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Dunlop Conveyor Belt Design Manual
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DUNLOP Belting
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Conveyor Belt Design Manual
INDEX
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
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.
http://www.ckit.co.za/Secure/Conveyor/Troughed/belt_tension/Dunlop/Belting%20B...
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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
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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
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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. Fireresistant 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.
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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
2.
of joining the belt.

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.
3.
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.
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:
Q = 0,278
or
Q=
3,600S
The effective tension is made up of 4 components
The tension to move the empty belt Tx
The tension to move the load horizontally Ty
The tension to raise or lower the load Tz
The tension to overcome the resistance of accessories Tu
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The effective tension is the sum of these four components
Te = Tx + Ty + Tz +Tu
Tx = 9,8G x fx x Lc
Tz = 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 Tus
9,8fs x Q x Ls
Tus =
S x b
Tension to overcome the resistance of scrapers
Tuc = A x x fc
In the case of a belt plow the additional tension required to overcome the resistance of each plow is
Tup = 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
Tut = 0,01
do x T 1
Dt
Corrected length Lc
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.
LC = L + 70
The length correction factor is
C=
Lc
L
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 T2, is induced by the take-up system. In the case of a simple horizontal conveyor the
maximum belt tension T1 is the sum of the effective tension Te and the slack side tension T2
ie: T1 = Te + T2
T1 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 T1 = Te + T2 + Th
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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 T1 and T2 is
T1
T2
= e
Since T1 = Te + T2
T2 =
1
e - 1
Te
The expression
1
e - 1
is called the drive factor k. and the value of T2 that will just prevent slip is referred to as the minimum to prevent slip Tm and therefore
Tm = k x T e
Minimum tension to limit belt sag Ts

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.
Ts = 9,8Sf x (B + Q) x ld
The value of the slack side tension must ensure that both conditions are met and therefore T2 must be the larger of Tm or Ts.
Slope tension Th
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.
Th = 9,8B x H
Unit tension T
The maximum belt tension T1 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.
T=
T1
W
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 = Te 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:
Belt width
900 mm
Conveyor Length
250 m
Lift
20 m
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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
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1. Determine mass of the load per unit length
Q=
=
0,278
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.
LC = L + 70
= 250 + 70
= 320 m
C=
=
LC
L
320
250
= 1,28
4. Tension to move the empty belt.
TX = 9,8G x fX x LC
= 9,8 x 55 x 0,022 x 320
= 3794 N
5. Tension to move the load horizontally.
TX = 9,8Q x fY x LC
= 9,8 x 79,4 x 0,027 x 320
= 6723 N
6. Tension to lift the load.
TZ = 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.
Te = T X + T Y + T Z + T U
= 3794 + 6723 + 15562 + 0
= 26079 N
9. The absorbed power
P = Te 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.
Tm = k x T e
= 0,38 x 36079
= 9910 N
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.
TS = 9,8Sf (B + Q) x ld
= 9,8 x 6,3 x (11,1 + 79,4) x 1,2
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= 6705 N
The required slack side tension is the larger of Tm or TS and hence

T2 = 9910 N
11. Slope tension using the estimated belt mass found in Table 8 for medium load and 900 mm belt width is:
Th = 9,8B x H
= 9,8 x 11,1 x 20
= 2176 N
12. The maximum belt tension
T 1 = Te + T 2 + T h
= 26079 + 9910 + 2176
= 38165 N
The maximum belt tension is converted to the unit tension.

Effective tension.
T=
T1
W
38165
900
= 42,4 N/mm
= 42,4 kN/m
TABLE 1 TABLE OF SYMBOLS
Symbols
Description
Unit
Symbol
Description
Unit
Contact area of scraper blade
m2
Sf
Sag factor
Belt mass per unit length
kg/m
Unit tension
kN/m
Width between skirtplates
T1
Maximum belt tension across full belt width
Bc
Edge Distance
mm
T2
Slack side tension
Length correction coefficient
Te
Effective tension
Material Density
kg/m3
Th
Slope tension
Dt
Diameter of pulley t
mm
Tm
Minimum tension to prevent slip
do
Diameter of pulley bearings
mm
Ts
Minimum tension to limit sag
fc
Friction coefficient for scrapers
Tu
Tension induced in overcoming resistance of accessories
fs
Friction coefficient for skirtboards
Tuc
Tension to overcome resistance of scrapers
fx
Friction coefficient for empty belt
Tus
Tension to overcome resistance of skirtboards
fy
Friction coefficient for loaded belt
Tx
Tension to move the empty belt
Mass of moving parts
kg/m
Ty
Tension to move the load horizontally
Change in elevation along conveyor length
Tz
Tension to lift (or lower) the load
ld
Idler spacing (carry idlers)
Belt width
mm
Drive factor
Coefficient of friction between belt and drive pulley
Horizontal length of conveyor
Angle of wrap on the drive radians
radians
Lc
Corrected length of conveyor
Pressure of scraper on the belt
N/m2
Ls
Length of skirtboard
Belt capacity expressed in ton per hour
t/hr
Absorbed power
Trough angle
degree
Mass of load per unit length
kg/m
Material surcharge angle
degree
Belt Speed
m/s
TABLE 2 MATERIAL CHARACTERISTICS
Material
Characteristics
Suggested
Grade
Bulk
Angle of
Max. Rec.
Density Surcharge Conv. Slope
(t/m3) (degrees) (degrees)
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Acid phosphate
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MA
0,96
10
13
Alum
NA
0,80
25
22
Alumina
MA
0,90
10
12
Aluminium sulphate
NA
0,90
20
17
Ammonium chloride
MA
0,80
10
10
Ammonium nitrate
MA
0,70
25
23
Ammonium sulphate, granular
MA
0,80
10
10
Asbestos ore or rock
VA
N/M
1,30
20
18
Asbestos shred
MA
0,37
30
30
Ashes, coal, dry
MA
0,60
25
23
Ashes, coal, wet
MA
0,75
25
25
Ashes, fly
MA
0,70
30
23
Ashes, gas producer, wet
MA
1,20
30
28
Asphalt
NA
1,30
30
30
Bagasse
NA
N/PHR
0,13
30
30
Bark, wood, refuse
NA
0,24
30
27
Barley
NA
N/GF
0,60
10
12
Barytes, powdered
MA
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
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
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
1,20
20
18
Carbon black, pelletised
MA
0,35
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
10
Cement clinker
MA
N/DHR
1,36
25
18
Chalk, lumpy
MA
1,30
10
15
Chalk, 100 mesh and under
MA
1,10
25
28
MA
0,35
25
22
HA/S
2,10
10
17
Cinders, blast furnace
MA
N/M
0,90
10
18
Cinder, coal
MA
0,65
20
20
Clay, calcined
MA
1,44
25
22
Clay, dry, fines
MA
1,76
20
22
Charcoal
Chrome ore
Clay, dry, lumpy
VA
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
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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
HA/S
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
1,70
30
23
Feldspar
VA
N/M
1,44
25
17
Flaxseed
MA
0,70
10
12
Flour, wheat
NA
N/GF
0,60
30
21
Fluorspar
MA
1,70
30
20
Foundry sand, old sand cores etc.
VA
M/PHR
1,36
25
20
Fullers earth, dry
MA
0,50
10
15
Fullers earth, oily
MA
1,00
20
20
HA/S
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
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
1,50
20
20
Gypsum, dust, aerated
MA
1,04
30
23
Gypsum, 12mm screened
MA
1,20
25
21
Gypsum, 75mm lumps
MA
1,20
10
15
Illmenite ore
MA
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
1,00
20
19
Lead ores
MA
3,80
10
15
Lead oxide, heavy
MA
2,40
25
20
Lead oxide, light
MA
1,20
25
20
Lignite, air dried
MA
0,80
10
18
Lime, ground, 3mm and under
NA
1,00
30
23
Lime, hydrated
NA
0,60
25
21
Lime, pebble
MA
0,90
10
17
Limestone, agricultural 3mm and under
MA
1,10
10
20
Limestone, crushed
MA
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
3,60
10
15
Magnesium chloride
MA
0,53
30
23
Magnesium sulphate
MA
1,10
10
15
Manganese ore
VA
N/M
2,15
25
20
Gullet
Glass batch
24/05/2004
Page 12 of 33
Manganese sulphate
MA
1,10
10
15
Marble, crushed 12mm and under
VA
N/M
1,40
10
15
Mica, ground
MA
0,22
20
23
Mica, pulverized
MA
0,22
10
15
Mica, flakes
MA
0,32
Molybdenite, powdered
MA
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
0,27
10
Peanuts, shelled
NA
GF/PVC
0,65
10
Peas, dried
NA
GF/PVC
0,75
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
1,30
10
15
Pumice, 3 mm and under
MA
0,67
30
22
Pyrites, iron, 50 - 75mm in lumps
VA
N/M
2,25
20
17
Pyrites, pellets
Quartz
VA
N/M
2,00
10
15
HA/S
N/M
1,36
10
15
NA
GF/PVC
0,65
HA/S
N/M
2,15
20
18
Rubber, pelletised
MA
0,80
20
22
Rubber, reclaim
NA
0,45
20
18
Rye
NA
GF/PVC
0,70
10
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
Rice
Rock, crushed
Sandstone, broken
VA
N/M
1,44
20
20
Sawdust
NA
N/OR/PVC/W
0,20
25
22
Shale, broken
MA
1,50
10
18
Shale, crushed
MA
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
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
0,80
10
Soda ash, heavy
MA
0,96
20
18
Soda ash, light
MA
0,43
25
22
Sodium nitrate
MA
1,20
10
11
Sodium phosphate
MA
0,90
10
16
Soyabeans, cracked
NA
GF/PVC
0,56
20
18
24/05/2004
Page 13 of 33
Soyabeans, whole
NA
GF/PVC
0,77
10
14
Starch
NA
GF
0,60
10
12
HA/S
2,40
20
18
Sugar, granulated
NA
GF
0,83
10
15
Sugar, raw, cane
MA
0,96
20
22
Sulphate powdered
MA
0,90
10
21
Talc, powdered
NA
0,90
10
12
Titanium ore
VA
N/M
2,40
10
18
Titanium sponge
MA
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
0,25
20
23
Vermiculite, ore
MA
1,20
20
20
Walnut shells, crushed
NA
GF
0,65
20
20
Wheat
NA
N/GF/PVC
0,77
10
12
Steel trimmings
NA
OR/W
0,32
30
27
Zinc ore, crushed
HA/S
2,60
25
22
Zinc ore, roasted
HA/S
SPHR/DHR
1,76
25
25
Woodchips
Characteristics
Key: HA/S - Highly abrasive/sharp

MA - Mildly abrasive
NA - Non-abrasive
VA - Very abrasive
Cover Grade
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
TABLE 2(a) TYPICAL FLOWABILITY
Angle of
Angle of
Material Characteristics
Surcharge Repose
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)
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
24/05/2004
Page 14 of 33
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:
At = (Ab + As) / 106
Where
Ab = (0,371W + 6,3 + M x cos) (M x sin)
As =
0,186W + 3,2 + M x cos

sin
)2 (
180
sin2
2
M = 0,3145W - 3,2 - Bc
W - Belt width (mm)
Bc- Edge distance (mm)
- Iroughing angle (degree)
- Material surcharge angle (degree)
At - Cross sectional load area (m2)
The belt capacity in ton/hour is
Capacity = 3,6At x D x S
Where
D - Material Density (kg/m3)

S - Belt speed (m/s)
TABLE 3 CAPACITIES OF TROUGHED BELT CONVEYORS IN TON/HOUR
Recommended
Belt Max. Lump Size Trough Area of
Load
Width
Angle
Sized Unsized Degrees
mm
m2
mm
mm
600
750
900
125
150
175
200
250
300
Speed m/s
0,5
0,8
1,2
1,6
2,0
2,5
3,0
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
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
20
0,080
144
230
346
461
576
720
864
24/05/2004
1050
1200
1350
1500
1650
1800
2100
2200
200
250
275
300
350
350
350
350
350
400
500
600
700
700
700
700
Page 15 of 33
27
0,090
162
259
389
518
648
810
30
0,092
166
265
397
530
662
828
972
994
35
0,096
173
276
415
553
691
864
1037
45
0,101
182
291
436
582
727
909
1091
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
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
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
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
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
20
0,343
617
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
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
20
0,519
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
934
988
1482 1976 2470 3087 3704
1495 2245 2989 3737 4671 6505
TABLE 4 RECOMMENDED MAXIMUM BELT SPEEDS FOR NORMAL USE (METRES PER SECOND)*
Belt Width
(mm)
Grain or Other
Run of Mine
Hard Ores and Stone Free Flowing Material Coal and Earth + 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
4,0
3,8
1800
24/05/2004
Page 16 of 33
2000 and over
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
Troughing Idler - (m)

Belt Width
(mm)
Bulk Density of Material (t/m3)
Return Idlers
(m)
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
600
1,5
1,5
1,5
1,4
1,4
1,2
1,2
750
1,5
1,4
1,4
1,2
1,2
1,2
1,0
900
1,4
1,4
1,2
1,2
1,0
1,0
1,0
1050
1,2
1,2
1,0
1,0
1,0
1,0
0,9
1200
1,2
1,2
1,0
1,0
1,0
0,9
0,9
1350
1,2
1,0
1,0
1,0
0,9
0,9
0,9
1500
1,2
1,0
1,0
1,0
0,9
0,9
0,9
1650
1,2
1,0
1,0
0,9
0,9
0,9
0,9
1800
1,2
1,0
1,0
0,9
0,9
0,9
0,8
2000 and over 1,0
1,0
0,9
0,9
0,9
0,8
0,8
TABLE 6 FRICTION FACTORS
Value of the friction factor
Symbol
Very well aligned

Normal operating Normal operating
structure with no
conditions.
conditions.
tilted idlers etc. Regenerative
Horizontal length Horizontal length
Horizontal length
conveyor.
up to
more than
more than
250 meters.
250 meters.
500 meters.
Description
fC
Friction coefficient for scrapers
0,600
0,600
0,600
0,600
fS
Friction coefficient for skirtboards
0,650
0,650
0,650
0,650
fX
Friction coefficient for empty belt
0,022
0,020
0,020
0,018
fY
Friction coefficient for loaded belt
0,027
0,022
0,020
0,018
TABLE 7 SAG FACTOR
Percentage Sag Factor

Sag
Sf
3%
4,2
2%
6,3
1,5%
8,4
TABLE 7(a) RECOMMENDED PERCENTAGE SAG
Trough Angle
Fine
Lumps up to Max Lump
Material max lump size
(degree)
Size
20
3%
3%
35
3%
2%
3%
2%
45
3%
2%
1,5%
TABLE 8 ESTIMATED BELT MASS B
24/05/2004
Page 17 of 33
Operating Conditions
Belt Width
Light Duty Medium Duty Heavy Duty
(mm)
(kg/m)
(kg/m)
(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
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)
3 Roll Carry Idlers
Return Idlers
Roll Dia
Roll Dia
Belt Width
3 Roll Impact Idlers

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
TABLE 10 MASS OF MOVING PARTS G
Mass of Moving Parts (kg/m)

Belt Width
Light Duty
Medium Duty
Heavy Duty
Extra Heavy Duty
(mm)
102mm Idlers 127mm Idlers 152mm Idlers
152mm Idlers
Steel Cord Belt
Light Belt
Moderate Belt
Heavy 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
24/05/2004
Page 18 of 33
TABLE 11 DRIVE FACTOR k
Screw
Take-up
Angle of
Belt Wrap
at Drive
Type
of
Drive
150
Plain
1,5
160
Plain
1,4
170
Plain
180
Bare Lagged
Pulley Pulley
Gravity or Automatic
Winch Take-up
Bare
Pulley
Lagged
Pulley
1,0
1,08
0,670
0,9
0,99
0,600
1,3
0,9
0,91
0,550
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
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:
3.
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.
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).
24/05/2004
Page 19 of 33
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
Textile Reinforced Multi-ply and

Steelcord Reinforced Conveyor Belting
Solid Woven Carcass 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
630
50,0
St 500
75,0
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
TABLE 13 RECOMMENDED MINIMUM PULLEY DIAMETERS (mm)
Textile Reinforced Rubber Belting

Belt Class Pulley Type
2
160
200
250
315
400
500
630
Solid Woven
PVC Belting
No. of Plies
3
Steelcord
Reinforced
Rubber Belting
315
250
200
315
250
200
315
400
250
315
200
250
315
400
400
250
315
315
200
250
400
500
630
400
315
400
500
315
250
315
400
500
500
630
630
500
500
400
400
500
500
400
400
315
315
400
400
315
315
500
630
630
800
500
500
400
500
500
630
400
400
315
400
400
500
315
315
250
250
24/05/2004
800
1000
1250
1600
2000
2500
3150
4000
5000
6300
Page 20 of 33
630
800
800
800
500
500
500
630
630
630
400
400
400
500
500
500
315
315
630
800
1000
1000
630
500
500
630
800
800
500
400
400
500
630
630
400
315
1000
1000
1250
800
630
800
800
1000
630
500
630
630
800
500
400
1000
1250
1250
1000
800
800
1000
1000
800
630
630
800
800
630
500
1250
1400
1000
800
1000
1250
800
630
800
1000
630
500
1000
800
630
1250
1000
800
1250
1000
800
1400
1250
1000
1400
1250
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
C Low tension pulleys Wrap up to 45
High tension snub or bend pulleys

Low tension snub or bend pulleys
TABLE 14 LOAD SUPPORT
Recommended maximum belt width (mm) for correct load support. Multi-ply textile reinforced rubber belting.
Belt Spec
A
Light Duty
kg/m3
Up to 800
- 25mm Lumps
B
Light to Medium Duty
kg/m3
Up to 1200
- 50mm Lumps
C
Medium Duty
kg/m3
Up to 1600
- 100mm Lumps
D
Heavy Duty
kg/m3
E
Extra Heavy Duty
Up to 2400
- 250mm Lumps
Up to 3000 kg/m3
+ 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
24/05/2004
Page 21 of 33
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
TABLE 15 MAXIMUM NUMBER OF PLIES RECOMMENDED FOR CORRECT EMPTY BELT TROUGHING
Belt Width (mm)

Belt
Troughing
Class 350 400 450 500 600 750 900 1050 1200 1350 1500 1650 1800 2100 2200
Angle
160
200
250
315
400
500
630
800
1000
1250
1600
2000
20
35
20
35
20
35
20
35
20
35
20
35
20
35
20
35
20
35
20
35
20
35
20
35
TABLE 16 CARCASS THICKNESS (mm)
Belt Class

Solid Woven Steelcord Reinforced
No. of Plies
PVC Belting
Rubber Belting
2
3
4
5
160
2,0
200
2,6
250
2,7
3,2
315
2,8
3,5
4,9
24/05/2004
Page 22 of 33
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
12,0
13,0
12,4
5,4
2000
2500
7,0
3150
8,0
4000
9,0
5000
11,0
6300
12,0
Add the thickness of the covers to get the total belt thickness
TABLE 17 MASS OF BELT CARCASS (kg/m2)

No. of Plies
Belt Class
Solid Woven
PVC Belting Steelcord Reinforced
With Nominal
Rubber Belting
PVC Coating
160
2,8
200
3,0
250
3,1
3,9
315
3,4
4,2
400
3,7
4,4
6,0
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
14,2
14,9
18,0
15,3
9,0
2000
9,4
2500
18,7
3150
22,4
4000
28,4
5000
35,1
6300
38,7
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)
Grade of Cover
Mass
(kg/m2)
Grade of Cover
Mass
(kg/m2)
1,14
PHR
1,17
1,10
SPHR
1,21
OR
1,41
DHR
1,34
GF
1,37
PVC
1,37
FR
1,27
Nitrile
1,32
RATE OF WEAR VS THICKNESS OF COVER
24/05/2004
Page 23 of 33
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
Material Class A
Material Class B
Material Class C
Material Class D
Non abrasive material

Abrasive material
Very abrasive material Very sharp abrasive material
such as lime, charcoal, such as salt, anthracite such as slag, copper ore, such as quartz, some ores,
Cycle
wood chips, bituminous coal, phosphate rock,
foundry refuse, glass batch,
sinter, coke sand,
time
iron borings
limestone, fullers earth
flue dust
coal grain
s
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
Cycle time - 2L/S
TABLE 20 BELT MODULUS (kN/m)
Belt Class
Multi-ply
Steelcord
Textile
Solid Woven
Reinforced
Reinforced PVC Belting
Rubber Belting
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
24/05/2004
Page 24 of 33
5000
300000
6300
377200
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.
4.
Calculate the mass of the load from the design capacity and the belt speed.
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.
6.
7.
8.
9.
Determine the minimum value for the slack side tension under maximum load condition.
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.
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.
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.
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
T2 value i.e. the value of T2 which
a.
prevents slip at the highest Te value and,
b.
limits sag between carry idlers.
It may be found that the value of T2 obtained when the maximum effective tension has been calculated is different to that used in the
calculations. If this is the case the new T2 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
Belt width
Conveyor length
Lift
Max capacity
Belt speed
Skirt length
Material conveyed
Lump size
1200 mm
500 m
45 m
4500 t/hr
3,5 m/s
3 m
Iron Ore
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

Drive wrap
0,45 m
210 degree
Drive surface
Rubber lagged
Take-up type
Gravity
Step 1
24/05/2004
Page 25 of 33
Calculate the length correction factor
C=
L + 70
L
570
=
=
500
1,14
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
Q=
=
=
0,278
0,278 x 4500
3,5
357,4 kg/m
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 Tx and
only the loaded length to calculate Ty. 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.
Tx = 9,8G x fx C x L
= 9,8 x 71 x 0,020 x 1,14 x 500
= 7932N
Effective tension to move the load horizontally.
Ty = 9,8Q x fy C x L
= 9,8 x 357,4 x 0,020 x 1,14 x 350
= 30745N
Effective tension to lift the load.
Tz = 9,8Q x H
= 9,8 x 357,4 x 70
= 245176N
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.
9,8fs x Q x Ls
Tus =
=
S x b2
9,8 x 357,4 x 0,020 x 1,14 x 350
3,5 x 0,64
= 3050N
The total effective tension is the sum of the above four.
Te = Tx + Ty + Tz + Tus
= 7932 + 30745 + 245176 + 3050
= 286903N
24/05/2004
Page 26 of 33
Step 5
The minimum slack side tension to prevent slip is:
Tm = k x T e
k = 0,38 from Table 11 and hence
Tm = 0,38 x 286903
= 109023
The minimum slack side tension to prevent excessive belt sag is:
Ts = 9,8Sf x (B + Q) x Id
= 9,8 x 6,3 x (14,8 + 357,4) x 1,2
= 27576N
From Table 8 the estimated belt mass is 14,8 kg/m
Since
Tm > Ts
T2 = Tm
i.e. T2 = 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'.
For the empty belt
Te = 7665N
For the fully loaded belt
Te = 174188N
For all non-declines loaded Te = 283609N

For only declines loaded
Te = -101755N
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 T2 value.
The highest Te value occurs when all non-declines are loaded. i.e. Te = 283609N
Based on this value
Tm = k x T e
=
0,38 x 283609N
107771N
24/05/2004
Page 27 of 33
Since Ts, calculated in step 5, is less than Tm
T2 = Tm
i.e. T2 = 107771N
Thus, for example, the effective tension at run L - M takes the following values:
1. Empty Belt
4302N
2. Fully loaded
- 24577N
3. Non-declines loaded 6059N

4. Declines loaded
-26334N
From these it is determined that the tension at point M under the four cases, given by
Te + T2 + Th 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
CLIENT NAME
Belt width
CONVEYOR EQUIPMENT NO.

W
1200 mm
Conveyor length
500 m
Lift
45 m
Max capacity
4500 t/hr
Belt speed
3,5 m/s
Skirt length
Ls
Material conveyed
3 m
Iron Ore
Lump size
100 mm
Bulk densiy
Corrected length
Lc
Correction factor
Idler Data
Carry Return Impact
Trough Angle
35
35
2,4 t/m3
Roll Diameter
127
127
159
mm
570 m
Spacing
1,2
3,6
0,45
17,1
22,9
kg/set
1,14
Rotating Parts Mass M 19,9
degree
Friction Factors
Rotating Parts fx
0,020
Load Friction fy
0,022
Skirt Friction fs
Scraper Friction fc
Drive Surface
Take-up Type
0,65
Drive
Head
mm
0,60
HT Bend
mm
Tail
500
mm
Take-up
500
mm
Take-up Bend
500
mm
D,F
LT Bend
450
mm
Tripper
mm
Drive Factor k
Bare
Gravity
Location
mm
210
Lagged
Diameter
630
Drive & Take-up

Angle of Wrap
Pulleys
Head
Screw
0,38
24/05/2004
Length
of Run
Run
(m)
Lr
Idler
Mass
(kg/m)
Mr =
M/Id
Page 28 of 33
Tension to Overcome Friction (N)

Lift Tension to Effective Accumulative
Load
Absorbed
Belt
of Overcome Tension
Effective
Mass
Power
Pulley
Mass
Run
Gravity
for Run
Tension
Idlers
Belt
Load
(W)
(kg/m) (kg/m)
0,01(do/D)
(N)
(N)
(N)
(m)
9,8LrCfxMr 9,8LrCfxB
9,8LrCfxQ
B
Qr
T eS
T2
9,8QHr
Ter
Te
Hr
A-B
14,8
178
185
185
647
B-C
98
5,7
14,8
125
324
25
449
634
2218
C-D
15
5,7
14,8
19
50
178
-3
247
881
3082
D-E
14,8
178
178
1059
3706
E-F
14,8
178
178
1237
4330
F-G
330
5,7
14,8
420
1091
-67
1512
2749
9621
G-H
50
5,7
14,8
64
165
10
229
2978
10422
H-I
20
5,7
14,8
25
66
178
270
3248
11367
I-J
14,8
3255
11390
J-K
50,9
14,8
34
10
178
222
3477
12168
K-L
17
16,5
14,8
63
56
178
297
3774
13208
L-M
50
16,5
14,8
184
165
178
-10
528
4302
15055
M-N
330
16,5
14,8
1217
1091
178
70
2486
6788
23757
N-O
100
16,5
14,8
369
331
178
-25
887
7665
36829
SHEET 1 - EMPTY BELT
CLIENT NAME
Belt width

W
1200 mm
Conveyor length
500 m
Lift
45 m
Max capacity
4500 t/hr
Belt speed
3,5 m/s
Skirt length
Ls
Material conveyed
3 m
Iron Ore
Lump size
100 mm
Bulk densiy
2,4 t/m3
Corrected length
Lc
Correction factor
Idler Data
570 m
Carry Return Impact
Trough Angle
35
35
Roll Diameter
127
127
159
mm
Spacing
1,2
3,6
0,45
17,1
22,9
kg/set
1,14
degree
Friction Factors
Rotating Parts fx
0,020
Load Friction fy
0,022
Skirt Friction fs
Scraper Friction fc
Pulleys
mm
0,65
Drive
Head
mm
0,60
HT Bend
mm
Tail
500
mm
Take-up
500
mm
Take-up Bend
500
mm
D,F
LT Bend
450
mm
Tripper
mm
210
Drive Surface
Lagged
Take-up Type
Drive Factor k
Length
of Run
Run
(m)
Lr
Idler
Mass
(kg/m)
Mr =
M/Id
Bare
Gravity
Location
630
Drive & Take-up

Angle of Wrap
Diameter
Head
Screw
0,38

Load
Absorbed
Belt
of Overcome Tension
Effective
Mass
Power
Pulley
Mass
Run
Gravity
for Run
Tension
Idlers
Belt
Load
(W)
(kg/m) (kg/m)
0,01(do/D)
(N)
(N)
(N)
(m)
9,8LrCfxQ
B
Qr
T eS
T2
9,8QHr
Ter
Te
Hr
A-B
14,8
178
185
185
647
B-C
98
5,7
14,8
125
324
25
449
634
2218
C-D
15
5,7
14,8
19
50
178
-3
247
881
3082
D-E
14,8
178
178
1059
3706
E-F
14,8
178
178
1237
4330
F-G
330
5,7
14,8
420
1091
-67
1512
2749
9621
G-H
50
5,7
14,8
64
165
10
229
2978
10422
H-I
20
5,7
14,8
25
66
178
270
3248
11367
24/05/2004
Page 29 of 33
I-J
14,8
3255
11390
J-K
50,9
14,8
357,4
34
10
178
264
485
3740
13090
K-L
17
16,5
14,8
357,4
63
56
178
1493
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
SHEET 2 - FULLY LOADED BELT
CLIENT NAME
Belt width
1200 mm
Conveyor length
500 m
Lift
45 m
Max capacity
4500 t/hr
Belt speed
3,5 m/s
Skirt length
Ls
Material conveyed
3 m
Iron Ore
Lump size
100 mm
Bulk densiy
Corrected length
Lc
Correction factor
Idler Data
Carry Return Impact
Trough Angle
35
35
2,4 t/m3
Roll Diameter
127
127
159
mm
570 m
Spacing
1,2
3,6
0,45
17,1
22,9
kg/set
1,14
degree
Friction Factors
Rotating Parts fx
0,020
Load Friction fy
0,022
Skirt Friction fs
Scraper Friction fc
Pulleys
mm
0,65
Drive
Head
mm
0,60
HT Bend
mm
Tail
500
mm
Take-up
500
mm
Take-up Bend
500
mm
D,F
LT Bend
450
mm
Tripper
mm
210
Drive Surface
Lagged
Take-up Type
Drive Factor k
Length
of Run
Run
(m)
Lr
Idler
Mass
(kg/m)
Mr =
M/Id
Bare
Gravity
Location
630
Drive & Take-up

Angle of Wrap
Diameter
Head
Screw
0,38

Load
Absorbed
Belt
of Overcome Tension
Effective
Mass
Power
Pulley
Mass
Run
Gravity
for Run
Tension
Idlers
Belt
Load
(kg/m)
(W)
(kg/m)
0,01(do/D)
(N)
(N)
(N)
(m)
9,8LrCfxQ
B
Qr
T eS
T2
9,8QHr
Ter
Te
Hr
A-B
14,8
178
185
185
647
B-C
98
5,7
14,8
125
324
25
449
634
2218
C-D
15
5,7
14,8
19
50
178
-3
247
881
3082
D-E
14,8
178
178
1059
3706
E-F
14,8
178
178
1237
4330
F-G
330
5,7
14,8
420
1091
-67
1512
2749
9621
G-H
50
5,7
14,8
64
165
10
229
2978
10422
H-I
20
5,7
14,8
25
66
178
270
3248
11367
I-J
14,8
3255
11390
J-K
50,9
14,8
357,4
34
10
178
264
485
3740
13090
K-L
17
16,5
14,8
357,4
63
56
178
1493
1791
5531
19357
L-M
50
16,5
14,8
184
165
178
-10
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
369
331
178
-25
877
283609
992631
SHEET 3 - NON-DECLINES LOADED
CLIENT NAME
24/05/2004
Page 30 of 33
Belt width
1200 mm
Conveyor length
500 m
Lift
45 m
Max capacity
4500 t/hr
Belt speed
3,5 m/s
Skirt length
Ls
Material conveyed
3 m
Iron Ore
Idler Data
Carry Return Impact
Lump size
100 mm
Trough Angle
35
35
Bulk densiy
2,4 t/m3
Roll Diameter
127
127
159
mm
Spacing
1,2
3,6
0,45
17,1
22,9
kg/set
Corrected length
Lc
Correction factor
570 m
1,14
degree
Friction Factors
Rotating Parts fx
0,020
Load Friction fy
0,022
Skirt Friction fs
Scraper Friction fc
Pulleys
mm
0,65
Drive
Head
mm
0,60
HT Bend
mm
Tail
500
mm
Take-up
500
mm
Take-up Bend
500
mm
D,F
LT Bend
450
mm
Tripper
mm
210
Drive Surface
Lagged
Take-up Type
Drive Factor k
Length
of Run
Run
(m)
Lr
Idler
Mass
(kg/m)
Mr =
M/Id
Bare
Gravity
Location
630
Drive & Take-up

Angle of Wrap
Diameter
Head
Screw
0,38

Load
Absorbed
Belt
of Overcome Tension
Effective
Mass
Power
Pulley
Mass
Run
Gravity
for Run
Tension
Idlers
Belt
Load
(W)
(kg/m) (kg/m)
0,01(do/D)
(N)
(N)
(N)
(m)
9,8LrCfxQ
B
Qr
T eS
9,8QHr
Ter
Te
Hr
T2
A-B
14,8
178
185
185
647
B-C
98
5,7
14,8
125
324
25
449
634
2218
C-D
15
5,7
14,8
19
50
178
-3
247
881
3082
D-E
14,8
178
178
1059
3706
E-F
14,8
178
178
1237
4330
F-G
330
5,7
14,8
420
1091
-67
1512
2749
9621
G-H
50
5,7
14,8
64
165
10
229
2978
10422
H-I
20
5,7
14,8
25
66
178
270
3248
11367
I-J
14,8
3255
11390
J-K
50,9
14,8
34
10
178
222
3477
12168
K-L
17
16,5
14,8
63
56
178
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
1217
1091
178
70
2486
-23848
-83467
N-O
100
16,5
14,8
357,4
369
331
178
8785
-25
-87570
-77907
-101755
-356143
SHEET 4 - DECLINES LOADED
CLIENT NAME
Belt width
Conveyor length
_______ mm
_______ m
Lift
_______ m
Max capacity
_______ t/hr
Belt speed
_______ m/s
Skirt length
Ls
Material conveyed
_______ m
_______
Lump size
_______ mm
Bulk densiy
_______ t/m3
Idler Data
Carry Return Impact
Trough Angle
_____ _____
_____ degree
Corrected length
Lc
_______ m
Roll Diameter
_____ _____
_____ mm
Correction factor
_______
Spacing
_____ _____
_____ m
Rotating Parts Mass M _____ _____
_____ kg/set
24/05/2004
Page 31 of 33
Friction Factors
Rotating Parts fx
_______
Load Friction fy
_______
Skirt Friction fs
Scraper Friction fc
Drive Surface
Take-up Type
Drive Factor k
Idler
Mass
(kg/m)
Length
of Run
Run
(m)
Mr =
M/Id
Lr
Gravity
Location
mm
_______
Drive
_______
mm
_______
_______
HT Bend
_______
mm
_______
Tail
_______
mm
_______
Take-up
_______
mm
_______
Take-up Bend
_______
mm
_______
LT Bend
_______
mm
_______
Tripper
_______
mm
_______
_______
Lagged
Diameter
_______
Drive & Take-up

Angle of Wrap
Pulleys
Head
Bare
Screw
_______
_______

Load
Absorbed
Belt
of Overcome Tension
Effective
Mass
Power
Pulley
Mass
Run
Gravity
for Run
Tension
Idlers
Belt
Load
(kg/m)
(W)
(kg/m)
0,01(do/D)
(N)
(N)
(N)
(m)
9,8LrCfxQ
B
Qr
T eS
T2
9,8QHr
Ter
Te
Hr
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
R=
113 Tp
B
Where
R = radius of curvature (m)

Tp = 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
24/05/2004
R=
2.
Sin x W x E
8988 (tr - 5,2)
Maximum allowable change of incline per idler to prevent overstress of belt edges
4.
Sin x W x E
4494 (tr - tc)
Minimum radius to prevent buckling
R=
3.
Page 32 of 33
5,1 (tr - tc) x 1000

W x E x Sin
Maximum allowable change of incline per idler to prevent buckling
2,55 (tc - 5) x 1000

W x E x Sin
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.
tr = Rated belt tension (kN/m)

R = Radius of curvature (m)
= Troughing angle (degrees)
W = Belt width (mm)
E = Belt modulus (kN/m)
tc = 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:
(D + d)N
24/05/2004
L=
Page 33 of 33
Rolled belt diameter:
or
Assuming the length of belt is large and the thickness not
abnormally small, then the core diameter can be neglected in
approximate calculations.
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.
USEFUL DATA CONVERSION FACTORS
Imperial to metric
To convert from
To
Multiply by
in
mm 25,4
in
cm
2,54
ft
0,3048
in2
cm2
24/05/2004
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Dunlop Conveyor Belt Design Manual

Conveyor Belt Design Manual

Dunlop Conveyor Belt Design Manual

DUNLOP CONVEYOR BELTING RANGE

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

Riffled concentrator belting

Grey food belting

Salmon pink food belting

Oil resistant belting

Solid woven PVC belting

Standard solid woven PVC belting

Nitrile covered PVC 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

Dunlop Conveyor Belt Design Manual

High speed truly endless belting

XT Rubber Conveyor Belting (conforms to SABS 1173-1977)

Cut resistant XT Rubber Belting

Phoenix Heat Resistant Belting

Super Phoenix Heat Resistant Belting

Delta Hete Heat Resistant Belting

Fire Resistant Belting (conforms to SABS 971-1980)

Riffled Concentrator Belts

Food Quality Belting

Dunlop Conveyor Belt Design Manual

Solid Woven (PVC) Belting (conforms to SABS 971-1980)

Nitrile Covered (PVC) Belting

Steelcord Belting (conforms to SABS 1366-1982)

Oil Resistant Belting

Shuron Breaker Ply (XT belting)

Chevron Breaker (XT belting)

Dunlop Conveyor Belt Design Manual

SABS 1173-1977 - General purpose textile reinforced conveyor belting.

SABS 971-1980 - Fire-resistant textile reinforced conveyor belting.

SABS 1366-1 982- Steelcord reinforced conveyor belting.

Further information regarding SABS specifications will be supplied on request.

CONVEYOR BELT DESIGN

A conveyor belt comprises two main components:

of joining the belt.

provide load support for the duty.

conform to the contour of the troughing idlers when empty, and

flex satisfactorily around the pulleys used on the conveyor installation.

Mass of Moving Parts

Mass of the load per unit length

The effective tension is made up of 4 components

The tension to move the empty belt Tx

The tension to move the load horizontally Ty

The tension to raise or lower the load Tz

The tension to overcome the resistance of accessories Tu

Dunlop Conveyor Belt Design Manual

The effective tension is the sum of these four components

Tension required to overcome the resistance of skirtboards Tus

Tension to overcome the resistance of scrapers

The length correction factor is

T1 is the tight side tension and 12 is the slack side tension