Celebrating 35 years 1980-2015

Wenco Steel Cord Conveyor Belting

Current mining techniques demand that Conveyor Belts
handle ever greater volumes with increased centre
distances and high lifts, all of which necessitate stronger
belts. The high strength of Steel Cord tension carrier is
not the only reason why Steel Cord belts are increasingly
being used as an economic alternative to other bulk
material handling methods.

WENCO STEEL CORD BELT ADVANTAGES

1. DELIVER EXTREMELY HIGH STRENGTHS
When operating tensions in excess of 2500 KN/m
are required, belts reinforced with Steel Cord are the
only alternative and today Steel Cord belts are being
designed for ratings up to ST10000. Due to its numerous
advantages, Steel Cord belts are increasingly used even in
ratings as low as ST 500 or ST 630.

2. LONG LIFE EXPECTANCY

Conveyor Belts with Steel Cord reinforcement members
are virtually maintenance-free and can be supplied with
increasingly thicker rubber covers for the same rating. The
carcass, having a minimal risk of failure, yields very long
life without affecting the overall design, sometimes even
lasting for the entire duration.

3. LARGE CENTRE DISTANCES CAN BE PLANNED

Steel Cord Belts have very low elongation and
consequently systems with large centre distances can be
planned, without having to account for limitations of take ups
and transfer points.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

4. LOW PULLEY DIAMETERS CAN BE USED

For the same rating, the thickness of the tension member
(carcass thickness) in Steel Cord belts is considerably
lower than that in a fabric reinforced belt and hence is
able to operate with lower pulley diameters. The superior
dynamic modulus of the Steel Cords over the fabric
carcass also ensures that flex fatigue sets in very slowly
making the selection of lower pulley diameters technically
viable. Again the safety factor requirements for Steel
Cord Belts are 6.67 against 9 – 10 for Textile Conveyor
Belts and therefore when compared with textile belts
of equivalent rating, the difference in pulley diameters
becomes even more striking.

5. LOW ELONGATION, HIGH IMPACT RESISTANCE

The elongation of Steel Cord Belt is a function of elastic
modulus of the steel and the amount of twist in the cord.
The very low elongation of Steel Cord makes short take
ups possible. Typically elongation is down to 0.25% on
total belt lengths. The geometry of a Steel Cord Belt
provides for greater rubber per unit volume compared
to fabric reinforced belts permitting a more effective
absorption of impact energy. Consequently Steel Cord
Belts allow discontinuous feed of heavy individual pieces
without localized elongation.

6. EXCELLENT TROUGHABILITY
Even the strongest Steel Cord Belts trough perfectly on
deep troughed idler sites. This ensures easy belt training
and the realisation of superior volumetric capacity of the
belt, whereby the user can either convey more material at
the same speed or employ narrower conveyor systems.

7. LONG SPLICE LIFE AND STRENGTH

Properly provided Belt Splices can last as long as the Belt
itself. They can also achieve spliced strength equivalent to
almost 100% of the strength of the Belt.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

WENCO STEEL CORD BELT: COMPONENTS

CONVEYOR BELT CROSS-SECTION
A Typical Steel Cord Conveyor belt has three distinct components and a fourth optional protective
element. These are the steel cable, the bonder layer and the top and bottom covers. To prevent
longitudinal rips, optional components such as sensor loops or breakers may be incorporated.

STEEL CORD
The ‘building block’ for the reinforcing Steel Cords are round steel wires. These Zinc/Brass coated
high-carbon wires are laid helically with a uniform twist around a central core to form the ‘Strand’.
Strands so formed are, in turn, helically laid around a central strand to form the reinforcement ‘Cord’ of the
Steel Cord belt.

Wenco sources Steel Cords only from globally established manufacturers and conducts periodic
checks on the cords supplied to evaluate the Component Dimensions, Tensile Strength, Elongation
(Static & Dynamic), Openness, Effectiveness of coating, Cord Pullout strength etc. Cord types 7x7
and 7x19 are most popular and can cover a large range of Steel cord Belt ratings.

BONDER RUBBER
The function of the bonder rubber is to maintain a bond between the metallic cords and the rubber
polymer in the Steel Cord Belt. The bonder rubber not only has to create the metal-rubber bond
but – for optimal product performance – is also required to be viscous enough to flow into the
air gaps/voids between individual filaments in each cord to offer additional protection against
environmental threats as well as to protect adjacent filaments from chafing against each other.

COVER QUALITIES
Wenco manufactures its entire range of Steel Cord Belts (in widths up to 2500mm and in ratings
up to ST 10000) in General Purpose or Fire Resistant Grades (refer to chart below). For extreme
applications, Heat Resistant and Oil Resistant Belts can be supplied.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

All General Purpose Grade Belts and Fire Resistant Belts can also be supplied with a low rolling
resistance compound for the back cover to optimize power consumption. For detailed technical
specifications please refer to WENCO.

Cover Grade Reference Standards Applications

X, Y, W DIN 22131 X, M, H, D - are for toughest applications where
H, D, L EN ISO 15236 very large abrasive lumps are handled.
A, M, N AS 1333 A, Ware for handling of high abrasive material.
M, N SABS 1366 N, L, Y are General purpose for handling of
M, N, A IS 15427 moderate abrasive materials.
K DIN 22131, EN ISO Very high Fire Resistant properties. Used for
15236 surface conveyor.

F ISO 340, SABS 1366 &

CAN-CSA-M422-M87
S AS 4606 IS 15143 MSHA Excellent self-extinguishing properties used
FR-U mainly for underground mining.
FR-U

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

MINIMUM RECOM
PULLEY DIAMETERS
ST PITCH BELT WIDTH (mm) (mm) MENDED FOR
RECOMMENDED MAWT UTILISATION
RATING (mm)
CORD DIA (mm) > 60 %
(kN/m) ± 1.5
800 1000 1200 1400 1600 1800 2000 A B C
NO. OF CORDS
800 3.5 12 64 81 97 114 131 147 164 500 400 300
1000 4.1 12 64 81 97 114 131 147 164 630 500 400
1250 4.9 14 55 69 84 98 112 127 141 800 630 500
1600 5.6 15 50 64 77 90 104 117 130 800 630 500
2000 5.6 12 64 81 97 114 131 147 164 800 630 500
2500 7.2 15 50 64 77 90 104 117 130 1250 1000 800
3150 8.1 15 50 64 77 90 104 117 130 1250 1000 800
3500 8.6 15 50 64 77 90 104 117 130 1250 1000 800
4000 8.9 15 50 64 77 90 104 117 130 1400 1250 1000
4500 9.7 16 46 59 71 84 96 109 121 1600 1400 1250
5000 10.9 17 43 55 66 78 90 102 113 1600 1400 1250
5400 11.3 17 43 55 66 78 90 102 113 1800 1600 1400

Note: - The values provided are nominal and should be considered for design purpose only.
- Wenco reserves the right to change the parameters and values as per normal
development of technology without any notice.
- ST ratings of 500 and 630 can be offered on special request.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

REC- MINIMUM RECOM-

OM- MENDED PULLEY
ST BELT WIDTH (mm) DIAMETERS (mm)
MEND- PITCH
RAT- FOR MAWT UTILI-
ED (mm)
ING SATION > 60 %
CORD ± 1.5
(kN/m)
DIA 800 900 1000 1050 1200 1400 1500 1600 1800 2000
(mm) A B C
NO. OF CORDS
500 2.6 13.8 56 63 70 74 84 99 106 113 128 142 500 400 315
560 2.8 13.8 56 63 70 74 84 99 106 113 128 142 500 400 315
630 3 13.8 56 63 70 74 84 99 106 113 128 142 500 400 315
710 3.1 13.8 56 63 70 74 84 99 106 113 128 142 630 500 400
800 3.3 13.8 56 63 70 74 84 99 106 113 128 142 800 630 500
900 3.8 15.3 50 56 63 66 76 89 96 102 115 128 800 630 500
1000 4 15.3 50 56 63 66 76 89 96 102 115 128 800 630 500
1120 4.3 15.3 50 56 63 66 76 89 96 102 115 128 800 630 500
1250 4.5 15.3 50 56 63 66 76 89 96 102 115 128 800 630 500
1400 4.8 15.3 50 56 63 66 76 89 96 102 115 128 1000 800 630
1600 5.5 17.3 45 50 56 59 67 79 85 90 102 113 1000 800 630
1800 5.9 17.3 45 50 56 59 67 79 85 90 102 113 1000 800 630
2000 6.4 17.3 45 50 56 59 67 79 85 90 102 113 1000 800 630
2250 6.8 17.3 45 50 56 59 67 79 85 90 102 113 1250 1000 800
2500 7.4 19.4 40 45 50 52 60 70 75 81 91 101 1250 1000 800
2800 8 19.4 40 45 50 52 60 70 75 81 91 101 1400 1250 1000
3150 8.6 19.4 40 45 50 52 60 70 75 81 91 101 1400 1250 1000
3550 9.2 19.4 40 45 50 52 60 70 75 81 91 101 1400 1250 1000
4000 9.8 19.4 40 45 50 52 60 70 75 81 91 101 1600 1400 1250
4500 10.4 19.4 40 45 50 52 60 70 75 81 91 101 1600 1250 1000
5000 11 19.4 45 50 52 60 70 75 81 91 101 1600 1250 1000
5600 11.8 19.4 45 50 52 60 70 75 81 91 101 2000 1800 1600
6300 12.8 20 43 48 50 58 68 73 78 88 98 2000 1800 1600

Note: - The values provided are nominal and should be considered for design purpose only.
- Wenco reserves the right to change the parameters and values as per normal
development of technology without any notice.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

Testing Equipment
The Lab is equipped with the most modern testing equipment’s which covers testing requirements
as specified in all National and International standards for conveyor belts.

The Lab also has a facility to do testing of all the raw materials used for manufacturing of Steel
Cord conveyor belt among the big list of Lab equipment’s most important are:

Rheometer, 5MT and 10MT Capacity universal testing machine, Abrasion Testing Machine,
Multicell Ageing Oven, Dynamic cord, Pull Out Test Machine, Torsion Bending Test Machine,
Longitudinal Flexing Test Machine, Troughability Test Machine, Drum, Friction Test Machine, Flame
Test Cabinet, Air Permeability Test Machine etc.

STEEL CORD BELT SPLICING

The most popular and effective means of splicing Steel Cord belts is with the FINGER SPLICE
method where cords from the mating sections of the belt in opposing directions are brought
together as shown below. Different splice making protocols are employed depending on the
strength of the belt and these different types are referred to as Type I, Type II and so on up to
Type V splice joints for very high strength belts.

BELT TYPE Number of Steps Minimum step Length(ls) Splice Length (lv)
ST-1250 and below 1 350 650
ST 1600 1 450 750
ST 2000 2 400 1150
ST 2500 2 500 1350
ST 3150 2 650 1650
ST 3500 3 650 2350
ST 4000 3 750 2650
ST 4500 3 800 2800

The Steel Cord splicing kit is a vital component in the splicing

operations and it is usually advisable to use splicing kits manufactured
by the belt supplier only. Especially when making high strength splices
or for special rubber cover grades like Fire Resistant, Heat Resistant and
Oil Resistant grade.

For specialised applications such as Pipe Conveyor belts and high angle
sidewall belts employing Steel Cord belting, it is always recommended
that the splicing kit is procured from the belt manufacturer only
to ensure optimal compatibility between the belt and the splicing
compounds.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

TRANSITION DISTANCE
Steel Cord reinforced belts require greater transition distance at the terminal ends to offset high
stress build up at the edges and are therefore not recommended for troughed Conveyors with a
centre to centre distance of less than 50 to 60 metres. The recommended minimum transition
distance is given below.

RECOMMENDED MINIMUM TRANSITION DISTANCE

PERCENTAGE CASE 1 CASE 2
OF FULL TROUGHING ANGLE TROUGHING ANGLE
RATED
TENSION 20º 30º 35º 45º 20º 30º 35º 45º
Below 50 2.00w 3.30w 3.60w 4.50w 1.12w 1.60w 1.90w 2.40w
50-89 2.42w 3.50w 4.06w 5.00w 1.25w 1.80w 2.20w 2.70w
90-100 2.53w 3.70w 4.25w 5.20w 1.40w 2.00w 2.40w 3.00w
w' = width of the belt

Special attention to transition distance calculation is required, so that there is no over-stressing on

the edges or slackness at belt edges.

RIP PROTECTION AND SURVEILLANCE

Steel Cord Conveyor Belts do not have a weft reinforcement member and therefore rip easily if
sharp foreign materials come in contact with it. Wenco offers Rip Stop fabric incorporated in
the belting and the experience of our technology partner shows it to be an extremely successful
method of protecting the belt from such rips even as it contributes to improving the dynamic
performance of the belt by enhancing bond properties and Splice efficiency. Such Rip stop rot -
proof fabric can be inserted in the covers across the belt width and along the length of the roll.

• Increased belt service life • Easily spliced or repaired using standard materials
• Increased rip and penetration resistance • Rot proof synthetic `Rip stop’ fabric
• Increased cord protection against impact damage • Perfect bonding between `Rip stop’ fabric and rubber
matrix.
• Perfect trough ability • Superior mechanical deformtation performance of `Rip
stop’ fabric.
• Unchanged pulley diameters

Wenco also works along with leading global manufacturers like Coal
Control to provide Sensor Loops which can be retro-fitted into the belts
and electronically monitored to suit customer requirements. Such
protection systems with appropriate site maintenance are emerging as
fail safe rip detection systems for Steel Cord Belts worldwide. Please ask
Wenco for further details.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

BELT PACKING, TRANSPORTATION & STORAGE

Packing of Steel Cord belts demand special attention not only because it is an expensive product
that requires the best protection from damage in transit, but also because it is a product for
application in high-tension Conveyors and is therefore best supplied in lengths as long as possible
to minimise the number of splice joints. Customers prefer packing in drums, often in steel drums
where

Extended storage is likely. Some users insist on oblong type packing to maximise the roll length
and some others specify cassette type packing.

On the other hand, there are numerous dimensional and weight constraints for material
transportation – either by marine container or by road. These constraints need to be weighed in
conjunction

With handling capabilities available at the unloading point to decide

On optimal supply roll lengths.

ROLL DIAMETER CALCULATIONS AND CHART

D = √(4/π) x d x L+K2 L = Belt Length (m)

D = Drum Diameter (m) K = Reel Core Diameter (m)
d = Belt Thickness (m) (Wenco Standard K = 0.5 m)

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia
 Celebrating 35 years 1980-2015

Belt BELT THICKNESS d (mm)

Length
L(m) 10 12 14 16 18 20 20 24 26 28 30 32 34 36 38 40
10 0.61 0.63 0..65 0.67 0.69 0.71 0.73 0.75 0.76 0.78 0.79 0.81 0.83 0.84 0.86 0.87
20 0.71 0.75 0.78 0.81 0.84 0.87 0.9 0.93 0.96 0.98 1.01 1.03 1.06 1.08 1.1 1.13
40 0.87 0.93 0.98 1.03 1.08 1.13 1.17 1.21 1.25 1.29 1.33 1.37 1.41 1.44 1.48 1.51
60 1.01 1.08 1.15 1.21 1.27 1.33 1.39 1.44 1.5 1.55 1.59 1.64 1.69 1.73 1.78 1.82
80 1.13 1.21 1.29 1.37 1.44 1.51 1.58 1.64 1.7 1.78 1.82 1.87 1.93 1.98 2.03 2.08
100 1.23 1.33 1.43 1.51 1.59 1.67 1.75 1.82 1.89 1.95 2.02 2.08 2.14 2.2 2.26 2.31
120 1.33 1.44 1.55 1.64 1.73 1.82 1.9 1.98 2.05 2.13 2.2 2.27 2.33 2.4 2.46 2.52
140 1.43 1.55 1.66 1.76 1.86 1.95 2.04 2.13 2.21 2.29 2.37 2.44 2.51 2.58 2.65 2.72
160 1.51 1.64 1.76 1.87 1.98 2.08 2.17 2.27 2.36 2.44 2.52 2.6 2.68 2.75 2.83 2.9
180 1.59 1.73 1.85 1.98 2.09 2.2 2.3 2.4 2.49 2.58 2.65 2.75 2.84 2.92 2.99 3.07
200 1.67 1.82 1.95 2.08 2.2 2.31 2.42 2.52 2.62 2.72 2.81 2.9 2.98 3.07 3.15 3.23
220 1.75 1.9 2.04 2.18 2.3 2.42 2.53 2.64 2.74 2.84 2.94 3.04 3.13 3.21 3.3 3.38
240 1.82 1.98 2.13 2.27 2.4 2.52 2.64 2.75 2.86 2.97 3.07 3.17 3.26 3.35 3.44 3.53
260 1.89 2.05 2.21 2.36 2.49 2.62 2.74 2.86 2.98 3.09 3.19 3.29 3.39 3.49 3.53 3.67
280 1.95 2.13 2.29 2.14 2.58 2.72 2.64 2.97 3.09 3.2 3.31 3.41 3.53 3.62 3.71 3.8
300 2.02 2.2 2.37 2.52 2.67 2.8 2.94 3.07 3.19 3.31 3.42 3.53 3.64 3.74 3.84 3.94
320 2.08 2.27 2.44 2.6 2.75 2.9 3.04 3.17 3.29 3.41 3.53 3.65 3.78 3.85 3.97 4.07
340 2.14 2.33 2.51 2.68 2.84 2.98 3.13 3.26 3.39 3.52 3.64 3.76 3.87 3.98 4.09
360 2.2 2.4 2.58 2.75 2.92 3.07 3.21 3.35 3.49 3.62 3.74 3.86 3.98 4.09
380 2.26 2.46 2.65 2.83 2.99 3.15 3.3 3.44 3.58 3.71 3.84 3.97 4.09
400 2.31 2.52 2.72 2.9 3.07 3.23 3.38 3.53 3.67 3.81 3.94 4.07
420 2.37 2.58 2.78 2.97 3.14 3.31 3.47 3.62 3.76 3.9 4.04
440 2.42 2.64 2.84 3.04 3.21 3.38 3.55 3.7 3.85 3.99
460 2.47 2.7 2.91 3.1 3.29 3.46 3.62 3.78 3.93 4.08
480 2.52 2.75 2.97 3.17 3.35 3.53 3.7 3.86 4.02

The effective durability of a conveyor belt can be adversely affected by

improper handling / storage and the user needs to consider this on priority.
Ideally, movement of the belts should be by hoisting and not rolling. A
transverse spreader bar is recommended for larger belt rolls in order to
hold the lifting chains or cables away from the belt edges. Smaller / lighter
belts can be rolled but in the direction the belt is wound.

Careless handling with a forklift can cause damage by rubbing against the
forks and hence the roll should first be placed on a pallet. This also avoids
damage to the belt because of sagging over the edges of the forks.

If the belt is stored for a year or more, it should be kept on the supplier's
reel or hung into an A-frame or placed on a pallet. In any case the
storage ground must be even and free from stones etc. The belt should
not be exposed to direct contact with stagnant water, oil, grease or any
other chemicals that react with rubber. Further protection is usually
not necessary for Wenco Steel Cord Belts, which are resistant to most
environmental influences.

T +61 8 9267 5509

Rubber Lining, Conveyors & Ceramics E [email protected]
The above values are approximate value only and should be used as a guideline only. 1 Ladner Street
Wenco reserves the right to make specification changes without notice or without incurring liability. O’Connor 6163, Western Australia