations

Multiple Slope and Vertical Curve Conveyors …………………………………….. 7-1

Terminal Troughing Idler Arrangements ……………………………………………. 7-4

Transitions …………………………………………………………………..…………... 7-4

Take – Up Arrangements ………………………………………………………………. 7-5

Table 1 Average Elastic Modulus ‘E’ ……………………………….… 7-3

Table 2 Transition Distances for Head Pulleys ……………………… 7-4
Table 3 Transition Distances for Tail End Loading Points ………..… 7-5
Table 4 Gravity Take – Up Travel ………………………………..…… 7-6
8. General Data

Belt Mass and thickness………………………..………………………………,,,,,,,,,,, 8-1

Shipping dimensions and roll sizes…………………………….………………...… 8-1

Length of belt on a roll…………………………………………………………...…… 8-2

Belt transport guidelines……………………………………………………….…… 8-3

Table 1 Belt carcass mass and thickness

– standard constructions……………………………………………… 8-4
Table 2 Belt carcass mass and thickness
– CoalMaster series…………………………………………………… 8-5
Table 3 Belt carcass and cover mass factors……………………………….. 8–6

8-0
8. General Data

BELT MASS AND THICKNESS

On the following pages are three tables:

Table 1
Belt Carcass Mass and Thickness for Standard Belt Constructions
(other than CoalMaster belting for underground coal mining)

Table 2
Belt Carcass Mass and Thickness for CoalMaster Belting
(for underground coal mining)

Table 3
Carcass Mass Factor and Cover Mass Factor

To calculate Belt Mass

• Look up Belt Carcass Mass (kg/m2) from either table 1 - Standard Belt Constructions or table 2 -
CoalMaster Belting as applicable.
• To obtain the actual Belt Carcass Mass, multiply this by the Belt Carcass Mass factor from table
3.
• To obtain the mass of the belt covers, add together the top and bottom cover thickness and
multiply this by the Belt Cover Mass factor, also from table 3.
• Add together the mass of the Belt Carcass and Covers for the belt mass per square metre
(kg/m2) and multiply by the belt width (in metres) for the belt mass per metre run (kg/m).

To obtain belt thickness

• Look up Belt Carcass Thickness (mm) from either table 1 - Standard Belt Constructions or table
2 - CoalMaster Belting as applicable.
• Add to this the thickness of both the top and bottom covers.

SHIPPING DIMENSIONS AND ROLL SIZES

Roll diameter

Roll diameter for belts can be determined from figure 1 below. The diameters shown are for a belt
wrapped on a 600mm-diameter centre. For belts supplied on enclosed drums, an additional 0.15m
should be added for clearance and slats where fitted.

Alternatively the diameter can be calculated from the following formula:

______________ ____
D = √ d2 + (0.001273 x L x G)

Where D = Overall diameter (m)

d = core diameter (m)
L = Belt length (m)
G = Belt thickness (mm)

8-1
Shipping dimensions

Add 50mm to belt width for clearance on belts supplied on cores.

For belts supplied on enclosed drums:
- Add 300mm to belt width
- Add 150mm to belt diameter

Figure 1. Belt roll diameter

4
Belt thickness (mm)

3.5
30 25
20
3 15
12.5
Roll diameter (m)

10
2.5
7.5

2 5

1.5

0.5
0

0
50

10

15

20

25

30

35

40

45

50

55

60

Belt length (m)

LENGTH OF BELT ON A ROLL

The length of belt on a roll may be determined using the following formula:

L = (d + (D – d) / 2) x π) x N

Where D = outside diameter of the roll (m)

d = diameter of the roll centre (m)
N = the number of wraps of the belt
π = 3.1416

8-2
BELT TRANSPORT GUIDELINES

Road freight

Trailer type Maximum roll diameter Load weight

Tray 2.75m 20 – 22 tonne
Drop-deck 3.20m 20 tonne
Low loader 3.8m * 1 roll

* may vary with loader height and state regulations

Sea freight

Container type Maximum roll diameter Load weight

2o ft. or 40 ft. * 2.29m 18.3 tonne
Heavy duty 2.29m 21.3 tonne

*Container internal dimensions (nominal):

20ft – 2.29m high x 2.35m wide x 5.93m long
40ft – 2.29m high x 2.35m wide x 12.0m long

8-3
TABLE 1
STANDARD CONSTRUCTIONS
(other than CoalMaster series)

BELT CARCASS MASS AND THICKNESS

Number of plies 2 3 4 5 6

PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6

plain weave Mass 3.7 kg/m2 4.4 kg/m2 5.8 kg/m2 7.3 kg/m2 8.8 kg/m2
Thickness 2.7 mm 3.3 mm 4.6 mm 5.9 mm 7.1 mm

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6

plain weave Mass 4.4 kg/m2 5.1 kg/m2 6.8 kg/m2 8.5 kg/m2 10.2 kg/m2
Thickness 3.3 mm 3.9 mm 5.3 mm 6.8 mm 8.2 mm

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Mass 4.4 kg/m2 5.8 kg/m2 7.7 kg/m2 9.6 kg/m2 11.5 kg/m2
Thickness 3.3 mm 4.5 mm 6.1 mm 7.8 mm 9.5 mm

PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6

plain weave Mass 5.4 kg/m2 6.8 kg/m2 9.1 kg/m2 11.4 kg/m2 14.6 kg/m2
Thickness 4.1 mm 5.4 mm 7.4 mm 9.4 mm 11.8 mm

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5

plain weave Mass 7.2 kg/m2 9.7 kg/m2 12.1 kg/m2
Thickness 5.6 mm 7.7 mm 9.8 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

plain weave Mass 6.0 kg/m2 7.7 kg/m2 10.4 kg/m2 13.9 kg/m2
Thickness 4.7 mm 6.1 mm 8.4 mm 11.3 mm

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5

Crow's foot Mass 6.0 kg/m2 7.7 kg/m2 10.3 kg/m2 13.0 kg/m2
weave Thickness 4.7 mm 6.1 mm 8.4 mm 10.7 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5

Crow's foot Mass 6.4 kg/m2 8.3 kg/m2 11.1 kg/m2 14.0 kg/m2
weave Thickness 5.0 mm 6.7 mm 9.1 mm 11.6 mm

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5

Crow's foot Mass 9.5 kg/m2 12.7 kg/m2 15.9 kg/m2
weave Thickness 7.7 mm 10.5 mm 13.3 mm

PN 450 PN900 /2 PN1350 /3

Double weave Mass 7.0 kg/m2 11.0 kg/m2
Thickness 5.5 mm 9.0 mm

8-4
TABLE 2
COALMASTER SERIES
(For underground coal mining)

BELT CARCASS MASS AND THICKNESS

Add 1.4 kg/m2 for each millimetre of cover

Number of plies 2 3 4 5 6

PN 150 - 160 PN630 /4 PN800 /5

plain weave Mass 7.8 kg/m2 9.6 kg/m2
Thickness 4.6 mm 5.9 mm

PN 200 - 220 PN800 /4 PN1000 /5 PN1200 /6

plain weave Mass 9.5 kg/m2 11.9 kg/m2 14.2 kg/m2
Thickness 5.8 mm 7.4 mm 9.0 mm

PN 250 PN1000 /4 PN1250 /5 PN1500 /6

plain weave Mass 11.1 kg/m2 13.9 kg/m2 16.6 kg/m2
Thickness 6.9 mm 8.8 mm 10.7 mm

PN 300 - 315 PN1250 /4 PN1500 /5

plain weave Mass 11.7 kg/m2 14.0 kg/m2
Thickness 7.4 mm 9.0 mm

PN 320 - 350 PN1400 /4 PN1750 /5

plain weave Mass 12.2 kg/m2 15.3 kg/m2
Thickness 7.7 mm 9.8 mm

PN 360 - 400 PN1600 /4 PN2000 /5

plain weave Mass 13.3 kg/m2 16.5 kg/m2
Thickness 8.6 mm 10.9 mm

PN 315 - 375 PN1120 /3 PN1400 /4 PN1600 /5

Crow's foot Mass 9.8 kg/m2 13.0 kg/m2 16.2 kg/m2
weave Thickness 6.1 mm 8.4 mm 10.7 mm

PN 360 - 400 PN1200 /3 PN1600 /4 PN1875 /5

Crow's foot Mass 10.5 kg/m2 13.9 kg/m2 17.3 kg/m2
weave Thickness 6.7 mm 9.1 mm 11.6 mm

PN 450 - 500 PN1500 /3 PN2000 /4 PN2500 /5

Crow's foot Mass 11.7 kg/m2 15.5 kg/m2 19.3 kg/m2
weave Thickness 7.7 mm 10.5 mm 13.3 mm

PN 450 PN1350 /3
Double weave Mass 14.1 kg/m2
Thickness 9.0 mm

8-5
TABLE 3
BELT CARCASS AND
COVER MASS FACTORS

Carcass Cover
Belt Cover Grade
Mass Factor Mass Factor

Mining, Quarrying and General Service belts

Grade M - 1.11
Grade N - 1.11
Grade A - 1.11
Super M - 1.10
Grade MA - 1.10
XCG - 1.14
QuarryMaster - 1.11

Heat resistant grades

CRHR - 1.15
EPT-GP - 1.05
EPT-Super - 1.05
HRNR - 1.10
Hi-Temp Nitrile 1.05 1.16

Oil and Chemical Resistant grades

Nitrile 1.05 1.16
ORS Neoprene 1.2 1.40
PVC Nitrile 1.05 1.19
SOR - 1.14
K, SOR - 1.24
EPT-GP - 1.05

Fire Resistant and Anti-static belts

Use table 2
Grade S,D & grade S 1.40
CoalMaster
Grade D,E,F & grade E,F 1.2 1.40
Grade K,D 1.2 1.40
Grade K,L & grade K 1.1 1.28
Grade K, SOR - 1.24
Grade E - 1.11

8-6
9. Solid Woven Belting

Belt construction…………………………………………………………………………. 9-1

Belt and cover thickness……………………………………………………………….. 9-2

Operating temperature range………………………………………………………….. 9-2

Operating factor of safety………………………………………………………………. 9-2

Safety………………………………………………………………………………………. 9-2

Table 1 Belt Designations…………………………….. ….……..…………….… 11 – 2

9-0
9. Solid Woven belting

BELT CONSTRUCTION

Fenaplast conveyor belting consists of three main components: -

♦ Textile Solid Woven Carcass

♦ PVC Impregnation
♦ Cover Material

THE TEXTILE CARCASS

The solid-woven carcass is generally woven with nylon or polyester load bearing warp fibres and
nylon or nylon/cotton weft. Synthetic binder yarns follow a complex pattern to give the carcass its
solid-woven properties. Various combinations of synthetic, and natural fibres are chosen, together
with the fabric design to meet the requirements of impact resistance, belt elongation, flexibility for
troughing and small diameter pulleys, load support and fastener retention. The patented Fenaplast
PVC impregnation method also renders the carcass impervious to attach from moisture, dirt,
chemicals, bacteria, and oils. Cotton pile warp yarns may be included for improved impact
resistance and special edge reinforcement can be included where these are particular problems.
The Fenaplast carcass design facility enables users to choose the properties of a custom-built belt.

All Fenaplast belts have a solid woven carcass where all layers of yarn are mechanically
interlocked during the weaving process and bound together by a self binding warp yarn
interweave, thus making subsequent delamination impossible. High tenacity continuous filament
synthetic yarns are used for the warp fie length direction), such yarns also provide most of the
necessary strength in the weft (transverse/width) direction.

PVC IMPREGNATION

After weaving the roll of carcass is vacuum impregnated with PVC plastisol containing a careful
blend of polymer, plasticisers, stabilisers, fire retardants, and special additives, with special
attention being given to viscosity control in order to ensure full impregnation of the woven
structure.

Whilst the textile elements fix many of the belts properties such as tensile strength and elongation
in service, the properties of the plastisol are equally important, and it's formulation will influence not
only the fire performance properties but also operational factors such as troughability and the
ability to hold fasteners.

COVER MATERIAL

PVC covers
PVC covers to meet numerous fire resistance specifications or for other properties such as
resistance to oils, chemicals, fertiliser etc., are generally available up to 3mm thick per side. They
can also be compounded to give improved abrasion resistance or coefficients of friction.

9-1
COVER MATERIAL …continued

Rubber covers
Rubber covers to a specified safety standard may be applied on one or both sides of a PVC
impregnation parent belt up to a maximum of 6mm + 2mm, dependent on belt width, tensile and
construction. SR wear-resistant nitrile rubber covers are also available, single or double sided, up
to 6mm + 2mm maximum, dependent on belt construction.

BELT AND COVER THICKNESS

When considering cover thickness the user should be aware of the thick, high textile content of
Fenaplast and the special solid-woven carcass properties. Consequently thinner covers may
generally be chosen than normal with rubber, plied belting; the Fenaplast carcass being more
substantial and providing the necessary load support and impact resistance.

OPERATING TEMPERATURE RANGE

Above 90°C PVC softens and the belt properties change, therefore Fenaplast is not recommended
for conveying materials above this temperature. Standard Fenaplast can be used in cold climates
at minus 15°C and special cover compounds are available for operation down to minus 40°C. Cold
weather details should be supplied to ensure a belt with suitable coefficient and flexibility
characteristics is supplied.

OPERATING FACTOR OF SAFETY

With good quality mechanical fasteners or vulcanised joints a factor of safety of 8:1 may be
acceptable.

SAFETY

Fenaplast is used extensively in underground coal mines and as such it exhibits excellent Fire
Resistant, Anti-Static properties.

In Australia it is manufactured to AS 1332 and is tested to AS1334.

It meets or exceeds all of the requirements of AS 4606-2000.

9-2
 TABLE 1
BELT DESIGNATIONS

Minimum Minimum
Minimum recommended pulley
warp weft Nominal belt Nominal belt
Belt diameters
strength strength thickness weight
Designation
High tension Low tension
kN/m kN/m mm kg/m2 mm mm
2240 400 160 4.8 6.2 250 225
2800 500 245 7.7 10.5 315 250
3300 580 24 8.0 10.7 355 315
3500 630 263 8.1 11.0 400 315
4000 700 263 8.4 11.0 400 355
4500 800 315 8.5 11.0 500 355
5000 875 320 8.7 11.3 500 355
6000 1 050 350 8.9 11.4 630 400
6500 1140 350 9.0 11.5 630 400
7000 1250 350 9.3 11.8 750 450
8000 1400 350 9.8 12.7 750 450
9000 1600 450 11.0 14.2 800 600
10000 1750 450 12.0 14.6 800 600
12000 2100 450 14.0 16.2 1000 750
15000 2625 450 15.3 17.4 1250 800
18000 3150 450 17.6 21.4 1500 1000

BELT DESIGNATION: Belts can be produced to various tensile specifications, using either polyamide or
polyester base warp yarn. Some markets still prefer to specify belt types based on tensile strength
expressed in Ibs/in width (the Fenaplast Belt Designation uses this terminology), whilst others opt for the
preferred ISO types expressed in kN/m.

BELT WEIGHTS: The above table shows some typical figures for minimum warp and weft strengths, belt
thickness and weight for a selection of belt types, based on In- PVC covers. For thicker covers, add 1.3
kg/m2/mm for PVC covers and 1.4 kg/m2/mm for rubber covers. The nominal figures quoted for thickness
and weight are based on specific belt constructions and PVC covers of l mm. Alternative belt constructions
may vary these figures which are only for indicative purposes and establishing shipping capacities.

ALTERNATIVE CONSTRUCTIONS: Many alternative constructions are available which give values higher
than those in the table. This is particularly relevant to weft strength, where special yarns designs may be
recommended for improved properties such fastener holding, load support, weft stability etc. The use of such
special yarns may increase the belt weight and thickness which may be critical for shipping purposes or
underground transportation. An APEX FENNER engineer should always be consulted where this information
is likely to be critical.

PULLEY DIAMETERS: The drum diameters are the minimum recommended without complete application
details. With information regarding wrap configurations, tensions, belt speeds, jointing methods, etc., it may
be possible to accept smaller drums.

9-3
10. Trouble Shooting

General Maintenance .…………………..…………………………………..… 10 – 1

Loading point considerations……………………………………………….. 10 - 2

Random events ………………………………………………………………… 10 - 4

Troubleshooting ………………….………………………………………………….… 10 - 5

10 - 0
10. Trouble shooting

GENERAL MAINTENANCE

Conveyor belting represents a very significant portion of the overall plant cost and as such warrants
regular inspection and maintenance to protect this investment.

Broadly speaking, apart from normal wear, rubber conveyor belting fails through chemical attack or
mechanical damage in one form or another.

♦ Chemicals such as all greases, oils, solvents and animal fats should be removed as soon as
detected from belts not designed to handle these materials. Susceptible belts including all natural
rubber belts should be washed down with water and detergent immediately after contamination.

♦ Ozone is a common cause of premature failure in natural rubber and many synthetic and rubber
belts, particularly when operating near the sea, enclosed near electrical machinery or in a salty
environment. APEX FENNER belts are supplied with high levels of ozone resistance, and this
level of protection can be increased by special request at the time of ordering for extreme
conditions.

♦ Mechanical damage is best prevented by clean design and erection, (no jagged edges) good
path clearance, generous belt paths, frequent checking and prompt remedying of all faults.

♦ Belt cleaners perform a very important role in the protection of the belt. Properly sited and fitted
they protect the belt from damage through:
♦ Trapping of material between return belt flight and pulley.
♦ Belt wander through running off as material forms a crown on the pulley.
♦ Damage to pulley face through belt edge slapping and grinding at the pulley face
edges.
♦ Spill from the return side building up under the belt to damage both belt and return
idlers.
♦ Belt cleaners must be selected carefully and deserve frequent attention.

♦ Idlers - All noisy idler should be looked at immediately. All jammed or broken idlers should be
removed immediately. Hot idlers should be hosed down and remain under supervision whilst the
conveyor is stopping and down to ambient temperature. It must be removed immediately the
conveyor is stopped. A jammed idler causes increased friction resulting in excess cover wear,
higher power consumption and may create sufficient heat to start a fire when the belt stops.

♦ Pulleys - Material trapped between a pulley and the belt may cause belt wander and if hard lumps
are present may rupture the belt. Plough cleaners should be fitted wherever a spill onto the return
belt is carried onto a pulley. This is crucial at high tension pulleys but can lead to tracking and
loading problems after the tail pulley.

♦ Take-up may be automatic or manual. The Automatic Take-up is the most desirable as properly
maintained, it is able to maintain the correct tension in the belt under all normal operating
conditions including starting, running, stopping and changes in belt length caused by changes in
ambient and operating temperature .

If for any reason the Automatic Take-up travel becomes restricted or jammed, belt slippage at the
drive may occur, this will cause extreme damage to the belt.

10 - 1
 The Manual Take-Up has the advantages of compactness and low cost, however it is unable to
maintain optimum tension through the normal operating conditions including starting, running,
stopping and changes in belt length caused by changes in ambient and operating temperature.

♦ Be aware of abnormal or changed noises emanating from the conveyor as these, if left
unattended, could lead to a fire, gearbox or pulley / coupling failure to name just two items. The
following plant items should be frequently listened to and looked at. Analyse the problem and
take maintenance precautions.

LOADING POINT CONSIDERATIONS:

Chutes, loading boots and skirts - These items are frequent trouble spots when fitted too closely to
the belt. They can cause rapid localised cover wear and in extreme cases, slit the belt.

Conversely when installed with too much clearance, material is allowed to spill over, often falling onto
the return belt and building up on the tail pulley causing tracking problems in the loading boot further
exacerbating the problem. If the spilled material is hard, the belt may also be punctured.

Also to be considered is wedging between a chute wall and the belt. In the mildest occurrence, this
will accelerate the cover wear, in more severe occurrences the belt carcass is permanently damaged.

Most wear and tear on the belt takes place at the loading point. The manner of loading may influence
the life expectancy of the belt and the components of the loading boot. Loading points should be
arranged with particular care and the following points should be observed:

♦ The material being conveyed should be fed onto the belt at belt speed in the running direction of
the belt.
♦ The height of the drop from the feeding point onto the belt should be as small as possible.

♦ Impact idlers should be installed at the loading points.

The following sketches show some loading point arrangements.

Loading Point Arrangements

10 - 2
10 - 3
RANDOM EVENTS AND CAUSES OF BELT DAMAGE

TRAMP IRON

Most rips, some continuing the entire length of the belt, are caused by tramp iron becoming wedged
into the belt at loading chutes. If this hazard is prevalent, the installation of a mechanical or magnetic
detector to stop the belt may be justified. Dangerous material can be magnetically extracted or some
reliable rip detection/protection device may be warranted.

Work practices and vigilance among all employees and contractors can also reduce this problem.

MINOR REPAIRS

Unless repaired, minor tears quickly become major repairs or catastrophic failure. Early detection and
prompt attention is the best long-term strategy.

10 - 4
TROUBLESHOOTING

The following tables list problems sometimes encountered and suggests possible solutions.
The causes are in the left-hand column and the corrections in the right hand column.

Conveyor belt problems – causes and corrections

1. Conveyor running to one side at a given point on structure:

A) One or more idlers immediately A.1) Utilising slots in idler stand, foot rotate entire idler
preceding trouble point not square (at assemblies in same direction as for the steering
right angles) to longitudinal axis of belt. wheel of an automobile, to steer belt back to
centre.

B) Conveyor frame or structure crooked. B.1) Stretch string along to determine extent and
make correction.

C) One or more idler stands not centred C.1) Same as B.1 above.
under belt.

D) Sticking idlers. D.1) Improve maintenance and lubrication.

E) When the run-off begins on a terminal E.1) Re-align pulley.

pulley, it follows that terminal pulley is
out of alignment. Note that a conveyor
belt shifts to the low or short side.

F) Build-up of material on idlers and F.1) Improve maintenance.

pulleys. F.2) Install scrapers or other cleaning device.

G) Structure not level and belt tends to G.1) Level structure.

shift to low side.

2. Particular section of conveyor belt runs to one side at all points on a conveyor

A) Belt not joined squarely. A.1) Cut ends square and re fasten.

B) Bowed belt. B.1) Avoid bad storage conditions such as telescoped

rolls or one edge close to damp ground or wall.
B.2) With a new belt, this condition should disappear
as soon as the belt has operated under full load
and tension, and becomes "broken in".
B.3) Use self-aligning idlers, particularly on return run
approaching tail pulley to obtain central loading.
B.4) In rare instances belt must be replaced.

10 - 5
3. Conveyor belt runs to one side for long distance along bed

A) Load being placed on belt off-centre. A.1) Adjust chute and loading conditions so as to
place load in centre of belt.

C) See 1.E See 1.E

C) See 1.G See 1.G

4. Belt is erratic (follows no pattern of performance)

A) Belt too stiff to train. A.1) Use self-aligning idlers.

A.2) Tilt troughing idlers forward, but not more that 2
degrees.
A.3) Use more troughable belt.

5. Severe wear on pulley side of conveyor belt

A.) Slippage on drive pulley. A.1) Increase the tension through screw take-up or
more counterweight.
A.2) Lag drive pulley.
A.3) Increase the arc of contact on the drive pulley
with a snub pulley.

B) Spillage of material which is ground B.1) Improve loading conditions with a chute.
between belt and pulley or which B.2) If belt is overloaded, increase belt speed or
builds up at loading point until belt is decrease feed onto belt.
dragging. B.3) install decking between top and return runs.
B.4) Install ploughs or scrapers in front of tail pulley on
return run
B.5 Prevent leakage of abrasive fines at fasteners by
changing to plate fasteners or vulcanised splice.

C) Sticking idlers C.1) Improve maintenance and lubrication.

D) Bolt head protruding above pulley D.1) Tighten bolts.

lagging. D.2) Replace worn lagging.
D.3) Use vulcanised-on lagging.

E.1) Adjust to not more that 2 degrees from line

E) Excessive tilt to troughing idlers.
perpendicular to belt.

10 - 6
6. Excessive stretch in conveyor

A) Tension too high. A.1) Increase speed, keeping tonnage same.

A.2) Reduce tonnage at same speed.
A.3) Reduce friction with better maintenance and
replacing of worn out and frozen idlers.
A.4) Decrease tension by improving drive with
lagging, increase arc contact and counterweight
take-up.
A.5) Replace with heavier belt.
Above is based on the assumption that
adequate take-up is available.

7. Belt shrinks

A) Belt absorbing moisture. A.1) Put in extra piece, installing with take-up half
way down.

8. Lengthwise gouging or stripping of top cover

A) Skirt board seals too stiff and pressed A.1) Use more pliable seals.
against belt. A.2) Adjust to relieve pressure on belt.

B) Excessive space between belt and skirt B.1) Adjust seals to minimum clearance.
seals.

C) Metal sides of chute or skirts too close C.1) Adjust to at least 50mm gap between metal
to belt and gap not increasing in and belt and have gap increasing in direction
direction of travel. of travel so as to prevent material jamming at
this point.

8. Lengthwise gouging or stripping of top cover (Cont.)

D) Belt spanks down under impact at D.1) Install cushion or pneumatic idlers to hold belt
loading point, allowing material to be up against skirts.
trapped under skirts.

E) Material hanging under back panel. E.1) Improve loading to prevent spillage or install
baffle.

F) Jamming of material in chute. F.1) Widen chute.

10 - 7
9. Short breaks in carcass parallel to belt edge and star breaks in carcass

A) Impact of lumps failing on belt. A.1) Reduce impact.

A.2) Use cushion idlers.

B) Material trapped between belt and B.1) Install plows or scrapers on return run ahead of
pulley. tail pulley.

10. Transverse breaks at belt edges

A) Belt edges folding up on structure due A.1) See troubles (1), (2), (3) and (4).
to wander or pressing too hard against A.2) Install limit switches to stop belt in cases of
side guide idlers. extreme shifting.

B) Mildew. B.1) Replace with APEX FENNER belt.

C) Final idler before head pulley located C.1) Adjust idler position in accordance with normal
too close or too high in respect to head design practice.
pulley.

11. Cover blisters or sand blisters

A) Cover cuts or very small cover A.1) Make spot repair with vulcaniser or "cold"
punctures allow fine particles of "sand" patches.
to work under cover and cut cover A.2) In severe and repeating cases refer all details to
away from carcass. APEX FENNER for analysis.

12. Belt rises up off troughing idlers, bowing towards load

A) Oil contamination in material. A.1) Remove source of oil, if possible.

A.2) To eke out the life of present belt, cut longitudinal
grooves in cover with tyre grooving tool to relieve
transverse pressure exerted by swelling rubber.
A.3) For proper selection of replacement belt, send in
sample of oil to determine best oil resisting
compounds.

10 - 8
13. Cover swells in spots, or lines of swelling on pulley side coincident with junction or
troughing idler rolls.

A) Spilled oil or grease. A.1) Better housekeeping.

B) Over-lubrication of top run idlers. B.1) Reduce quantity of lubricant used.

14. Excessive top cover wear, uniform around belt

A) Dirty return rolls. A.1) Install cleaning devices.

A.2) Wash belt.
A.3) Use rubber disc return idlers.

B) Cover quality too low. B.1) Replace with better belt.

C) Pile up of spilled material at tail pulley. C.1) Improve housekeeping and loading.

D) Slide loading, or poor loading, i.e. D.1) Redesign chute to make load feed onto belt in
speed of delivery of material too slow. same direction as belt runs and at approximately
same speed as belt.

E) Excessive sag between idlers causing E.1) Increase tension where it is unnecessarily low.
load to work and shuffle on belt as it E.2) Reduce idler spacing.
passes over idlers. E.3) Replace with belt of heavier carcass.

15. Fasteners pulling out

A) Mildew. A.1) Replace with APEX FENNER belt.

B) Wrong type of fastener or fasteners B.1) Re fasten belt and set up schedule for frequent
not tight. fastener inspection. Re-tighten new fasteners
after a few hours run.

C) Tension too high. C.1) Check tension in belt and if too high, see item (6)
for corrections.
C.2) Use vulcanised splice.

D) Heat. D.1) Use heavier top covers.

D.2) Consult APEX FENNER.

10 - 9
6. Transverse breaks in belt immediately behind fasteners

A) Fastener plates too long for pulley A.1) Change to smaller, shorter fasteners.
sizes. A.2) Increase pulley size.

B) Mildew. B.1) Replace with APEX FENNER belt.

17. Lengthwise rips partially or entirely through belt

A) See trouble (8)

B) Belt running off and snagging on B.1) See trouble (1), (2), (3) and (4)
structure.

C) Puncture by tramp iron at chute. C.1) Use metal detector.

18. Crescent breaks in carcass, or mushy spots where carcass rotted under cover

A) Mildew. A.1) Replace with APEX FENNER belt.

19. Lengthwise rupture of carcass with top cover and possible parts of pulley cover unbroken

A) Belt running off against structure and A.1) See troubles (1), (2), (3) and (4)
folding back on itself as it passes A.2) Install limit switches.
around terminal pulley.

20. Hardening and cracking of covers with eventual hardening of carcass and loss of duck
strength

A) Heat. A.1) Consult APEX FENNER for thorough analysis

of conditions for application of correct heat
resisting belt.

10 - 10
APEX FENNER CONVEYOR BELTING Australasia

Victoria – Head office and factory

Address 268 Geelong Road, West Footscray Victoria 3012
P.O Box 4006, West Footscray, Victoria 3012
Telephone 03 9680 4500
Fax 03 9689 9191

New South Wales

Address 81 Milperra Road, Revesby, NSW 2212
P.O Box 4756, Milperra, NSW 1891
Telephone 02 9773 0411
Fax 02 9772 1808
Address 11 Aruma Pl Cardiff 2285
P.O Box 612 Cardiff 2285
Telephone 02 4956 9377
Fax 02 4956 9293
Address 31 Eddie Rd Minchinbury 2770
P.O Box
Telephone 02 9832 0755
Fax 02 9832 2400
Address 13 Doyle Av Unanderra 2526
P.O Box 361 Unanderra 2526
Telephone 02 4272 9266
Fax 02 4272 9223
Address Unit 7/40 Main St Wallerawang 2845
P.O Box 74 Wallerawang 2845
Telephone 02 6355 7661
Fax 02 6355 7659
Address 19 Piercefield Rd Mt Thorley 2330
P.O Box 2006 Singleton 2330
Telephone 02 6574 6622
Fax 02 6574 6652
Address Corner Mitchell Ave & Government Road, Weston 2325
P.O Box 93, Cessnock NSW 2325
Telephone 02 4937 3199
Fax 02 4937 2579
Address 59 Railway Avenue, Gunnedah NSW 2380
P.O Box 743, Gunnedah NSW 2380
Telephone 02 6742 5711
Fax 02 6742 2969
Address Unit 1, 3 Fox Street, Narellan NSW 2567
P.O Box
Telephone 02 4647 1624
Fax 02 4627 1705
Address Unit 2, 1 O’Connor Street, Lithgow NSW 2790
P.O Box
Telephone 02 6351 4875
Fax 02 6351 3098
QUEENSLAND
Address Young St Gladstone, Qld 4680
P.O Box 1307 Gladstone, Qld 4680
Telephone 07 4972 2155
Fax 07 4972 2664
Address Lot 8 Nightingale Ave Capella.
P.O Box 1688 Emerald Qld 4720. All postage to this address
Telephone 07 4982 4577
Fax 07 4982 4401
Address 3 David Muir St Slade Point 4740
P.O Box 48 Mackay Qld 4740
Telephone 07 4955 1877
Fax 07 4955 2353 (Admin)
07 4955 4445 (Sales)
Address Ron Searl Dr Mt Bassett 4740
P.O Box 48 Mackay Qld 4740
Telephone 07 4955 2560
Fax 07 4955 2433
Address 614 Ingham Rd Garbutt Qld 4814
P.O Box 7541 Garbutt Qld 4814
Telephone 07 4774 8238
Fax 07 4774 8239
Address Lot 64 John Vella Drive, Central Park Ind. Estate, Mackay Qld 4740
P O Box 5597, Mackay Qld 4740
Telephone 07 4952 2077
Fax 07 4952 2744
Address Unit 1/12-14 Hasell St, Cairns Qld 4871
P.O Box 5991 Cairns Mail Centre 4871
Telephone 07 4035 6411
Fax 07 4035 6433
Address 241B George St Rockhampton, Qld 4700
P.O Box
Telephone 07 4922 8984
Fax 07 4922 8949
Address 26 Ryan Rd Mt Isa 4825
P.O Box 2247 Mt Isa 4825
nd
Telephone 07 4743 6622 / 4743 3215 (2 line)
Fax 07 4743 8622

SOUTH AUSTRALIA
Address 151 William St Beverley, South Aust. 5009
P.O Box 131 Welland SA 5007
Telephone 08 8268 4255
Fax 08 8347 1087

WESTERN AUSTRALIA
Address 11 Kitson Pl Maddington, West Australia 6109
P.O Box PO Box 121 Maddington 6989
Telephone 08 9452 8389
Fax 08 9452 8361