07 CB Conveyor Belt Design Manual

Conveyor Belt Design Manual
INDEX
INTRODUCTION
Dunlop Africa Industrial Products is the leading designer and manufacturer of industrial rubber products in South Africa. In fact our belting
systems can be seen on some highly productive plants all around the globe.
What more can you expect, when you consider that our belts have been designed and fabricated by some of the best engineers in the
industry and from only the finest raw materials.
Using the most current technology, many components have taken years of refinement to attain such technological precision. And every belt
is guaranteed to provide maximum performance and maximum life.
DUNLOP Belting
Print
Introduction
Dunlop Conveyor Belting Range
Belting Characteristics
Additional Features
SABS Specifications
Conveyor Belt Design
Step By Step Example of Belt Tension Calculation

Table 1: Table of Symbols
Table 2: Material Characteristics
Table 2(a): Typical Flowability
Determination of Conveyor Capacities

Table 3: Capacities of Troughed Belt Conveyors
Table 4: Recommended Maximum Belt Speed for Normal Use
Table 5: Recommended Idler Spacing
Table 6: Friction Factors
Table 7: Sag Factor
Table 7(a): Recommended Percentage Sag
Table 8: Estimated Belt Mass
Table 9: Typical Mass of Rotating Parts of Idlers
Table 10: Mass of Moving Parts
Table 11: Drive Factor
Conveyor Belt Selection

Table 12: Maximum Recommended Operating Tensions
Table 13: Recommended Minimum Pulley Diameters
Table 14: Load Support
Table 15: Maximum Number of Plies Recommended for Correct Empty Belt Troughing
Table 16: Carcass Thickness
Table 17: Mass of Belt Carcass
Table 18: Mass of Covers per mm of Thickness
Rate of Wear Graph

Table 19: Minimum Belt Top Cover Gauge Guide
Table 20: Belt Modulus
Tabulator Calculations
Sheet 1: Empty Belt
Sheet 2: Fully Loaded Belt
Sheet 3: Non-Declines Loaded
Sheet 4: Declines Loaded
Tension Tabulator
Vertical Curves
Maximum Incline Angle
Graph for Estimating Belt Length/Rolled Belt Diameter
Useful Data Conversion Factors
Conveyor Belting Design Manual
Page 1 of 33 Dunlop Conveyor Belt Design Manual
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And with some 750 000 various specifications available, you can expect to find the right belt for your requirements no matter how
specialised.
This manual contains all the elements, formulae and tables you need to specify the exact belt. It has been compiled for your benefit, as a
quick reference book for easy selection. If however you have an application not covered in the following pages, please contact Dunlop Africa
Industrial Products. A team of experienced and helpful engineers will be pleased to assist you.
Our range of excellent products, competitive pricing and impeccable service, has earned Dunlop Africa Industrial Products the reputation of
being the market's first choice.
DUNLOP CONVEYOR BELTING RANGE
Dunlop Africa Industrial Products manufactures the most comprehensive range of conveyor belting in South Africa.
Multi-ply rubber covered conveyor belting
XT textile reinforced conveyor belting with grade N covers
XT textile reinforced conveyor belting with grade M cut resistant covers
Phoenix heat resistant belting
Super Phoenix heat resistant belting
Delta Hete heat resistant belting
Fire resistant belting
Rufftop belting
Riffled concentrator belting
Grey food belting
Salmon pink food belting
Endless belts
Woodmaster
Oil resistant belting
Solid woven PVC belting
Standard solid woven PVC belting
Nitrile covered PVC belting
Steelcord belting
Fire resistant steelcord belting
Steelcord reinforced conveyor belting with cut resistant type M covers
Steelcord reinforced conveyor belting with type N covers
Steelcord reinforced conveyor belting with "Ripstop" protection
Steelcord reinforced conveyor belting with rip detection loops
Flinger belts
High speed truly endless belting
BELTING CHARACTERISTICS
XT Rubber Conveyor Belting (conforms to SABS 1173-1977)
From the early days of cotton duck plies, progress has been made in the manufacture of all-synthetic plies offering many
advantages.
The range of strengths has been greatly increased, with improvements in the flexible structure. The modern multi-ply belt is
manufactured with a synthetic fibre carcass in a wide slab, then slit to width as required for individual orders.
A wide range of belt specifications is available with current belt constructions having versatile applications.
The standard XT belting (Grade N) incorporates covers suitable for the handling of most abrasive materials, having a blend of
natural and synthetic rubber.
Cut resistant XT Rubber Belting
Grade M Belts have covers with high natural rubber content recommended for belts operating under extremely arduous conditions
where cutting and gouging of covers occurs.
Phoenix Heat Resistant Belting
Phoenix Heat Resistant belting covers are styrene butadiene based and are recommended for belts handling materials with
temperatures up to 1200C.
Super Phoenix Heat Resistant Belting
Super Phoenix Heat Resistant belts have chlorobutyl covers and are recommended for belts handling materials with temperatures
of up to 1700C.
Delta Hete Heat Resistant Belting
Delta Hete heat resistant belting with EPDM synthetic rubber covers in a formulation developed to allow conveying materials of
temperatures up to 2000C.
Fire Resistant Belting (conforms to SABS 971-1980)
Fire Resistant XT belting is manufactured with covers containing neoprene and multi-ply carcass constructions to meet the
stringent standards for safety in all underground mining industries and is therefore particularly suited to shaft applications.
Woodmaster
This belt has been especially developed for the Timber Industry. The rubber has been compounded to provide resistance to oil and
resin, and is non-staining.
Rufftop Belting
This is a range of rough top package belting, of two or three ply all-synthetic carcass belts with deep impression rubber covers.
The range is ideal for the packaging and warehousing industries and baggage handling installations such as airports and railway
stations etc.
Riffled Concentrator Belts
Riffled conveyor belting has raised edges, is 1 500 mm wide and available in endless form. These belts are uniquely applied at
gold mine concentrators.
Food Quality Belting
Food quality belting is ideal where foodstuffs come into direct contact with the belt surface. This range of belting is manufactured
from non-toxic materials and is resistant to oils, fats and staining, and meets the strict hygiene requirements laid down by the
food processing industry. The two types available are Grey food belting and Salmon pink belting
Endless Belting
The complete XT range can be made available as factory spliced endless belts. These belts are recommended for short conveyor
installations. (Suitable for lengths up to 50 in.)
Flinger Belts
Flinger Belts are fitted to flinger conveyors, the primary function of which is to disperse the discharging material over a wide area,
thus minimising heap build-up below the main conveyor. The flinging effect is achieved by running the flinger belt at a high speed
in a U configuration. Flinger belts are built and cured on a drum to eliminate a spliced join.
Solid Woven (PVC) Belting (conforms to SABS 971-1980)
Commonly known as 'Vinyplast' solid woven PVC. The construction has inherently high fastener holding qualities. The belting is
constructed of polyester and nylon with a cotton armouring, is impregnated with PVC and has PVC covers. These belts have been
specially developed to resist impact, tear, rot and abrasion and to meet the most stringent flame-resistant standards.
Nitrile Covered (PVC) Belting
The nitrile cover on solid woven PVC belts is specially designed to meet the SABS specifications for use in mines, where a fire
hazard exists. In general the nitrile cover has good flame-retardant properties and oil, abrasion and heat resistance.
Steelcord Belting (conforms to SABS 1366-1982)
Steelcord conveyor belting is designed for very long hauls where textile reinforcement would either not achieve the requisite
strength or would have too high an elongation at reference load. Resistance to severe shock and exceptional tensile loading is
achieved by the wire reinforcement encased between thick top and bottom covers of the highest quality rubber. These belts are
designed to conform to or exceed the requirements of stringent standards and offer a long belt life.
Fire Resistant Steelcord Belting (Conforms to SABS 1366. 1982 type F).
Steelcord belting of fire-resistant quality is made with specially compounded rubbers which render it self extinguishing. Fire-
resistant steelcord belting offers great advantages in maintenance-free operation and long belt life for conveyors situated in fiery
mines.
Oil Resistant Belting
Oil resistant belting provides easily cleanable covers of either nitrile or neoprene on all-synthetic fabric plies. Choice of covers
gives maximum resistance to mineral and vegetable oils thus permitting the user to convey a wide variety of materials containing
mineral and vegetable oils.
ADDITIONAL FEATURES
1. Rip Protector
As an additional feature rip protection can be incorporated into the belt by means of arranging strong nylon fibres transversely or
by inclusion of electronic loops. The textile rip protection can be built into the belt in 2-metre lengths at regular intervals or over
the full length of the belt.
2. Shuron Breaker Ply (XT belting)
For applications where the lump size of the material carried is large and where adverse loading conditions exist, an open weave
breaker ply can be incorporated below the top cover as an extra protection for the carcass.
3. Chevron Breaker (XT belting)
This incorporates steel tyre cord in a 'V shape, as a rip protection, at intervals over the belt length. Particularly recommended for
XT belting where arduous conditions are experienced i.e. slag transportation.
4. Belt Edges
Many conveyor belts track off at some stage of their lives, causing edge damage to a greater or lesser extent. Belts can be
supplied with either slit or moulded edges.
Slit edges:
All-synthetic constructed carcasses have good resistance to edge chafing, due to modern fibre construction In addition there is
minimal penetration of moisture to the carcass and therefore no problem with carrying out hot vulcanised splices or repairs.
Moulded edges:
A moulded rubber edge can be provided to protect the carcass from acids, chemicals and oils. In most applications a moulded
edge is unnecessary as synthetic fibres will not rot or be degraded by mildew.
SABS SPECIFICATIONS
Dunlop Africa Industrial Products conveyor belting complies with the stringent standards as laid down by the SABS.
1. SABS 1173-1977 - General purpose textile reinforced conveyor belting.
2. SABS 971-1980 - Fire-resistant textile reinforced conveyor belting.
3. SABS 1366-1 982- Steelcord reinforced conveyor belting.
The above specifications cover the requirements of the various conveyor belts and are classified according to the minimum full thickness
breaking strength of the finished belting in kilonewtons per metre width.
Further information regarding SABS specifications will be supplied on request.
CONVEYOR BELT DESIGN
Introduction
A conveyor belt comprises two main components:
1. Reinforcement or a carcass which provides the tensile strength of the belt, imparts rigidity for load support and provides a means
of joining the belt.
2. An elastometric cover which protects the carcass against damage from the material being conveyed and provides a satisfactory
surface for transmitting the drive power to the carcass.
In selecting the most suitable belt for a particular application, several factors have to be considered:
1. The tensile strength of the belt carcass must be adequate to transmit the power required in conveying the material over the
distance involved.
2. The belt carcass selected must have the characteristics necessary to:
a. provide load support for the duty.
b. conform to the contour of the troughing idlers when empty, and
c. flex satisfactorily around the pulleys used on the conveyor installation.
3. The quality and gauge of cover material must be suitable to withstand the physical and chemical effects of the material conveyed.
Belt Tensions
In order to calculate the maximum belt tension and hence the strength of belt that is required, it is first necessary to calculate the effective
tension. This is the force required to move the conveyor and the load it is conveying at constant speed. Since the calculation of effective
tension is based on a constant speed conveyor, the forces required to move the conveyor and material are only those to overcome frictional
resistance and gravitational force.
Mass of Moving Parts
For the sake of simplicity the conveyor is considered to be made up of interconnected unit length components all of equal mass. The mass
of each of these units is called the mass of the moving parts and is calculated by adding the total mass of the belting, the rotating mass of
all the carrying and return idlers and the rotating mass of all pulleys. This total is divided by the horizontal length of the conveyor to get the
mean mass of all the components. At the outset the belt idlers and pulleys have not been selected and hence no mass for these components
can be determined. Therefore the mass of the moving parts is selected from the tabulated values to be found in Table 10.
Mass of the load per unit length
As is the case with the components the load that is conveyed is considered to be evenly distributed along the length of the conveyor. Given
the peak capacity in ton per hour the mass of the load per unit length is given by:
The effective tension is made up of 4 components
The tension to move the empty belt T
x

The tension to move the load horizontally T
y

The tension to raise or lower the load T
z

The tension to overcome the resistance of accessories T
u
Q = 0,278

or Q =

S 3,600S
The effective tension is the sum of these four components
T
e
= T
x
+ T
y
+ T
z
+T
u

T
x
= 9,8G x f
x
x L
c

T
z
= 9,8Q x H

Various conveyor accessories that add resistance to belt movement are standard on most conveyors. The most common are skirtboards at
the loading point and belt scrapers. Other accessories include movable trippers and belt plows.
Tension required to overcome the resistance of skirtboards T
us

Tension to overcome the resistance of scrapers
T
uc
= A x x f
c

In the case of a belt plow the additional tension required to overcome the resistance of each plow is
T
up
= 1,5W

Moving trippers require additional pulleys in the system and therefore add tension. If the mass of the additional pulleys has been included in
the mass of moving parts then no additional tension is added. However, if a separate calculation of the tension to overcome the resistance
of the additional pulleys is required this can be determined for each additional pulley as follows
Corrected length L
c

Short conveyors require relatively more force to overcome frictional resistance than longer conveyors and therefore an adjustment is made
to the length of the conveyor used in determining the effective tension. The adjusted length is always greater than the actual horizontal
length.
L
C
= L + 70

The length correction factor is
All conveyors require an additional tension in the belt to enable the drive pulley to transmit the effective tension into the belt without
slipping. This tension, termed the slack side tension T
2
, is induced by the take-up system. In the case of a simple horizontal conveyor the
maximum belt tension T
1
is the sum of the effective tension Te and the slack side tension T
2

ie: T
1
= T
e
+ T
2

T
1
is the tight side tension and 12 is the slack side tension

For a more complex conveyor profile that is inclined, additional tensions are induced due to the mass of the belt on the slope. This tension is
termed the slope tension 'h and increases the total tension.
Thus T
1
= T
e
+ T
2
+ T
h

T
us
=
9,8f
s
x Q x L
s
S x b
T
ut
= 0,01
d
o
x T
1
D
t

C =
L
c
L
The slack side tension is determined by consideration of two conditions that must be met in any conveyor. The first condition is that there
must be sufficient tension on the slack side to prevent belt slip on the drive. The second condition is that there must be sufficient tension to
prevent excessive sag between the carrying idlers.
Minimum tension to prevent slip Tm
At the point of slipping the relationship between T
1
and T
2
is

Since T
1
= T
e
+ T
2

is called the drive factor k. and the value of T
2
that will just prevent slip is referred to as the minimum to prevent slip T
m
and therefore

T
m
= k x T
e

Minimum tension to limit belt sag T
s

The tension required to limit sag is dependent on the combined mass of belt and load, the spacing of the carry idlers and the amount of sag
that is permissable.
T
s
= 9,8S
f
x (B + Q) x l
d

The value of the slack side tension must ensure that both conditions are met and therefore T
2
must be the larger of T
m
or T
s
.

Slope tension T
h

The slope tension is the product of the belt weight and the vertical lift and has its maximum value at the highest point of the conveyor.
T
h
= 9,8B x H

Unit tension T
The maximum belt tension T
1
has as its reference width the full width of the belt. Usually this is converted to the tension per unit of belt
width as this is the reference dimension for belt strengths.
Absorbed power
The amount of power required by the conveyor is by definition of power equal to the product of the force applied and the speed at which the
conveyor belt travels. The force applied is the effective tension and hence the power required at the shaft of the drive pulley/s is
P = T
e
x S

STEP BY STEP EXAMPLE OF BELT TENSION CALCULATION
As an example of the application of the formulae the belt tensions for the following conveyor will be determined:
T
1
= e
T
2
T
2
=
1
T
e
e
- 1
The expression
1
:
e
- 1
T =
T
1
W
Belt width 900 mm
Conveyor Length 250 m
Lift 20 m
Capacity 400 t/hr
Belt speed 1,4 m/s
Material conveyed ROM coal
Drive 210 degree wrap. Lagged drive pulley.
Take-up Gravity
Idler spacing 1,2 m
Idler roll diameter 127 mm
1. Determine mass of the load per unit length
Q = 0,278
S
=
0,278 x 400
1,4
= 79,4 kg/m
2. Look up the value of the mass of moving parts in Table 10. From the idler roll diameter and the nature of the material conveyed
the application is considered as medium duty. For a 900 mm wide belt the mass of moving parts from Table 10 is 55 kg/m
3. Calculate the corrected length and the length correction factor.
L
C
= L + 70
= 250 + 70
= 320 m
C =
L
C
L
=
320
250
= 1,28
4. Tension to move the empty belt.
T
X
= 9,8G x f
X
x L
C
= 9,8 x 55 x 0,022 x 320
= 3794 N
5. Tension to move the load horizontally.
T
X
= 9,8Q x f
Y
x L
C
= 9,8 x 79,4 x 0,027 x 320
= 6723 N
6. Tension to lift the load.
T
Z
= 9,8Q x H
= 9,8 x 79,4 x 20
= 15562 N
7. No accessories are present and therefore the tension to overcome the resistance of accessories is zero.
8. Effective tension.
T
e
= T
X
+ T
Y
+ T
Z
+ T
U
= 3794 + 6723 + 15562 + 0
= 26079 N
9. The absorbed power
P = T
e
x S
= 26079 x 1,4
= 36511W
10. The slack side tension.
Slack side tension to prevent slip.
The drive factor for 210 degree wrap and lagged pulley with a gravity take-up, as given in Table 11, is 0,38.
Slack side tension to limit sag to 2%. The sag factor for 2% sag is 6,3 and the estimated belt mass for a medium load and 900
mm belt width, as given in Table 8, is 11,1kg/m.
T
m
= k x T
e
= 0,38 x 36079
= 9910 N
T
S
= 9,8S
f
(B + Q) x l
d
= 9,8 x 6,3 x (11,1 + 79,4) x 1,2
TABLE 1 TABLE OF SYMBOLS
TABLE 2 MATERIAL CHARACTERISTICS
The required slack side tension is the larger of T
m
or T
S
and hence

T
2
= 9910 N
= 6705 N
11. Slope tension using the estimated belt mass found in Table 8 for medium load and 900 mm belt width is:
T
h
= 9,8B x H
= 9,8 x 11,1 x 20
= 2176 N
12. The maximum belt tension
The maximum belt tension is converted to the unit tension.
Effective tension.
T
1
= T
e
+ T
2
+ T
h
= 26079 + 9910 + 2176
= 38165 N
T =
T
1
W
=
38165
900
= 42,4 N/mm
= 42,4 kN/m
Symbols Description Unit

Symbol Description Unit
A Contact area of scraper blade m2 S
f
Sag factor
B Belt mass per unit length kg/m T Unit tension kN/m
b Width between skirtplates m T
1
Maximum belt tension across full belt width N
B
c
Edge Distance mm T
2
Slack side tension N
C Length correction coefficient T
e
Effective tension N
D Material Density kg/m3 T
h
Slope tension N
D
t
Diameter of pulley t mm T
m
Minimum tension to prevent slip N
d
o
Diameter of pulley bearings mm T
s
Minimum tension to limit sag N
f
c
Friction coefficient for scrapers T
u
Tension induced in overcoming resistance of accessories N
f
s
Friction coefficient for skirtboards T
uc
Tension to overcome resistance of scrapers N
f
x
Friction coefficient for empty belt T
us
Tension to overcome resistance of skirtboards N
f
y
Friction coefficient for loaded belt T
x
Tension to move the empty belt N
G Mass of moving parts kg/m T
y
Tension to move the load horizontally N
H Change in elevation along conveyor length m T
z
Tension to lift (or lower) the load N
l
d
Idler spacing (carry idlers) m W Belt width mm
k Drive factor Coefficient of friction between belt and drive pulley
L Horizontal length of conveyor m Angle of wrap on the drive radians radians
L
c
Corrected length of conveyor m Pressure of scraper on the belt N/m
2
L
s
Length of skirtboard m Belt capacity expressed in ton per hour t/hr
P Absorbed power W Trough angle degree
Q Mass of load per unit length kg/m Material surcharge angle degree
S Belt Speed m/s
Material Characteristics
Suggested
Grade
Bulk
Density
(t/m3)
Angle of
Surcharge
(degrees)
Max. Rec.
Conv. Slope
(degrees)
24/05/2004
Acid phosphate MA N 0,96 10 13
Alum NA N 0,80 25 22
Alumina MA N 0,90 10 12
Aluminium sulphate NA N 0,90 20 17
Ammonium chloride MA N 0,80 10 10
Ammonium nitrate MA N 0,70 25 23
Ammonium sulphate, granular MA N 0,80 10 10
Asbestos ore or rock VA N/M 1,30 20 18
Asbestos shred MA N 0,37 30 30
Ashes, coal, dry MA N 0,60 25 23
Ashes, coal, wet MA N 0,75 25 25
Ashes, fly MA N 0,70 30 23
Ashes, gas producer, wet MA N 1,20 30 28
Asphalt NA N 1,30 30 30
Bagasse NA N/PHR 0,13 30 30
Bark, wood, refuse NA N 0,24 30 27
Barley NA N/GF 0,60 10 12
Barytes, powdered MA N 2,10 10 15
Bauxite, ground, dry VA N/M 1,10 20 18
Bauxite, mine run VA N/M 1,36 20 17
Bauxite, crushed, 75mm VA N/M 1,30 20 20
Beans NA N/GF 0,70 5 7
Beet, pulp, dry NA N/GF 0,22 30 25
Beet, pulp, wet NA N/GF 0,60 30 25
Beets, whole NA N/GF 0,76 20 20
Borax MA N 0,90 20 20
Bran NA N/GF 0,30 10 12
Brewers grain, spent, dry NA N/GF 0,45 30 27
Brewers grain, spent, wet NA N/GF 0,90 30 27
Brick VA N/M 1,76 30 27
Calcium carbide MA N 1,20 20 18
Carbon black, pelletised MA N 0,35 5 5
Carborundum 75mm VA N/M 1,60 10 15
Cashew nuts MA N/GF 0,56 30 22
Cement, portland NA N/PHR 1,50 25 20
Cement, portland, aerated NA N/PHR 1,06 5 10
Cement clinker MA N/DHR 1,36 25 18
Chalk, lumpy MA N 1,30 10 15
Chalk, 100 mesh and under MA N 1,10 25 28
Charcoal MA N 0,35 25 22
Chrome ore HA/S N 2,10 10 17
Cinders, blast furnace MA N/M 0,90 10 18
Cinder, coal MA N 0,65 20 20
Clay, calcined MA N 1,44 25 22
Clay, dry, fines MA N 1,76 20 22
Clay, dry, lumpy VA N 1,10 20 20
Coal, anthracite, 3mm and under NA N/PVC 0,96 20 18
Coal, anthracite, sized NA N/PVC 0,90 10 16
Coal, bituminous, mined 50 mesh and under NA N/PVC 0,83 30 24
Coal, bituminous, mined and sized NA N/PVC 0,80 20 16
Coal, bituminous, mined, run of mine MA N/PVC 0,90 25 18
Coal, bituminous, mined, slack 12mm and under MA N/PVC 0,75 25 22
Coal, lignite MA N/PVC 0,75 25 22
Cocoa beans NA N/GF 0,56 10 12
Coke, loose VA N/M 0,48 30 18
Coke, petroleum, calcined VA N/M 0,64 20 20
Coke, breeze, 6mm and under VA N/M 0,48 20 22
Concrete, 100mm lumps VA N/M 2,10 10 18
Concrete wet VA N/M 2,20 24 18
Copper ore VA N/M 2,17 20 20
Copper sulphate VA N/M 1,30 20 17
Corn, ear NA N/GF 0,90 25 18
Corn, shelled NA N/GF 0,70 10 10
Cornmeal NA N/GF 0,65 20 22
Cottonseed cake NA N/GF 0,67 20 20
Gullet HA/S M 1,60 20 20
Dolomite VA N/M 1,60 18 20
Earth, as dug, dry VA N/M 1,20 20 20
Earth, wet, with clay MA N 1,70 30 23
Feldspar VA N/M 1,44 25 17
Flaxseed MA O 0,70 10 12
Flour, wheat NA N/GF 0,60 30 21
Fluorspar MA N 1,70 30 20
Foundry sand, old sand cores etc. VA M/PHR 1,36 25 20
Fullers earth, dry MA N 0,50 10 15
Fullers earth, oily MA O 1,00 20 20
Glass batch HA/S M 1,44 10 22
Grain, distillery, spent dry NA N/GF 0,48 10 15
Granite, broken, 75mm lumps VA N/M 1,44 10 18
Graphite, flake NA N 0,65 10 15
Gravel, bank run VA N/M 1,52 25 20
Gravel, dry, sharp VA N/M 1,52 20 16
Gravel, pebbles VA N/M 1,52 10 12
Gypsum, dust, not-aerated MA N 1,50 20 20
Gypsum, dust, aerated MA N 1,04 30 23
Gypsum, 12mm screened MA N 1,20 25 21
Gypsum, 75mm lumps MA N 1,20 10 15
Illmenite ore MA N 2,40 10 18
Iron ore, coarse crushed VA N/M 3,00 20 18
Iron ore, crushed fine VA N/M 3,50 20 18
Kaolin clay, 75mm and under MA N 1,00 20 19
Lead ores MA N 3,80 10 15
Lead oxide, heavy MA N 2,40 25 20
Lead oxide, light MA N 1,20 25 20
Lignite, air dried MA N 0,80 10 18
Lime, ground, 3mm and under NA N 1,00 30 23
Lime, hydrated NA N 0,60 25 21
Lime, pebble MA N 0,90 10 17
Limestone, agricultural 3mm and under MA N 1,10 10 20
Limestone, crushed MA N 1,40 25 18
Linseed cake NA OR/PVC 0,80 20 15
Linseed meal NA OR/PVC 0,43 20 20
Litharge, pulverized (lead oxide) MA N 3,60 10 15
Magnesium chloride MA N 0,53 30 23
Magnesium sulphate MA N 1,10 10 15
Manganese ore VA N/M 2,15 25 20
Manganese sulphate MA N 1,10 10 15
Marble, crushed 12mm and under VA N/M 1,40 10 15
Mica, ground MA N 0,22 20 23
Mica, pulverized MA N 0,22 10 15
Mica, flakes MA N 0,32 5 8
Molybdenite, powdered MA N 1,70 20 25
Mortar, wet VA N/M 2,20 24 18
Nickel-cobalt VA N/M 1,80 10 20
Oats NA GF/PVC 0,42 10 10
Peanuts in shells NA N 0,27 10 8
Peanuts, shelled NA GF/PVC 0,65 10 8
Peas, dried NA GF/PVC 0,75 5 8
Phosphate, triple super ground fertilizer MA N/OR/PVC 0,80 20 18
Phosphate rock, broken, dry VA N/M 2,00 20 18
Phosphate rock, pulverized VA N/M 2,10 25 18
Potash ore MA N 1,30 10 15
Pumice, 3 mm and under MA N 0,67 30 22
Pyrites, iron, 50 - 75mm in lumps VA N/M 2,25 20 17
Pyrites, pellets VA N/M 2,00 10 15
Quartz HA/S N/M 1,36 10 15
Rice NA GF/PVC 0,65 5 8
Rock, crushed HA/S N/M 2,15 20 18
Rubber, pelletised MA N 0,80 20 22
Rubber, reclaim NA N 0,45 20 18
Rye NA GF/PVC 0,70 10 8
Salt, common dry, coarse MA N/GF/PVC 0,75 10 20
Salt, common dry, fine MA GF/PVC 1,20 10 11
Sand, bank, damp VA N/M 1,90 30 22
Sand, bank, dry VA N/M 1,60 20 18
Sand, foundry, prepared VA N/M 1,36 30 24
Sand, foundry, shakeout VA N/M/PHR 1,50 25 22
Sand, Silica, dry VA N/M 1,50 10 12
Sand, core VA N/M 1,04 25 26
Sandstone, broken VA N/M 1,44 20 20
Sawdust NA N/OR/PVC/W 0,20 25 22
Shale, broken MA N 1,50 10 18
Shale, crushed MA N 1,40 25 22
Sinter VA N/M/PHR 1,80 10 15
Slag, blast furnace, crushed VA M/PHR/DHR 1,36 10 10
Slag, furnace, granular, dry VA M/PHR/DHR 1,00 10 15
Slag, furnace, granular, wet VA N/M 1,50 30 22
Slate MA N 1,36 20 18
Soap, beads or granules NA N/PVC 0,32 10 12
Soap, chips NA N/PVC 0,32 10 18
Soda ash, briquettes MA N 0,80 10 7
Soda ash, heavy MA N 0,96 20 18
Soda ash, light MA N 0,43 25 22
Sodium nitrate MA N 1,20 10 11
Sodium phosphate MA N 0,90 10 16
Soyabeans, cracked NA GF/PVC 0,56 20 18
Characteristics
Cover Grade
TABLE 2(a) TYPICAL FLOWABILITY
Determination of Conveyor Capacities
The capacity of a troughed belt is a function of:
1. The cross sectional area of the load which can be carried without spillage.
2. The belt speed.
3. The material density.
The cross sectional area is influenced by many factors including the flowability of the material, the angle of surcharge and the incline angle
Soyabeans, whole NA GF/PVC 0,77 10 14
Starch NA GF 0,60 10 12
Steel trimmings HA/S M 2,40 20 18
Sugar, granulated NA GF 0,83 10 15
Sugar, raw, cane MA N 0,96 20 22
Sulphate powdered MA N 0,90 10 21
Talc, powdered NA N 0,90 10 12
Titanium ore VA N/M 2,40 10 18
Titanium sponge MA N 1,04 30 25
Traprock VA N/M 1,60 20 18
Triple super phosphate MA N/OR/PVC 0,80 20 18
Vermiculite, expanded MA N 0,25 20 23
Vermiculite, ore MA N 1,20 20 20
Walnut shells, crushed NA GF 0,65 20 20
Wheat NA N/GF/PVC 0,77 10 12
Woodchips NA OR/W 0,32 30 27
Zinc ore, crushed HA/S M 2,60 25 22
Zinc ore, roasted HA/S SPHR/DHR 1,76 25 25
Key: HA/S - Highly abrasive/sharp
MA - Mildly abrasive
NA - Non-abrasive
VA - Very abrasive
Code: N - SASS 1173 NH polyisoprine
M - Higher natural rubber content SASS 1173
OR - Oil resistant
GF - Grey Food
PHR - Phoenix Heat Resistant
SPHR - Super Phoenix heat resistant
W - Wood master
DHR - Delta Hete heat resistant
PVC - Polyvinylchloride
FR - Fire resistant SASS 971
Angle of
Surcharge
Angle of
Repose
Material Characteristics
5 0 - 19 Uniform Size
10 20 - 29 Rounded, dry ,medium weight
20 30 - 34 Granular lumpy (Coal, Clay)
25 35 - 39 Coal, stone, ores
30 40 - 45 Irregular (wood chips)
at the load point of the conveyor. To achieve optimum load area the loading chutes must be designed to ensure the most advantageous
initial load shape and this can only be achieved if:
1. The load is placed centrally on the belt.
2. The material is delivered in the direction of belt travel and at a speed approaching that of the belt.
3. The angle of incline at the load area must be less than 1 ~O,
To ensure that the optimum load shape is maintained along the entire belt length:
1. The idler pitch should be such as to limit sag to acceptable levels.
2. The belt must be trained properly.
3. The lump size in relation to belt width must be within the recommended limits.
4. The belt must give adequate support to the load.
Under ideal conditions the cross sectional load area is:
A
t
= (A
b
+ A
s
) / 10
6

Where
A
b
= (0,371W + 6,3 + M x cos) (M x sin)

M = 0,3145W - 3,2 - B
c

W - Belt width (mm)
B
c
- Edge distance (mm)

- Iroughing angle (degree)
- Material surcharge angle (degree)
A
t
- Cross sectional load area (m
2
)
The belt capacity in ton/hour is
Capacity = 3,6A
t
x D x S
Where
D - Material Density (kg/m
3
)

S - Belt speed (m/s)

TABLE 3 CAPACITIES OF TROUGHED BELT CONVEYORS IN TON/HOUR
A
s
= (
0,186W + 3,2 + M x cos
)
2
(

-
sin2
)
sin 180 2
Belt
Width
mm
Recommended
Max. Lump Size
Trough
Angle
Degrees
Area of
Load
m
2
Speed m/s
Sized
mm
Unsized
mm
0,5 0,8 1,2 1,6 2,0 2,5 3,0
600 125 200 20 0,033 59 95 142 190 236 297 357
27 0,037 66 106 160 213 266 333 400
30 0,038 69 110 164 218 274 342 410
35 0,040 72 115 173 230 288 360 432
45 0,042 76 121 181 242 303 378 436
750 150 250 20 0,054 97 156 233 311 389 486 583
27 0,060 109 173 259 346 432 540 648
30 0,062 112 179 268 357 446 558 670
35 0,065 117 187 281 375 468 585 702
45 0,068 122 196 294 392 490 612 734
900 175 300 20 0,080 144 230 346 461 576 720 864
TABLE 4 RECOMMENDED MAXIMUM BELT SPEEDS FOR NORMAL USE (METRES PER SECOND)*
27 0,090 162 259 389 518 648 810 972
30 0,092 166 265 397 530 662 828 994
35 0,096 173 276 415 553 691 864 1037
45 0,101 182 291 436 582 727 909 1091
1050 200 350 20 0,111 200 320 480 639 799 1000 1199
27 0,124 223 357 536 714 839 1116 1339
30 0,128 230 369 553 737 922 1152 1382
35 0,134 241 386 579 772 965 1206 1447
45 0,140 252 403 605 806 1008 1260 1512
1200 250 400 20 0,147 265 423 635 847 1058 1323 1588
27 0,165 297 475 713 950 1188 1485 1782
30 0,170 306 490 734 979 1224 1530 1836
35 0,178 320 513 769 1025 1282 1602 1922
45 0,186 335 536 804 1071 1339 1674 2009
1350 275 500 20 0,189 340 544 816 1089 1361 1701 2041
27 0,211 380 608 912 1215 1519 1899 2279
30 0,217 391 625 937 1250 1562 1953 2344
35 0,227 409 654 981 1308 1634 2043 2452
45 0,238 428 685 1028 1371 1714 2142 2570
1500 300 600 20 0,235 423 676 1015 1357 1692 2115 2538
27 0,263 473 757 1136 1515 1894 2367 2840
30 0,271 488 780 1171 1561 1951 2439 2927
35 0,283 509 815 1223 1630 2038 2547 3056
45 0,296 533 852 1279 1905 2131 2664 3197
1650 350 700 20 0,286 515 824 1236 1649 2059 2574 3089
27 0,321 578 924 1387 1849 2311 2889 3467
30 0,330 594 950 1426 1901 2367 2970 3564
35 0,345 621 994 1490 1987 2484 3105 3726
45 0,361 650 1040 1560 2079 2599 3249 3899
1800 350 700 20 0,343 617 988 1482 1976 2470 3087 3704
27 0,384 691 1106 1659 2212 2765 3456 4147
30 0,395 711 1138 1706 2275 2844 3555 4266
35 0,413 743 1189 1784 2379 2976 3717 4460
45 0,432 778 1244 1866 2488 3110 3888 4666
2100 350 700 20 0,472 850 1359 2039 2719 3398 4248 5098
27 0,528 950 1521 2281 3041 3802 4752 5702
30 0,543 977 1564 2346 3128 3910 4887 5864
35 0,568 1022 1636 2454 3272 4090 5112 6134
45 0,594 1069 1711 2566 3421 4277 5346 6415
2200 350 700 20 0,519 934 1495 2245 2989 3737 4671 6505
27 0,581 1046 1673 2510 3347 4183 5229 6275
30 0,598 1076 1722 2583 3444 4306 5382 6458
35 0,625 1125 1800 2700 3600 4500 5625 6750
45 0,654 1161 1858 2786 3715 4644 5805 6966
Belt Width
(mm)
Grain or Other
Free Flowing Material
Run of Mine
Coal and Earth +
Hard Ores and Stone -
Primary Crushed ++
300 2,5 1,5 1,5
400 2,5 2,0 1,8
500 3,0 2,0 1,8
600 3,0 2,5 2,3
750 3,6 3,0 2,8
900 4,0 3,3 3,0
1050 4,0 3,6 3,0
1200 4,6 3,6 3,3
1350 5,0 3,6 3,3
1500 5,0 3,6 3,3
1800 4,0 3,8
* These speeds are intended as guides to general practice and are not absolute.
+ Moderately abrasive materials.
++ Very abrasive materials.
Note: In the case of belts loaded on inclines of 100 or more it may be necessary to reduce the above speeds in order to achieve maximum
capacity.
TABLE 5 RECOMMENDED IDLER SPACING
TABLE 6 FRICTION FACTORS
TABLE 7 SAG FACTOR
TABLE 7(a) RECOMMENDED PERCENTAGE SAG
TABLE 8 ESTIMATED BELT MASS B
2000 and over 4,0 3,8
Belt Width
(mm)
Troughing Idler - (m)
Return Idlers
(m)
Bulk Density of Material (t/m3)
0,5 0,8 1,2 1,6 2,0 2,5 3,0
450 1,5 1,5 1,5 1,4 1,4 1,4 1,4 3
600 1,5 1,5 1,5 1,4 1,4 1,2 1,2 3
750 1,5 1,4 1,4 1,2 1,2 1,2 1,0 3
900 1,4 1,4 1,2 1,2 1,0 1,0 1,0 3
1050 1,2 1,2 1,0 1,0 1,0 1,0 0,9 3
1200 1,2 1,2 1,0 1,0 1,0 0,9 0,9 3
1350 1,2 1,0 1,0 1,0 0,9 0,9 0,9 3
1500 1,2 1,0 1,0 1,0 0,9 0,9 0,9 3
1650 1,2 1,0 1,0 0,9 0,9 0,9 0,9 3
1800 1,2 1,0 1,0 0,9 0,9 0,9 0,8 3
2000 and over 1,0 1,0 0,9 0,9 0,9 0,8 0,8 3
Symbol Description
Value of the friction factor
Normal operating
conditions.
Horizontal length
up to
250 meters.
Normal operating
conditions.
Horizontal length
more than
250 meters.
Very well aligned
structure with no
tilted idlers etc.
Horizontal length
more than
500 meters.
Regenerative
conveyor.
f
C
Friction coefficient for scrapers 0,600 0,600 0,600 0,600
f
S
Friction coefficient for skirtboards 0,650 0,650 0,650 0,650
f
X
Friction coefficient for empty belt 0,022 0,020 0,020 0,018
f
Y
Friction coefficient for loaded belt 0,027 0,022 0,020 0,018
Percentage
Sag
Sag Factor
S
f
3% 4,2
2% 6,3
1,5% 8,4
Trough Angle
(degree)
Fine
Material
Lumps up to
max lump size
Max Lump
Size
20 3% 3% 3%
35 3% 2% 2%
45 3% 2% 1,5%
Note:
The values given in the table are estimated values for use in the calculation of maximum belt operating tension necessary to make the
correct belt selection. When the belt specification has been determined, the mass should be checked more accurately from Table 17. If the
actual mass of the specification differs considerably from the approximate value obtained from the table the tension calculation should be
rechecked using the more accurate belt mass.
TABLE 9 TYPICAL MASS OF ROTATING PARTS OF IDLERS (kg/m)
TABLE 10 MASS OF MOVING PARTS G
Belt Width
(mm)
Operating Conditions
Light Duty
(kg/m)
Medium Duty
(kg/m)
Heavy Duty
(kg/m)
500 4,1 6,2 10,3
600 5,0 7,4 12,3
750 6,2 9,3 15,5
900 7,4 11,1 18,5
1050 8,6 13,0 21,6
1200 9,8 14,8 24,7
1350 11,0 16,7 27,8
1500 12,3 18,6 30,9
1650 13,5 20,5 33,9
1800 14,7 22,3 37,0
2100 17,2 26,0 43,3
2200 18,0 27,3 45,3
Belt Width
3 Roll Carry Idlers Return Idlers 3 Roll Impact Idlers
Roll Dia Roll Dia Roll Dia
102 127 152 102 127 152 133 159
450 8,0 10,5 13,1 6,0 7,7 9,4 8,8 11,5
500 8,5 11,1 13,9 6,5 8,4 10,1 9,3 12,2
600 9,5 12,4 15,4 7,5 9,6 11,6 10,4 13,6
750 11,0 14,2 17,6 9,0 11,4 13,9 12,1 15,6
900 12,5 16,1 19,9 10,6 13,3 16,1 13,8 17,7
1050 14,0 18,0 22,2 12,1 15,2 18,4 15,4 18,8
1200 15,5 19,9 24,4 13,6 17,1 20,6 17,1 21,9
1350 17,0 21,8 26,6 15,1 19,0 22,9 18,7 24,0
1500 18,5 23,6 28,9 16,6 20,8 25,1 20,3 26,0
1650 20,0 25,5 31,2 18,1 22,7 27,4 22,0 28,9
1800 21,6 27,4 33,4 19,6 25,6 29,6 23,8 30,1
2100 24,6 31,2 37,9 22,6 28,4 34,2 27,1 34,3
2200 25,6 32,4 39,4 23,6 29,6 35,7 28,2 35,6
2400 27,6 34,9 42,4 25,7 32,1 38,7 30,4 38,4
Belt Width
(mm)
Mass of Moving Parts (kg/m)
Light Duty
102mm Idlers
Light Belt
Medium Duty
127mm Idlers
Moderate Belt
Heavy Duty
152mm Idlers
Heavy Belt
Extra Heavy Duty
152mm Idlers
Steel Cord Belt
450 23 25 33
600 29 36 45 49
750 37 46 57 63
900 45 55 70 79
1050 52 64 82 94
1200 63 71 95 110
1350 70 82 107 127
1500 91 121 143
1650 100 132 160
1800 144 178
2100 168 205
2200 177 219
TABLE 11 DRIVE FACTOR k
Notes:
1. When calculating the driving tension required for dual drive units, the drive factor selected must correspond to the total angle of
driving wrap.
2. The drive factors quoted for gravity or automatic take-up systems are minimum values based on the relationship between angle of
wrap and coefficient of friction between belt and drum at the point of slip. In the case of screw take-up units, an adjustment has
been made to the drive factor to allow for the extra tension which may be induced in the belt either:
a. to compensate for the effect of belt elongation when the material is loaded.
b. due to the difficulty in measuring the amount of tension applied.
3. In those cases where an electrically or hydraulically loaded winch type take-up is used, where the induced tension can be preset
and controlled, the drive factor should be selected to correspond with a gravity take-up system.
CONVEYOR BELT SELECTION
Belt carcass selection criteria
In selecting the optimum belt construction for a given application it is necessary to consider the following:
Tensile strength
The belt class required is that which has an operating tension greater than or equal to the calculated maximum unit tension T. (Table 12).
Load support
Choose the lowest class which meets the tensile strength requirement. Looking at Table 14, determine which load category best describes
the load being conveyed i.e. A, B, C, D or E category load. The value obtained at the intersection of the belt specification row and the load
category column gives the maximum width at which that belt specification can be used.
Number of plies for troughability
The maximum number of plies allowable, in order to ensure that the empty belt will conform to the contour of the troughing idlers, must be
checked referring to Table 15. For a particular belt class the value shown at the intersection of the belt width column and troughing angle
row, is the maximum number of plies that should be used.
Minimum pulley diameters
If the size of the pulleys is already determined, the belt construction provisionally selected from the previous considerations can be checked
against the relevant pulley diameters for suitability. For a new installation, the pulley diameters should be equal to or larger than those
given in Table 13 (It should be noted that, in this context, the diameters quoted refer to the minimum pulleys around which the particular
belt construction will flex satisfactorily. The conveyor designer should also take into account the gearbox ratio and required belt speed when
selecting the drive pulley diameter.)
Gauge of covers required
The correct gauge of cover necessary to give protection to the belt carcass from material impact and wear must be determined by
consideration of the size and density of the material to be handled. (Table 19).
Angle of
Belt Wrap
at Drive
Type
of
Drive
Screw
Take-up
Gravity or Automatic
Winch Take-up
Bare
Pulley
Lagged
Pulley
Bare
Pulley
Lagged
Pulley
150 Plain 1,5 1,0 1,08 0,670
160 Plain 1,4 0,9 0,99 0,600
170 Plain 1,3 0,9 0,91 0,550
180 Plain 1,2 0,8 0,84 0,500
190 Snubbed 1,1 0,7 0,77 0,450
200 Snubbed 1,0 0,7 0,72 0,420
210 Snubbed 1,0 0,7 0,67 0,380
220 Snubbed 0,9 0,6 0,62 0,350
230 Snubbed 0,9 0,6 0,58 0,320
240 Snubbed 0,8 0,6 0,54 0,300
340 Dual 0,5 0,4 0,29 0,143
360 Dual 0,5 0,4 0,26 0,125
380 Dual 0,5 0,3 0,23 0,108
400 Dual 0,5 0,3 0,21 0,095
420 Dual 0,4 0,3 0,19 0,084
440 Dual 0,17 0,074
460 Dual 0,15 0,064
480 Dual 0,14 0,056
Additional Information
Belt modulus
Refer to Table 20 for belt modulus.
Belt mass
The mass of a particular belt construction can be determined by adding the carcass mass found in Table 17 to the combined mass of covers
found in Table 18. This will give the mass per unit area. To calculate the mass per unit length multiply by the belt width in metres.
Belt thickness
The belt thickness can be obtained from the information given in Table 16.
TABLE 12 MAXIMUM RECOMMENDED OPERATING TENSIONS
TABLE 13 RECOMMENDED MINIMUM PULLEY DIAMETERS (mm)
Textile Reinforced Multi-ply and
Solid Woven Carcass Conveyor Belting
Steelcord Reinforced Conveyor Belting
Belt
Class
Max recommended
Operating Tension (kN/m)
Belt
Class
Max recommended
Operating Tension (kN/m)
160 16,0
200 20,0
250 25,0
315 31,5
400 40,0
500 50,0 St 500 75,0
630 63,0 St 630 94,0
800 80,0 St 800 120,0
1000 100,0 St 1000 150,0
1250 125,0 St 1250 187,5
1600 160,0 St 1600 240,0
2000 200,0 St 2000 300,0
St 2500 375,0
St 3150 472,0
St 4000 600,0
St 5000 750,0
St 6300 945,0
Belt Class Pulley Type
Textile Reinforced Rubber Belting
Solid Woven
PVC Belting
Steelcord
Reinforced
Rubber Belting
No. of Plies
2 3 4 5
160
A 315
B 250
C 200
200
A 315
B 250
C 200
250
A 315 400
B 250 315
C 200 250
315
A 315 400 400
B 250 315 315
C 200 250 250
400
A 400 500 630 400
B 315 400 500 315
C 250 315 400 250
500
A 500 500 630 630 500 500
B 400 400 500 500 400 400
C 315 315 400 400 315 315
630
A 500 630 630 800 500 500
B 400 500 500 630 400 400
C 315 400 400 500 315 315

TABLE 14 LOAD SUPPORT
Recommended maximum belt width (mm) for correct load support. Multi-ply textile reinforced rubber belting.
800
A 630 800 800 800 500 500
B 500 630 630 630 400 400
C 400 500 500 500 315 315
1000
A 630 800 1000 1000 630 500
B 500 630 800 800 500 400
C 400 500 630 630 400 315
1250
A 1000 1000 1250 800 630
B 800 800 1000 630 500
C 630 630 800 500 400
1600
A 1000 1250 1250 1000 800
B 800 1000 1000 800 630
C 630 800 800 630 500
2000
A 1250 1400 1000 800
B 1000 1250 800 630
C 800 1000 630 500
2500
A 1000
B 800
C 630
3150
A 1250
B 1000
C 800
4000
A 1250
B 1000
C 800
5000
A 1400
B 1250
C 1000
6300
A 1400
B 1250
C 1000
Pulley types Examples
A High tension pulleys Wrap exceeding 45 Head, drive & tripper
B Low tension pulleys Wrap exceeding 45 Tail, take-up, Take-up bend
or
High tension pulleys Wrap up to 45 High tension snub or bend pulleys
C Low tension pulleys Wrap up to 45 Low tension snub or bend pulleys
Belt Spec
A
Light Duty
Up to 800 kg/m
3
- 25mm Lumps
B
Light to Medium Duty
Up to 1200 kg/m
3
- 50mm Lumps
C
Medium Duty
Up to 1600 kg/m
3
- 100mm Lumps
D
Heavy Duty
Up to 2400 kg/m
3
- 250mm Lumps
E
Extra Heavy Duty
Up to 3000 kg/m
3
+ 250mm Lumps
160/2 750 600 500 400 Not Recommended
200/2 750 600 600 4500 Not Recommended
250/2 900 750 750 600 500
250/3 1050 900 750 600 600
315/2 900 900 750 600 500
315/3 1200 1050 1050 750 600
400/2 1200 1050 1050 900 750
400/3 1200 1050 1050 900 750
400/4 1500 1500 1350 900 750
500/2 1200 1200 1200 1050 900
500/3 1350 1200 1200 1050 900
500/4 1650 1500 1350 1200 900
500/5 1800 1800 1800 1500 1350
TABLE 15 MAXIMUM NUMBER OF PLIES RECOMMENDED FOR CORRECT EMPTY BELT TROUGHING
TABLE 16 CARCASS THICKNESS (mm)
630/2 1200 1200 1200 1050 900
630/3 1650 1350 1200 1050 1050
630/4 1650 1500 1350 1200 1050
630/5 2100 2100 1800 1650 1350
800/2 1650 1500 1500 1350 1200
800/3 1800 1650 1500 1350 1200
800/4 2100 1800 1650 1500 1350
800/5 2400 2400 2100 1800 1500
1000/2 1800 1650 1500 1350 1200
1000/3 2100 1650 1500 1350 1200
1000/4 2400 1800 1800 1500 1350
1000/5 2400 2400 2200 1800 1500
1250/3 2100 1800 1800 1350 1200
1250/4 2400 2200 2200 1650 1500
1250/5 2400 2400 2400 1800 1800
1600/3 2400 2400 1800 1650 1650
1600/4 2400 2400 2200 1800 1800
1600/5 2400 2400 2400 2200 1800
2000/4 2400 2400 2400 1800 1800
2000/5 2400 2400 2400 2200 2100
Belt
Class
Belt Width (mm)
Troughing
Angle
350 400 450 500 600 750 900 1050 1200 1350 1500 1650 1800 2100 2200
160
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 20
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 35
200
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 20
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 35
250
- 3 3 3 3 3 3 3 3 3 3 3 3 3 3 20
- 2 2 2 3 3 3 3 3 3 3 3 3 3 3 35
315
- 2 3 3 3 4 4 4 4 4 4 4 4 4 4 20
- 2 3 3 3 3 4 4 4 4 4 4 4 4 4 35
400
- 2 4 4 4 4 4 4 4 4 4 4 4 4 4 20
- - 3 3 3 4 4 4 4 4 4 4 4 4 4 35
500
- - 4 4 4 4 4 4 4 4 4 4 4 4 4 20
- - 3 3 3 4 4 4 4 4 4 4 4 4 4 35
630
- - 4 4 4 4 4 4 4 4 4 4 4 4 4 20
- - 2 2 3 4 4 4 4 4 4 4 4 4 4 35
800
- - 3 3 4 4 4 4 4 4 4 4 4 4 4 20
- - 2 2 3 4 4 4 4 4 4 4 4 4 4 35
1000
- - - - 4 4 4 4 4 4 4 4 4 4 4 20
- - - - 2 3 4 4 4 4 4 4 4 4 4 35
1250
- - - - 4 4 4 4 4 4 4 4 4 4 4 20
- - - - 3 3 4 4 4 4 4 4 4 4 4 35
1600
- - - - 3 4 4 4 4 4 4 4 4 4 4 20
- - - - - 3 4 4 4 4 4 4 4 4 4 35
2000
- - - - - 4 5 5 5 5 5 5 5 5 5 20
- - - - - - 4 4 5 5 5 5 5 5 5 35
Belt Class
No. of Plies
Solid Woven
PVC Belting
Steelcord Reinforced
Rubber Belting
2 3 4 5
160 2,0
200 2,6
250 2,7 3,2
315 2,8 3,5 4,9
Add the thickness of the covers to get the total belt thickness
TABLE 17 MASS OF BELT CARCASS (kg/m
2
)

To obtain total belt mass add the mass of the combined covers from Table 18.
The mass per unit length is determined by multiplying the total mass by the belt width in metres.
TABLE 18 MASS OF COVERS PER mm OF THICKNESS (kg/m
2
)

RATE OF WEAR VS THICKNESS OF COVER
400 3,0 3,8 5,0
500 4,0 4,2 5,2 5,9 5,9 3,2
630 4,3 5,2 5,8 6,6 6,2 3,2
800 5,0 6,0 6,9 7,2 6,9 3,7
1000 5,7 6,5 7,6 8,5 7,4 3,7
1250 8,4 9,6 10,0 8,4 3,7
1600 9,5 10,5 11,0 9,9 5,4
2000 12,0 13,0 12,4 5,4
2500 7,0
3150 8,0
4000 9,0
5000 11,0
6300 12,0
Belt Class
No. of Plies
Solid Woven
PVC Belting
With Nominal
PVC Coating
Steelcord Reinforced
Rubber Belting
2 3 4 5
160 2,8
200 3,0
250 3,1 3,9
315 3,4 4,2 9,0
400 3,7 4,4 6,0 9,4
500 4,3 4,8 6,4 7,5 9,7 7,5
630 4,8 5,2 6,8 8,0 10,5 7,7
800 5,6 6,4 7,2 8,5 11,0 8,2
1000 6,5 7,3 8,5 9,0 11,7 9,0
1250 8,9 9,7 10,5 13,0 9,7
1600 10,7 11,5 12,5 15,0 13,4
2000 14,2 14,9 18,0 15,3
2500 18,7
3150 22,4
4000 28,4
5000 35,1
6300 38,7
Grade of Cover
Mass
(kg/m
2
)
N 1,14
M 1,10
OR 1,41
GF 1,37
FR 1,27

Grade of Cover
Mass
(kg/m
2
)
PHR 1,17
SPHR 1,21
DHR 1,34
PVC 1,37
Nitrile 1,32

The rate at which a belt cover wears is related to the thickness of the cover and to the impact energy imparted by material lumps.
Impact energy can be calculated for any material of known lump mass and vertical velocity.
- x
v
J

- Impact Energy (J)
- Mass of lump (kg)
v
- Verticle velocity (m/s)
TABLE 19 MINIMUM BELT TOP COVER GAUGE GUIDE
Cycle time - 2L/S
TABLE 20 BELT MODULUS (kN/m)
Cycle
time
s
Material Class A
Non abrasive material
such as lime, charcoal,
wood chips, bituminous
coal grain
Material Class B
Abrasive material
such as salt, anthracite
coal, phosphate rock,
limestone, fullers earth
Material Class C
Very abrasive material
such as slag, copper ore,
sinter, coke sand,
flue dust
Material Class D
Very sharp abrasive material
such as quartz, some ores,
foundry refuse, glass batch,
iron borings
Lump size (mm) Lump size (mm) Lump size (mm) Lump size (mm)
dust
to
12
12
to
50
50
to
150
150
and
over
dust
to
12
12
to
50
50
to
150
150
and
over
dust
to
12
12
to
50
50
to
150
150
and
over
dust
to
12
12
to
50
50
to
150
150
and
over
12 2,0 3,0 6,0 8,0 3,0 6,0 10,0 10,0 6,0 10,0 10,0 10,0 8,0 10,0 10,0 10,0
25 2,0 2,5 3,0 5,0 2,5 3,0 6,0 10,0 3,0 6,0 10,0 10,0 4,0 8,0 10,0 10,0
40 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 6,0 10,0 3,0 4,0 8,0 10,0
60 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 5,0 6,0 3,0 3,0 6,0 10,0
90 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 5,0 5,0 3,0 3,0 6,0 6,0
120 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 4,0 5,0 3,0 3,0 5,0 6,0
180 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 4,0 5,0 3,0 3,0 5,0 6,0
240+ 1,0 2,5 3,0 5,0 2,0 3,0 4,0 5,0 3,0 3,0 4,0 5,0 3,0 3,0 5,0 6,0
Belt Class
Multi-ply
Textile
Reinforced
Belting
Solid Woven
PVC Belting
Steelcord
Reinforced
Rubber Belting
160 1060
200 1330
250 1660
315 2070 1750
400 2950 2220
500 3330 2800 29000
630 4200 3500 37700
800 5330 4440 47900
1000 6660 5550 59800
1250 8330 6900 74800
1600 10660 8890 95800
2000 13330 11110 119700
2500 149700
3150 188600
4000 240000
TABULATOR CALCULATIONS
For the purposes of
1. Calculating vertical curves, or
2. Determining belt tension for conveyors of undulating profile.
It is necessary to calculate the belt tensions at various points on the conveyor.

Calculating the tension at any point along the conveyor.
The tabulation method described below is a convenient means of calculating the tensions at any point on the conveyor.
Blank copies of the "Conveyor Tabulation Sheets" are available from Dunlop Africa Industrial Products.
The following method is used to determine the tension at any point along the conveyor:
1. Calculate the length correction factor.
2. Look up the mass of moving parts in Table 10.
3. Calculate the mass of the load from the design capacity and the belt speed.
4. Calculate the maximum effective tension under constant speed operation. This will always occur when all the non-declined
sections of the conveyor are fully loaded and the declined sections empty.
5. Determine the minimum value for the slack side tension under maximum load condition.
6. Commencing from immediately behind the drive, label each pulley, intersection point and loading section. Start and end point of
each of the load lengths should also be labelled.
7. Determine the effective tension required to overcome the frictional and gravitational resistances for each of the segments of the
conveyor by using formulae on page 4.
The value of 12, determined in 5 above, is used to calculate the
effective tension to overcome pulley friction.
8. The effective tension at any point on the conveyor is the sum of the effective tensions of all preceeding segments. The total
effective tension for the conveyor is the sum of the effective tensions for all segments.
9. The tension at any point 'x' on the conveyor is made up of the effective tension at point 'x' plus the slope tension at point 'x'.
Superimposed on this is the tension applied by the take-up system. The tension applied by the take-up is given by the worst case
T
2
value i.e. the value of T
2
which

a. prevents slip at the highest T
e
value and,
b. limits sag between carry idlers.
It may be found that the value of T
2
obtained when the maximum effective tension has been calculated is different to that used in the
calculations. If this is the case the new T
2
value is used to calculate tensions at each point.
Steps 7, 8 and 9 should be repeated for four load cases viz empty, fully loaded, non-declined sections loaded and declined sections loaded.
EXAMPLE
Step 1
5000 300000
6300 377200
Belt width 1200 mm
Conveyor length 500 m
Lift 45 m
Max capacity 4500 t/hr
Belt speed 3,5 m/s
Skirt length 3 m
Material conveyed Iron Ore
Lump size 100 mm
Bulk density 2,4 t/m3
Carry idler diameter 127 mm
Carry idler spacing 1,2 m
Return idler diameter 127 mm
Return idler spacing 3,6 m
Impact idler diameter 159 mm
Impact idler spacing 0,45 m
Drive wrap 210 degree
Drive surface Rubber lagged
Take-up type Gravity
Calculate the length correction factor
Step 2
From Table 10 the mass of the moving parts for a 1200 mm wide conveyor of medium duty is 71 kg/m.
Step 3
Calculate the mass of the load
Step 4
Calculate the maximum effective tension when the non-declined sections of the conveyor are all carrying load and the declined sections
have no load. The total horizontal length of non-declined sections is 20 + 330 = 350 m.
The overall change in elevation on the non-declined sections is 70 in. Note that the actual length of the conveyor is used to calculate T
x
and
only the loaded length to calculate T
y
. The length correction factor is a constant and is used to convert the actual length to a corrected
length. The friction factors are determined by the total conveyor length in all cases.
Effective tension to move the empty belt.
Effective tension to move the load horizontally.
Effective tension to lift the load.
Effective tension to overcome skirtboard friction The inter-skirtboard width is assumed to be 2/3 of the belt width i.e. 0,8 m.
The total effective tension is the sum of the above four.
C =
L + 70
L
=
570
500
= 1,14
Q = 0,278

s
=
0,278 x 4500
3,5
= 357,4 kg/m
T
x
= 9,8G x f
x
C x L
= 9,8 x 71 x 0,020 x 1,14 x 500
= 7932N
T
y
= 9,8Q x f
y
C x L
= 9,8 x 357,4 x 0,020 x 1,14 x 350
= 30745N
T
z
= 9,8Q x H
= 9,8 x 357,4 x 70
= 245176N
T
us
=
9,8f
s
x Q x L
s
S x b
2

=
9,8 x 357,4 x 0,020 x 1,14 x 350
3,5 x 0,64
= 3050N
Te = T
x
+ T
y
+ T
z
+ T
us
= 7932 + 30745 + 245176 + 3050
= 286903N
Step 5
The minimum slack side tension to prevent slip is:
The minimum slack side tension to prevent excessive belt sag is:
From Table 8 the estimated belt mass is 14,8 kg/m
Since
T
m
> T
s

T
2
= T
m

i.e. T
2
= 109023N

Step 6
The conveyor is labelled from A to 0 as shown on example sheets 1 to 4.
Step 7
Calculations of the effective tension for each segment (or run) is shown on Sheet 1 for the empty belt, Sheet 2 for the fully loaded belt,
Sheet 3 for the case where only non-decline sections are loaded and Sheet 4 where only the decline sections are loaded.
Step 8
The accumulated effective tension column is the sum of the effective tensions of the current segment and all preceeding segments.
Step 9
The total effective tension for each load case is the value in the last row of the column titled 'Accumulated Effective Tension'.
The reason for the difference between the effective tension determine step 4 and that on Sheet 3 is the more accurate figures used for mass
of the moving parts on the tabulation sheets.
The tension at any point along the conveyor can now be determined, all load cases, by adding the effective tension at the point to the slope
tension at the point and then adding the worst case T
2
value.
The highest T
e
value occurs when all non-declines are loaded. i.e. T
e
= 283609N

Based on this value
T
m
= k x T
e
k = 0,38 from Table 11 and hence
T
m
= 0,38 x 286903
= 109023
T
s
= 9,8S
f
x (B + Q) x I
d
= 9,8 x 6,3 x (14,8 + 357,4) x 1,2
= 27576N
For the empty belt T
e
= 7665N
For the fully loaded belt T
e
= 174188N
For all non-declines loaded T
e
= 283609N
For only declines loaded T
e
= -101755N
T
m
= k x T
e
= 0,38 x 283609N
= 107771N
Since T
s
, calculated in step 5, is less than T
m

T
2
= T
m

i.e. T
2
= 107771N

Thus, for example, the effective tension at run L - M takes the following values:
From these it is determined that the tension at point M under the four cases, given by
T
e
+ T
2
+ T
h
is

Empty belt
4302 + 107771 + 0
= 112073N
Fully loaded belt
-24577 + 107771 + 0
= 83194N
Non-declines loaded
6059 + 107771 + 0
= 113830N
Declines loaded
-26334 + 107771 + 0
= 81437N

1. Empty Belt 4302N
2. Fully loaded - 24577N
3. Non-declines loaded 6059N
4. Declines loaded -26334N
CLIENT NAME CONVEYOR EQUIPMENT NO.
Belt width W 1200 mm
Conveyor length L 500 m
Lift H 45 m
Belt speed S 3,5 m/s
Skirt length L
s
3 m
Lump size 100 mm
Bulk densiy 2,4 t/m
3
Corrected length L
c
570 m
Correction factor C 1,14

Idler Data Carry Return Impact
Trough Angle 35 0 35 degree
Roll Diameter 127 127 159 mm
Spacing 1,2 3,6 0,45 m
Rotating Parts Mass M 19,9 17,1 22,9 kg/set
Friction Factors
Rotating Parts f
x
0,020
Load Friction f
y
0,022
Skirt Friction f
s
0,65
Scraper Friction f
c
0,60
Pulleys Diameter Location
Head 630 mm O
Drive Head mm O
HT Bend - mm -
Tail 500 mm I
Take-up 500 mm E
Take-up Bend 500 mm D,F
LT Bend 450 mm B
Tripper - mm -
Drive & Take-up
Angle of Wrap 210
Drive Surface Lagged Bare
Take-up Type Gravity Screw
Drive Factor k 0,38
SHEET 1 - EMPTY BELT

Run
Length
of Run
(m)
L
r
Idler
Mass
(kg/m)
M
r
=
M/Id
Belt
Mass
(kg/m)
B
Load
Mass
(kg/m)
Q
r
Tension to Overcome Friction (N) Lift
of
Run
(m)
H
r
Tension to
Overcome
Gravity
(N)
9,8QH
r
Effective
Tension
for Run
(N)
T
er
Accumulative
Effective
Tension
(N)
T
e

Absorbed
Power
(W)
T
e
S
Idlers
9,8L
r
Cf
x
M
r
Belt
9,8L
r
Cf
x
B
Pulley
0,01(d
o
/D)
T
2
Load
9,8L
r
Cf
x
Q
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 0 34 10 178 0 0 0 222 3477 12168
K-L 17 16,5 14,8 0 63 56 178 0 0 0 297 3774 13208
L-M 50 16,5 14,8 0 184 165 178 0 -10 0 528 4302 15055
M-N 330 16,5 14,8 0 1217 1091 178 0 70 0 2486 6788 23757
N-O 100 16,5 14,8 0 369 331 178 0 -25 0 887 7665 36829
Lift H 45 m
Skirt length L
s
3 m
Lump size 100 mm
Bulk densiy 2,4 t/m
3
Corrected length L
c
570 m

Spacing 1,2 3,6 0,45 m
Friction Factors
Rotating Parts f
x
0,020
Load Friction f
y
0,022
Skirt Friction f
s
0,65
Scraper Friction f
c
0,60
Head 630 mm O
Drive Head mm O
HT Bend - mm -
Tail 500 mm I
Take-up 500 mm E
LT Bend 450 mm B
Tripper - mm -
Drive & Take-up
Angle of Wrap 210
Drive Factor k 0,38
Run
Length
of Run
(m)
L
r
Idler
Mass
(kg/m)
M
r
=
M/Id
Belt
Mass
(kg/m)
B
Load
Mass
(kg/m)
Q
r
of
Run
(m)
H
r
Tension to
Overcome
Gravity
(N)
9,8QH
r
Effective
Tension
for Run
(N)
T
er
Accumulative
Effective
Tension
(N)
T
e

Absorbed
Power
(W)
T
e
S
Idlers
9,8L
r
Cf
x
M
r
Belt
9,8L
r
Cf
x
B
Pulley
0,01(d
o
/D)
T
2
Load
9,8L
r
Cf
x
Q
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
SHEET 2 - FULLY LOADED BELT

SHEET 3 - NON-DECLINES LOADED
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 357,4 34 10 178 264 0 0 485 3740 13090
K-L 17 16,5 14,8 357,4 63 56 178 1493 0 0 1791 5531 19357
L-M 50 16,5 14,8 357,4 184 165 178 4393 -10 -35028 -30108 -24577 -86019
M-N 330 16,5 14,8 357,4 1217 1091 178 28991 70 245196 276673 252096 882335
N-O 100 16,5 14,8 357,4 369 331 178 8785 -25 -8750 -77908 174188 609659
Lift H 45 m
Skirt length L
s
3 m
Lump size 100 mm
Bulk densiy 2,4 t/m
3
Corrected length L
c
570 m

Spacing 1,2 3,6 0,45 m
Friction Factors
Rotating Parts f
x
0,020
Load Friction f
y
0,022
Skirt Friction f
s
0,65
Scraper Friction f
c
0,60
Head 630 mm O
Drive Head mm O
HT Bend - mm -
Tail 500 mm I
Take-up 500 mm E
LT Bend 450 mm B
Tripper - mm -
Drive & Take-up
Angle of Wrap 210
Drive Factor k 0,38
Run
Length
of Run
(m)
L
r
Idler
Mass
(kg/m)
M
r
=
M/Id
Belt
Mass
(kg/m)
B
Load
Mass
(kg/m)
Q
r
of
Run
(m)
H
r
Tension to
Overcome
Gravity
(N)
9,8QH
r
Effective
Tension
for Run
(N)
T
er
Accumulative
Effective
Tension
(N)
T
e

Absorbed
Power
(W)
T
e
S
Idlers
9,8L
r
Cf
x
M
r
Belt
9,8L
r
Cf
x
B
Pulley
0,01(d
o
/D)
T
2
Load
9,8L
r
Cf
x
Q
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 357,4 34 10 178 264 0 0 485 3740 13090
K-L 17 16,5 14,8 357,4 63 56 178 1493 0 0 1791 5531 19357
L-M 50 16,5 14,8 0 184 165 178 0 -10 0 528 6059 21205
M-N 330 16,5 14,8 357,4 1217 1091 178 28991 70 245196 276673 282732 989559
N-O 100 16,5 14,8 0 369 331 178 0 -25 0 877 283609 992631

SHEET 4 - DECLINES LOADED
Lift H 45 m
Skirt length L
s
3 m
Lump size 100 mm
Bulk densiy 2,4 t/m
3
Corrected length L
c
570 m

Spacing 1,2 3,6 0,45 m
Friction Factors
Rotating Parts f
x
0,020
Load Friction f
y
0,022
Skirt Friction f
s
0,65
Scraper Friction f
c
0,60
Head 630 mm O
Drive Head mm O
HT Bend - mm -
Tail 500 mm I
Take-up 500 mm E
LT Bend 450 mm B
Tripper - mm -
Drive & Take-up
Angle of Wrap 210
Drive Factor k 0,38
Run
Length
of Run
(m)
L
r
Idler
Mass
(kg/m)
M
r
=
M/Id
Belt
Mass
(kg/m)
B
Load
Mass
(kg/m)
Q
r
of
Run
(m)
H
r
Tension to
Overcome
Gravity
(N)
9,8QH
r
Effective
Tension
for Run
(N)
T
er
Accumulative
Effective
Tension
(N)
T
e

Absorbed
Power
(W)
T
e
S
Idlers
9,8L
r
Cf
x
M
r
Belt
9,8L
r
Cf
x
B
Pulley
0,01(d
o
/D)
T
2
Load
9,8L
r
Cf
x
Q
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 0 34 10 178 0 0 0 222 3477 12168
K-L 17 16,5 14,8 0 63 56 178 0 0 0 297 3774 13208
L-M 50 16,5 14,8 357,4 184 165 178 4393 -10 -35028 -30108 -26334 -92169
M-N 330 16,5 14,8 0 1217 1091 178 0 70 0 2486 -23848 -83467
N-O 100 16,5 14,8 357,4 369 331 178 8785 -25 -87570 -77907 -101755 -356143
Belt width W _______ mm
Conveyor length L _______ m
Lift H _______ m
Max capacity _______ t/hr
Belt speed S _______ m/s
Skirt length L
s
_______ m
Material conveyed _______
Lump size _______ mm
Bulk densiy _______ t/m
3
Corrected length L
c
_______ m
Correction factor C _______

Trough Angle _____ _____ _____ degree
Roll Diameter _____ _____ _____ mm
Spacing _____ _____ _____ m
Rotating Parts Mass M _____ _____ _____ kg/set

TENSION TABULATOR
VERTICAL CURVES
Design of vertical curves
It is necessary to calculate the tension at the point under consideration following the method described in Tabulator Calculations.
Concave curves
The worst condition exists when the belt is loaded to the start of the curve and under these conditions the minimum radius of curvature to
prevent the belt lifting off the idlers is
Where
R = radius of curvature (m)
T
p
= Belt tension at the point under consideration (kN)

B = Belt mass per unit length (kg/m)
Convex curve requirements
The following conditions must be satisfied
1. Minimum radius to prevent overstress of the belt edges
Friction Factors
Rotating Parts f
x
_______
Load Friction f
y
_______
Skirt Friction f
s
_______
Scraper Friction f
c
_______
Head _______ mm _______
Drive _______ mm _______
HT Bend _______ mm _______
Tail _______ mm _______
Take-up _______ mm _______
Take-up Bend _______ mm _______
LT Bend _______ mm _______
Tripper _______ mm _______
Drive & Take-up
Angle of Wrap _______
Drive Factor k _______
Run
Length
of Run
(m)
L
r
Idler
Mass
(kg/m)
M
r
=
M/Id
Belt
Mass
(kg/m)
B
Load
Mass
(kg/m)
Q
r
of
Run
(m)
H
r
Tension to
Overcome
Gravity
(N)
9,8QH
r
Effective
Tension
for Run
(N)
T
er
Accumulative
Effective
Tension
(N)
T
e

Absorbed
Power
(W)
T
e
S
Idlers
9,8L
r
Cf
x
M
r
Belt
9,8L
r
Cf
x
B
Pulley
0,01(d
o
/D)
T
2
Load
9,8L
r
Cf
x
Q

R =
113 T
p
B
2. Minimum radius to prevent buckling
3. Maximum allowable change of incline per idler to prevent overstress of belt edges
4. Maximum allowable change of incline per idler to prevent buckling
The curve must be designed with a radius at least large enough to satisfy conditions 1 and 2 and the idler spacing must ensure that
conditions 3 and 4 are satisfied.
t
r
= Rated belt tension (kN/m)

R = Radius of curvature (m)
= Troughing angle (degrees)
W = Belt width (mm)
E = Belt modulus (kN/m)
t
c
= Belt tension at the curve (kN/m)
MAXIMUM INCLINE ANGLE
1. Conventional smooth surface conveyor belts
2. Ruftop package handling belts
3. Chevron top belts
4. Boxes belts with flexible side walls
5. Sandwich type conveyors
6. Elevator belts

GRAPH FOR ESTIMATING BELT LENGTH/ROLLED BELT DIAMETER
Belt length/rolled belt diameter
D = rolled belt diameter (mm)
L = belt length (m)
t = belt thickness (mm)
d = core diameter (mm)
N = number of coils on roll
Belt length:
R =
Sin x W x E
4494 (tr - tc)
R =
Sin x W x E
8988 (tr - 5,2)
=
5,1 (tr - tc) x 1000
W x E x Sin
=
2,55 (tc - 5) x 1000
W x E x Sin
(D + d)N
Rolled belt diameter:

USEFUL DATA CONVERSION FACTORS
Imperial to metric
L = 2

Assuming the length of belt is large and the thickness not
abnormally small, then the core diameter can be neglected in
approximate calculations.
or

Where d 0,3m for general stock belting and up to 0,5m for
heavy rolls of belting, such as steelcord belting or very wide
belts.
To convert from To Multiply by
in mm 25,4
in cm 2,54
ft m 0,3048
in
2 cm2
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