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CONVEYOR BELT
HAND BOOK
JBS Kumar Page 1
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Foreword
This CONVEYOR HANDBOOK is provided by WE to allow desi!ers to sele"t the "orre"t
spe"i#i"atio! belti! #or a!y parti"$lar i!stallatio!% This is &$st a e!eral $ideli!e a!d #i!al
de"isio!s are to be ta'e! by the $ser based o! a"t$al wor'i! "o!ditio!s%
(roperties o# #abri"s $sed i! (olyester Nylo! )$lti*ply belti! "o!str$"tio!s are ive! i! detail+
while the e!eral properties a!d appli"atio! areas o# spe"ial )$lti*ply "o!str$"tio!s+ solid
wove!+ Ara)id a!d steel belti! are also show!%
The $se o# vario$s !at$ral a!d sy!theti" r$bbers with these rei!#or"e)e!ts #or ha!dli!
di##ere!t servi"e "o!ditio!s is set o$t #or the desi!er%
Desi! "o!sideratio!s a##e"ti! power de)a!ds+ belt "$rves+ tra!sitio!s et"%+ are provided%
Whilst $sers are vitally i!terested i! these desi! "o!sideratio!s #or "o!veyors+ there is a
spe"ial se"tio! o! #a$lt dia!osis to e!able $sers to ide!ti#y "a$ses o# tro$bles whi"h )ay
o""$r a!d "orre"t the) be#ore belt da)ae either o""$rs or be"o)es e,te!ded%
The layo$t o# this )a!$al a!d easy approa"h to belt desi! will be readily #ollowed by belt
desi! e!i!eers%
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Index
1. Material o! "ontr#"tion
Rei!#or"e)e!ts ---------------------------- . * .
/e!eral (roperties --------------------------%% . * 0
$. Belt Ca%a"itie
Capa"ity Cal"$latio!s -------------------------% 1 * .
(roperties o# 2aterials -------------------------% 1 * 1
&. Belt 'ower and Tenion
Belt (ower Cal"$latio!s 3or)$lae -------------------% 0 * .
Cal"$latio! o# 2a,i)$) Te!sio!s -%------------------%% 0 * 4
/rad$ated 5dler 6pa"i!s -----------------------%%% 0 * 7
3eeder Belt Cal"$latio!s ------------------------% 0 * 8
A""eleratio! a!d De"eleratio! ---------------------%% 0 * .9
Appli"atio! o# 3or"es -------------------------%% 0 * .:
Alebrai" 6i!s o# Co!veyor 3or"es ------------------%% 0 * .4
Coasti! -------------------------------%% 0 * .;
Che"' <ist #or <are Co!veyor 6yste)s ----------------%%% 0 * .7
(. Belt Car"a )ele"tion
Belt Co!str$"tio! Re=$ire)e!ts -------------------%- : * .
Co!sideratio!s -%--------------------------- : * .
(ro"ed$re ---%%--------------------------- : * 1
*. Co+er ,a#-e and .#alitie
Co!sideratio!s----------------------------- 4 * .
6ele"tio!------%-------------------------%%4 * .
($lley side "over---------------------------- 4 * .
/. '#lle0 Dia1eter
(arallel #a"e p$lleys--------------------------%% ; * .
Crow! #a"e p$lleys--------------------------- ; * 1
($lley #a"e width---------------------------- ; * 1
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2. Dei-n Conideration
2$ltiple 6lope a!d Verti"al C$rve Co!veyors --------------%%% 7 * .
Ter)i!al Tro$hi! 5dler Arra!e)e!ts -----------------% 7 * :
Tra!sitio!s -------------------------%%-----%7 * :
Ta'e * >p Arra!e)e!ts ------------------------%% 7 * 4
3. ,eneral Data
Belt 2ass a!d thi"'!ess---------%%---------------% ? * .
6hippi! di)e!sio!s a!d roll si@es-----------%------%%%-%% ? * .
<e!th o# belt o! a roll----------------------%%%--% ? * 1
Belt tra!sport $ideli!es---------------------%---% ? * 0
4. )olid 5o+en Beltin-
Belt "o!str$"tio!----------------------------% 8 * .
Belt a!d "over thi"'!ess------------------------%% 8 * 1
Operati! te)perat$re ra!e----------------------%% 8 * 1
Operati! #a"tor o# sa#ety------------------------% 8 * 1
6a#ety-------------------------------- 8 * 1
16. Tro#7le )8ootin-
/e!eral 2ai!te!a!"e %-------%%----------------- .9 * .
<oadi! poi!t "o!sideratio!s------------------%%---% .9 * 1
Ra!do) eve!ts ----------------------------% .9 * :
Tro$bleshooti! -------%----------------%----% .9 * 4
11. Belt Intallation9 Maintenan"e and tro#7le 8ootin-
1$. Belt V#l"aniation
1&. Ta7le
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1 0
1. Material o! "ontr#"tion
Rei!#or"e)e!ts ----------------------------%% . A .
/e!eral (roperties --------------------------- . A 0
Table . Rei!#or"e)e!t 3abri"s ------------------- . A 1
Table 1A Cover Co)po$!ds --------------------%%% . A :
Table 1B Heat Resista!t Belts -------------------- . A 4
Table 1C Oil B Che)i"al Resista!t ------------------ . A ;
Table 1D 3ire Resista!t B A!ti 6tati" Belts --------------%% . A 7
1. Material o! "ontr#"tion
The "o)positio! o# a "o!veyor belt "a! be "o!sidered i! two partsC
A% The Car"ass+ whether ply type Dte,tileE or steel "ord "o!str$"tio!+ whi"h )$st have
s$##i"ie!t stre!th to ha!dle the operati! te!sio!s a!d to s$pport the load%
B% The Covers+ whi"h )$st have the re=$ired physi"al properties a!d "he)i"al resista!"e to
prote"t the "ar"ass a!d ive the "o!veyor belt a! e"o!o)i"al li#e spa!%
The e!eral properties a!d the appli"atio! $sae o# the )ore e"o!o)i"al available
rei!#or"e)e!t #abri"s a!d r$bber "o)po$!ds are dis"$ssed i! this se"tio!%
REINFORCEMENTS
Fabrics
3abri"s that are "o))o!ly $sed as rei!#or"e)e!t i! "o!veyor belts are show! i! Table . o#
this 6e"tio!
The #abri" desi!atio! i!di"ates the )aterial $sed i! both warp a!d we#t+ e%% E( si!i#ies that
the #abri" has (olyester warp #ibers a!d Nylo! we#t #ibers%
The $lti)ate stre!th o# the belt i! 'ilo !ewto!s per )etre width is show! alo! with the
!$)ber o# plies% E(.999F: desi!ates a belt with #o$r plies o# polyester warp+ !ylo! we#t #abri"
a!d a! $lti)ate #$ll*belt te!sile stre!th o# .999 'NF)% Alter!atively the belt "a! be o#te!
des"ribed as : ply E(149 where the stre!th o# the i!divid$al plies is show!%
The allowable wor'i! te!sio!s allo"ated are show! i! tables . a!d 1 i! se"tio! :%
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GENERAL PROPERTIES OF BELT COVERS AND GRADES
The #ollowi! tables ive a "o)pariso! o# e!eral "hara"teristi"s o# poly)ers $sed i! belti!
"o)po$!ds%
6pe"ial "o)po$!di! "a! res$lt i! s$bsta!tial "ha!es to these e!eral poly)er properties%
/e!erally "o!veyor belts are s$pplied with ele"tri"al resista!"e i! the a!ti*stati" ra!e a!d
sho$ld !ot be $sed #or ele"tri"al i!s$latio!% 6pe"ial !o!*"o!d$"tive rades are available o!
re=$est%
There are #o$r separate tablesC
Belts for Mining !"arr#ing an$ General Ser%ice
&eat Resistant belts
Oil an$ C'e(ical Resistant gra$es
Fire Resistant an$ Anti)static belts
Notes re#erred to i! these tables areC
.% Available with e,te!ded o@o!e resista!"e "apabilities o! spe"ial re=$est%
1% The low te)perat$re per#or)a!"e #i$res ive! i! the table are represe!tative o# e!eral
p$rpose "o)po$!ds i! ea"h "lassi#i"atio!% Belts #or operatio! at lower te)perat$res tha!
those ive! are available o! re=$est%
0% The hih te)perat$re per#or)a!"e #i$res ive! i! the table are represe!tative o# sit$atio!s
where the belt is s$b&e"t to relatively lo! e,pos$res o# bla!'eti! heat% Co!siderably hiher
te)perat$re b$l' )aterial "a! o#te! be "arried i! ve!tilated sit$atio!s or where the belt s$r#a"e
"a! be shielded to so)e e,te!t by a prote"tive layer o# "ooled #i!es%
:% Resist )ost a"ids e,"ept "o!"e!trated stro!ly o,idisi! ie%+ 6$lph$ri"+ Nitri" a!d their
derivatives%
4% 3ire resista!t a!d a!ti*stati" radesC
/RADE 6 )eets A6:;9; #or >NDER/RO>ND COA< 25N5N/%
/RADE E+ 3 #ire resista!t a!d a!ti*stati" * )ostly #or ENC<O6ED ABOVE /RO>ND >6E
/RADE K #ire retarda!t a!d a!ti*stati" * )eets 26HA 1/ a!d 56O:00 re=$ire)e!ts
;% Resists )ost oils however resista!"e )ay vary reatly depe!di! o! the type o# oil%
7% 2ay have poor resista!"e to oils with low a!ili!e poi!ts%
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(. Belt Car"a )ele"tion
Belt Constr"ction Re*"ire(ents +++++++++++++++++++ , ) -
Consi$erations +.+++++++++++++++++++++++++++, ) -
Proce$"re +++..+++++++++++++++++++++++++ , ) /
Table .A Allowable Wor'i! Te!sio!s A 6ta!dard "o!str$"tio!s-----%% : * 0
Table .B Allowable Wor'i! Te!sio!s A Coal 2aster series-------%% : * :
Table 1A <oad s$pport table A 6ta!dard "o!str$"tio!s---------%% - : * 4
Table 1B <oad s$pport table A Coal 2aster series------------- : * ;
Table 0 Belt tro$hability A---------------------% : * 7
(. Belt Car"a )ele"tion
BELT CONSTR0CTION RE!0IREMENTS.
To sele"t the opti)$) plied belt "ar"ass+ #ive properties )$st be "o!sideredC
The belt width%
The servi"e "o!ditio!s $!der whi"h the belt will operate%
The )a,i)$) operati! te!sio! DT )a,E A both steady state "o!ditio! a!d pea' Dsee
table .E%
The )i!i)$) !$)ber o# plies re=$ired to s$pport the load Dsee tables 1E%
The )a,i)$) !$)ber o# plies beyo!d whi"h tra!sverse #le,ibility is red$"ed a!d the
tro$hi! e##i"ie!"y is a##e"ted% This varies with the belt width+ tro$h a!le a!d the
idler roll arra!e)e!t Dsee table 0E%
CONSIDERATIONS1
O2erating con$itions
The allowable wor'i! te!sio!s show! o! Table . that #ollow are appli"able #or reaso!ably
well )ai!tai!ed "o!veyors operati! with )oderate i)pa"t+ i!#re=$e!t starts a!d ood loadi!%
(ea' te!sio! A o! starti! or bra'i!+ sho$ld !ot e,"eed .:9G o# the allowable wor'i!
te!sio!%
3or )ore severe operati! "o!ditio!s+ )oderate )ai!te!a!"e+ short ti)e "y"les+ #re=$e!t DO<
or loaded starts+ poor loadi! or severe i)pa"t+ hot )aterials ha!dli! et"%+ red$"e the tabled
#i$res by .4G% Te!sio! o! starti! or bra'i! sho$ld !ot e,"eed .49G o# the res$lti! rated
te!sio!%
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3or severe servi"e "o!ditio!s+ poor )ai!te!a!"e+ very hot )aterials+ "he)i"ally aressive
e!viro!)e!t+ severe i)pa"t a!d short ti)e "y"les et"%+ red$"e the tabled #i$res by 09G%
Te!sio! o! starti! or bra'i! sho$ld !ot e,"eed .;9G o# the res$lti! rated te!sio!%
Safet# factors
The wor'i! te!sio!s show! o! these tables are based o! the appli"atio! o# a sa#ety #a"tor o#
;%7C. o! the stre!th o# the belt at the spli"e or #aste!ed &oi!% The sa#ety #a"tor is i!"reased #or
)ore di##i"$lt operati! "o!ditio!s with #$rther restri"tio!s applyi! #or starti! a!d bra'i!%
Starting an$ bra3ing tensions
A "he"' sho$ld always be )ade "o)pari! the a""eleratio! or bra'i! te!sio! with the
allowable pea' te!sio! #or the belt+ i%e% .:9G o# rated wor'i! te!sio!% 5# the pea' te!sio!
e,"eeds the latter #i$re+ a stro!er belt "a! be sele"ted or the "hoi"e o# "o!trol )$st be
"ha!ed to red$"e pea' te!sio!%
Mec'anical fasteners
WE always re"o))e!d hot v$l"a!ised spli"es #or plai! weave plied belti!% Other
"o!str$"tio!s i!"l$di! the Crows 3oot Weave+ Do$ble Weave a!d 6olid Wove! (VC "a! be
s$""ess#$lly operated at "lose to v$l"a!i@ed &oi!t te!sio!s #or lo! periods o# ti)e whereas
plai! weave "o!str$"tio!s e!erally operate at red$"ed te!sio!s whe! #itted with )e"ha!i"al
#aste!ers
Re"o))e!ded pre"a$tio!s i!"l$di! #re=$e!t i!spe"tio! a!d )o!itori!+ a!y <o"al A$thority
restri"tio!s a!d reater tha! !or)al "are sho$ld always be observed whe! $si! 2e"ha!i"al
3aste!ers% Belt "lea!ers sho$ld o!ly be #itted i# spe"i#i"ally s$ited to operatio! with )e"ha!i"al
#aste!ers
5# a "o!veyor belt is to be operated #or a!y le!th o# ti)e with )e"ha!i"al #aste!ers the! the
sele"ted "o)bi!atio! o# belt a!d #aste!er sho$ld be stati"ally te!sile tested a!d a wor'i!
te!sio! o# !ot )ore tha! .4G o# that res$lt% Table . lists WE re"o))e!datio!s #or its "o))o!
ra!e o# belts%
Tro"g'abilit# an$ loa$ s"22ort
This table provides a $ide to the )a,i)$) width o# belt that will s$pport the load whe!
"arryi! )aterial with the b$l' de!sity show!%
This table provides a $ide to the )i!i)$) width o# belt that will tro$h satis#a"torily at the
tro$h a!le show!% The widths show! above are a $ide o!ly a!d e,perie!"e )ay di"tate the
sele"tio! o# a ply )ore or a ply less%
6o)e #a"tors that )ay i!#l$e!"e the "hoi"e areC
(artially #illed belt%
5dler tro$h a!le
Co!ve, or "o!"ave "$rve radi$s a!d idler pit"h
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<$)p si@e o# )aterial
5!stalled p$lley dia)eters
PROCED0RE1
Co!sider t'e 2ossible belt constr"ctions.
.% Cal"$late wor'i! te!sio! !eeded #or the both steady state a!d pea' Da""elerati! or
bra'i!E%
Re=$ired Wor'i! Te!sio! D'NF)E H T)a, D'NE
Belt width D)E
WhereC T)a,% H (ea' or 6teady 6tate te!sio! i! "o!veyor D'NE%
1% Co!sideri! operati! "o!ditio!s a!d starti! a!d bra'i! te!sio!s a!d deter)i!e s$itable
belt "o!str$"tio!s #ro) tables .A a!d .B% Wor'i! te!sio!s show! i! tables .A a!d .B are
appli"able #or reaso!ably well*)ai!tai!ed "o!veyors with )oderate i)pa"t+ i!#re=$e!t starts
a!d ood loadi! a!d are red$"ed where operati! "o!ditio!s are less #avo$rable * see
dis"$ssio! below%
0% Co!sider spe"ial !eeds a!d the $se o# spe"ial #abri"s s$"h as CrowIs #oot or Do$ble
weaves%
:% Establish the vario$s pra"ti"al "ar"assF ply !$)ber "o)bi!atio!s to s$pport the load #or the
"o!veyor wor'i! "o!ditio!s $!der review * DTablesE% <oad s$pport re=$ire)e!ts )ay
di"tate that the sele"ted belt is operati! at a #ra"tio! o# itIs allowable wor'i! te!sio!%
4% Che"' that the sele"ted "o!str$"tio!DsE are a""eptable #or tro$hi! * DTable 0E
;% Che"' that the i!stalled p$lley dia)eters are ade=$ate A Dre#er se"tio! ;E
T'e final selection s'o"l$ be c'ec3e$ 4it' 5E since cost a%ailabilit# an$ ser%ice
criteria can be a$$itional factors for consi$eration.
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*. Co+er ,a#-e and .#alitie
Consi$erations+++++++++++++++++++++++++++++ 6 ) -
Selection++++++.+++++++++++++++++++++++++.. 6 ) -
P"lle# si$e co%er++++++++++++++++++++++++++++ 6 ) -
Table - To2 Co%er T'ic3ness ++++++++++++++++++++++ 6 7 /
*. Co+er -a#-e and :#alitie
CONSIDERATIONS
There are a !$)ber o# #a"tors that )$st be ta'e! i!to a""o$!t whe! sele"ti! the belt rade or
"over )aterial+ s$"h asC
3ire resista!"e or a!ti*stati" properties
Resista!"e to oils or "he)i"als
Te)perat$re o# the operati! e!viro!)e!t or "o!veyed )aterial
Resista!"e to aei!+ weatheri! a!d o@o!e%
The type o# )aterial bei! "o!veyed
The l$)p si@e a!d shape o# the )aterial bei! "o!veyed
The )i, o# l$)ps a!d #i!es i! the )aterial
The abrasive!ess o# the )aterial
The )ethod o# loadi! the belt
The #all heiht o# )aterial to the belt
The "y"le ti)e o# the "o!veyor #or a si!le revol$tio! o# the belt
(er#or)a!"e or e,perie!"e i! a si)ilar appli"atio!
3or repla"e)e!t belts A the per#or)a!"e o# previo$s belts o! the sa)e i!stallatio!
Availability a!d "ost
SELECTION
(revio$s e,perie!"e will always be the best $ide to the opti)$) sele"tio! o# both the type
a!d thi"'!ess o# belt "over+ however i# this i!#or)atio! is !ot available as will be the "ase #or
!ew i!stallatio!s+ the #ollowi! steps sho$ld be #ollowed%
3ro) table . A 1 sele"t the )ost s$itable "over types o# "over or belt rades #or the
appli"atio!% 5! so)e "ases stat$tory re=$ire)e!ts or the operati! "o!ditio!s will li)it
sele"tio!s to o!e or two possibilities%
Cal"$late the ti)e "y"le o# the "o!veyor H D1 , <E
6
WhereC< H "o!veyor "e!tres D)E
6 H belt speed D)FsE
>se table . as a $ide to sele"t the appropriate thi"'!ess o# top "over% Co!sideratio!
sho$ld be ive! to the appli"able properties o# the "over i! )a'i! this sele"tio!%
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3or di##i"$lt appli"atio!s s$"h as belt #eeders+ or i)pa"t belts+ heavier "overs )ay be re=$ired%
P0LLE8 SIDE COVER
As a $ide+ p$lley side "over sho$ld e!erally be !ot less tha! .F: o# "arry side "over #or
"overs $p to 8)) a!d abo$t .F0 o# "arry "over thi"'!ess #or "overs heavier tha! 8))%
Operati! "o!ditio!s "a! di"tate that heavier p$lley side "overs are re=$ired%
3or lo! "e!tre+ lo! ti)e "y"le "o!veyors+ p$lley side "over "a! be $p to .F1 o# "arry side
"over%
/. '#lle0 Dia1eter
Parallel face 2"lle#s++++++++++++++++++++++++++.. 9 ) -
Cro4n face 2"lle#s+++++++++++++++++++++++++++ 9 ) /
P"lle# face 4i$t'++++++++++++++++++++++++++++ 9 ) /
Table . 6ta!dard "o!str$"tio!s
A operati! at over ;9G o# allowable wor'i! te!sio! ------ ; * 0
Table 1 6ta!dard "o!str$"tio!s
A operati! at 09 * ;9G o# allowable wor'i! te!sio! -%----- ; * :
/. '#lle0 dia1eter
The )i!i)$) p$lley dia)eter re"o))e!ded #or a parti"$lar belt depe!ds $po! three #a"torsC
Car"ass Thi"'!ess A The wire rope dia)eter i! the "ase o# 6teel Cord belts%
* The overall thi"'!ess o# all plies pl$s the r$bber s'i)s betwee!
plies i! the "ase o# (ly Type belts%
*The overall thi"'!ess o# the thi"' wove! #abri" separati! the top
a!d botto) "overs i! the "ase o# 6olid*wove! belts%
Operati! Te!sio! A The relatio!ship o# the operati! te!sio! o# the belt at the
parti"$lar p$lley to the beltIs Allowable Wor'i! Te!sio!%
Car"ass )od$l$s A The relatio!ship betwee! elo!atio! o# the "ar"ass a!d the
res$lti! stress%
Whatever the "ar"ass type+ 6teel Cord+ (ly Type or 6olid Wove!+ whe! the belt is be!t aro$!d
a s)all radi$s+ te!sio! stresses are developed i! the o$ter #ibers while "o)pressio! stresses
are b$ilt $p i! the i!!er #ibers% At a ive! te!sio!+ i# the radi$s is too s)all the elasti" li)it o#
the o$ter #ibers )ay be e,"eeded a!d #ra"t$re+ a!d at the sa)e ti)e+ the "o)pressio! o# the
i!!er #ibers )ay "a$se severe "ri!'li! a!d eve!t$al ply separatio!%
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6i!"e the elasti" properties o# the r$bber or (VC "over )aterial is so )$"h reater tha! the
"ar"ass )aterial+ the "over thi"'!ess o# the belti! is !ot a #a"tor i! deter)i!i! )i!i)$)
p$lley si@e+ a!d )ay be i!ored%
The tables o# re"o))e!ded p$lley dia)eters i! the 5N35N5TY ha!dboo' #or (ly Type belti!
are based o! the three "lasses o# p$lleys de#i!ed i! 56O 0;?:% vi@%J
Type KA A Hih te!sio! F tiht side p$lleys DT.E e%% head+ drive+ tripper a!d sh$ttle
p$lleys
Type KB A <ow te!sio! or sla"' side p$lleys DT1E s$"h as tail a!d ta'e $p p$lleys
Type KCL A <ow te!sio! s!$b or be!d p$lleys with wrap a!le o# less tha! 09 derees
Two sets o# ($lley Dia)eter tables #ollowC
3or belts operati! at over ;9G o# allowable wor'i! te!sio! Table . * #or sta!dard belt
"o!str$"tio!s

3or belts operati! at 09 A ;9G o# allowable wor'i! te!sio! Table 1 * #or sta!dard
belt "o!str$"tio!s
3or belts operati! at less tha! 09G o# the allowable wor'i! te!sio!+ the dia)eter o# Type KA
p$lleys "a! be red$"ed to the sa)e as Type KB%
PARALLEL FACE P0LLE8S
With &$st a #ew spe"ial e,"eptio!s+ all p$lleys $sed with )oder! hih stre!th+ hih )od$l$s
#abri" belts sho$ld be parallel #a"e types% 5t is absol$tely )a!datory that all p$lleys $sed i!
"o!veyors #itted with 6teel Cord belti! be parallel #a"e type% O!e !otable e,"eptio! to this
r$le is i! the "ase o# B$"'et Elevators whi"h+ la"'i! a!y other )ea!s o# tra"'i! the belt
"e!trally+ )ay be!e#it #ro) Crow! 3a"ed ($lleys%
CRO5N FACE P0LLE8S
A Crow! 3a"ed p$lley "a! have the e##e"t o# "e!teri! the tra"'i! o# the belt+ b$t o!ly i! the
"ase where there is a lo! $!s$pported le!th o# belt leadi! i!to the p$lley+ as the belt )$st
be able to be!d lo!it$di!ally alo! its "e!tre li!e to be!e#it #ro) the "row!% Hih )od$l$s (ly
Type belts have very little ability to be!d lo!it$di!ally a!d 6teel Cord belts have virt$ally !o
ability at all% 6olid Wove! belts are !ot =$ite so riid b$t still !eed a! $!s$pported dista!"e o#
so)ethi! li'e : to ; ti)es the belt width to be able to rea"t%
Apart #ro) !ot servi! )$"h p$rpose i! tro$hed "o!veyor syste)s+ Crow!ed p$lleys "a!
serio$sly da)ae the belt by severely overstressi! the "ar"ass i! the "e!tre o# the belt+
parti"$larly i! the "ase o# 6teel Cord belts%
The #ew spe"ial "ases where Crow!ed p$lleys are $se#$l i!"l$de+ B$"'et Elevators+ the Ta'e*
$p p$lley i! lo! ravity Ta'e*$p arra!e)e!ts a!d #or so)e short "e!tre * wide belt+
reversi! "o!veyors% 5! "ases li'e this where there are !o s$pporti! idlers to trai! the belt+
so)e be!e#it )ay be obtai!ed #ro) the i!stallatio! o# Crow!ed p$lleys%
5t is #airly "o))o! pra"ti"e to "row! a p$lley by )a"hi!i! a taper o# . i! .99 #ro) ea"h p$lley
ede
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towards the "e!tre over a dista!"e o# .F: p$lley #a"e% 5t is )ore "orre"t to relate the a)o$!t o#
p$lley
"row! to the p$lley dia)eter+ !ot to its #a"e width% Vi@%J $ : D ) ;.;;< = D
P0LLE8 FACE 5IDT&
As all belts te!d to wa!der a bit i! operatio!+ the overall #a"e width o# the p$lleys sho$ld
e,"eed the
belt width by the #ollowi! )i!i)$) a)o$!ts+ i# serio$s ede da)ae is to be avoidedJ
Belts $p to ;49)) wide -% -% -% -% -% -% -% -% .99))
Belts 749 to .:99)) wide -% -% -% -% -% -% -% -% .49))
Belts over .:99)) wide -% -% -% -% -% -% -% -% 199))
3or "o!veyors b$ilt o! $!stable ro$!d+ as i! $!derro$!d "oal )i!es a!d very lo! overla!d
"o!veyors+ the above allowa!"es sho$ld be i!"reased by 49))%
2. Dei-n Conideration
M"lti2le Slo2e an$ Vertical C"r%e Con%e#ors ++++++++++++++.. > ) -
Ter(inal Tro"g'ing I$ler Arrange(ents +++++++++++++++++. > ) ,
Transitions +++++++++++++++++++++++++..++++... > ) ,
Ta3e 7 02 Arrange(ents ++++++++++++++++++++++++. > ) 6
Table . Averae Elasti" 2od$l$s MEI ------------%- 7 * 0
Table 1 Tra!sitio! Dista!"es #or Head ($lleys --------- 7 * :
Table 0 Tra!sitio! Dista!"es #or Tail E!d <oadi! (oi!ts ---%%- 7 * 4
Table : /ravity Ta'e A >p Travel ------------%%-- 7 * ;
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3. ,eneral Data
Belt Mass and thickness..,,,,,,,,,,, 8 - 1
Shipping dimensions and roll sizes.... 8 - 1
Length of belt on a roll... 8 - 2
Belt transport gidelines. 8 - !
Table 1 Belt carcass mass and thickness
standard constructions 8 - 4
Table 2 Belt carcass mass and thickness
CoalMaster series 8 - 5
Table 3 Belt carcass and cover mass actors!! 8 "
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MISSING TABLE
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4. )olid 5o+en Beltin-
Belt constrction. " - 1
Belt and co#er thickness.. " - 2
$perating temperatre range.. " - 2
$perating factor of safet%. " - 2
Safet%. " - 2
Table 1 Belt #esi$nations!! !!!! 11 2
4. )olid 5o+en 7eltin-
B&L' ($)S'*+(',$)
%ena&last conve'or beltin$ consists o three main com&onents( -
Te)tile *olid +oven Carcass
,-C .m&re$nation
Cover Material
'-& '&.',L& (/*(/SS
The solid-/oven carcass is $enerall' /oven /ith n'lon or &ol'ester load bearin$ /ar& ibers and n'lon
or n'lon0cotton /et! *'nthetic binder 'arns ollo/ a com&le) &attern to $ive the carcass its solid-/oven
&ro&erties! -arious combinations o s'nthetic1 and natural ibers are chosen1 to$ether /ith the abric
desi$n to meet the re2uirements o im&act resistance1 belt elon$ation1 le)ibilit' or trou$hin$ and small
diameter &ulle's1 load su&&ort and astener retention! The &atented %ena&last ,-C im&re$nation
method also renders the carcass im&ervious to attach rom moisture1 dirt1 chemicals1 bacteria1 and oils!
Cotton &ile /ar& 'arns ma' be included or im&roved im&act resistance and s&ecial ed$e reinorcement
can be included /here these are &articular &roblems! The %ena&last carcass desi$n acilit' enables
users to choose the &ro&erties o a custom-built belt!
3ll %ena&last belts have a solid /oven carcass /here all la'ers o 'arn are mechanicall' interlocked
durin$ the /eavin$ &rocess and bound to$ether b' a sel bindin$ /ar& 'arn inter/eave1 thus makin$
subse2uent delimitation im&ossible! 4i$h tenacit' continuous ilament s'nthetic 'arns are used or the
/ar& ie len$th direction51 such 'arns also &rovide most o the necessar' stren$th in the /et
6transverse0/idth5 direction!
01( ,M0*&2)/',$)
3ter /eavin$ the roll o carcass is vacuum im&re$nated /ith ,-C &lastisol containin$ a careul blend o
&ol'mer1 &lastici7ers1 stabilisers1 ire retardants1 and s&ecial additives1 /ith s&ecial attention bein$ $iven
to viscosit' control in order to ensure ull im&re$nation o the /oven structure!
+hilst the te)tile elements i) man' o the belts &ro&erties such as tensile stren$th and elon$ation in
service1 the &ro&erties o the &lastisol are e2uall' im&ortant1 and it8s ormulation /ill inluence not onl'
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the ire &erormance &ro&erties but also o&erational actors such as trou$habilit' and the abilit' to hold
asteners!
($1&* M/'&*,/L
PVC co%ers
,-C covers to meet numerous ire resistance s&eciications or or other &ro&erties such as resistance
to oils1 chemicals1 ertili7er etc!1 are $enerall' available u& to 3mm thick &er side! The' can also be
com&ounded to $ive im&roved abrasion resistance or coeicients o riction!
R"bber co%ers
9ubber covers to a s&eciied saet' standard ma' be a&&lied on one or both sides o a ,-C
im&re$nation &arent belt u& to a ma)imum o "mm : 2mm1 de&endent on belt /idth1 tensile and
construction! *9 /ear-resistant nitrile rubber covers are also available1 sin$le or double sided1 u&
to "mm : 2mm ma)imum1 de&endent on belt construction!
B&L' /)3 ($1&* '-,(4)&SS
+hen considerin$ cover thickness the user should be a/are o the thick1 hi$h te)tile content o
%ena&last and the s&ecial solid-/oven carcass &ro&erties! Conse2uentl' thinner covers ma' $enerall'
be chosen than normal /ith rubber1 &lied beltin$; the %ena&last carcass bein$ more substantial and
&rovidin$ the necessar' load su&&ort and im&act resistance!
$0&*/',)2 '&M0&*/'+*& */)2&
3bove <=C ,-C sotens and the belt &ro&erties chan$e1 thereore %ena&last is not recommended or
conve'in$ materials above this tem&erature! *tandard %ena&last can be used in cold climates at minus
15C and s&ecial cover com&ounds are available or o&eration do/n to minus 4=C! Cold /eather
details should be su&&lied to ensure a belt /ith suitable coeicient and le)ibilit' characteristics is
su&&lied!
$0&*/',)2 5/('$* $5 S/5&'6
+ith $ood 2ualit' mechanical asteners or vulcani7ed >oints a actor o saet' o 8(1 ma' be acce&table!
S/5&'6
%ena&last is used e)tensivel' in under$round coal mines and as such it e)hibits e)cellent %ire
9esistant1 3nti-*tatic &ro&erties!
.n 3ustralia it is manuactured to 3* 1332 and is tested to 3*1334!
.t meets or e)ceeds all o the re2uirements o 3* 4"="-2===!
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BE<T DE65/NAT5ONC Belts "a! be prod$"ed to vario$s te!sile spe"i#i"atio!s+ $si! either polya)ide orpolyester
base warp yar!% 6o)e )ar'ets still pre#er to spe"i#y belt types based o! te!sile stre!the,pressed i! 5bsFi! width
Dthe 3e!aplast Belt Desi!atio! $ses this ter)i!oloyE+ whilst others opt #or thepre#erred 56O types e,pressed i!
'NF)%
BE<T WE5/HT6C The above table shows so)e typi"al #i$res #or )i!i)$) warp a!d we#t stre!ths+ belt
thi"'!ess a!d weiht #or a sele"tio! o# belt types+ based o! 5!* (VC "overs% 3or thi"'er "overs+ add .%0
'F)1F)) #or (VC "overs a!d .%: 'F)1F)) #or r$bber "overs% The !o)i!al #i$res =$oted #or thi"'!ess a!d
weiht are based o! spe"i#i" belt "o!str$"tio!s a!d (VC "overs o# l ))% Alter!ative belt "o!str$"tio!s )ay vary
these #i$res whi"h are o!ly #or i!di"ative p$rposes a!d establishi! shippi! "apa"ities%
A<TERNAT5VE CON6TR>CT5ON6C 2a!y alter!ative "o!str$"tio!s are available whi"h ive val$es hihertha!
those i! the table% This is parti"$larly releva!t to we#t stre!th+ where spe"ial yar!s desi!s )ay be
re"o))e!ded #or i)proved properties s$"h #aste!er holdi!+ load s$pport+ we#t stability et"% The $se o# s$"h
spe"ial yar!s )ay i!"rease the belt weiht a!d thi"'!ess whi"h )ay be "riti"al #or shippi! p$rposes or
$!derro$!d tra!sportatio!% A! A(EN 3ENNER e!i!eer sho$ld always be "o!s$lted where this i!#or)atio! is
li'ely to be "riti"al%
(><<EY D5A2ETER6C The dr$) dia)eters are the )i!i)$) re"o))e!ded witho$t "o)plete appli"atio! details%
With i!#or)atio! reardi! wrap "o!#i$ratio!s+ te!sio!s+ belt speeds+ &oi!ti! )ethods+ et"%+ it )aybe possible to
a""ept s)aller dr$)s%
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16. Tro#7le )8ootin-
2eneral Maintenance ..... 17 8 1
Loading point considerations.. 17 - 2
*andom e#ents 17 - 9
'robleshooting ... 17 - :
16. Tro#7le 8ootin-
2&)&*/L M/,)'&)/)(&
Conve'or beltin$ re&resents a ver' si$niicant &ortion o the overall &lant cost and as such
/arrants re$ular ins&ection and maintenance to &rotect this investment! Broadl' s&eakin$1
a&art rom normal /ear1 rubber conve'or beltin$ ails throu$h chemical attack or mechanical
dama$e in one orm or another!
(hemicals such as all $reases1 oils1 solvents and animal ats should be removed as
soon as detected rom belts not desi$ned to handle these materials! *usce&tible belts
includin$ all natural rubber belts should be /ashed do/n /ith /ater and deter$ent
immediatel' ater contamination!
$zone is a common cause o &remature ailure in natural rubber and man' s'nthetic
and rubber belts1 &articularl' /hen o&eratin$ near the sea1 enclosed near electrical
machiner' or in a salt' environment! .?%.?.T@ belts are su&&lied /ith hi$h levels o
o7one resistance1 and this level o &rotection can be increased b' s&ecial re2uest at the
time o orderin$ or e)treme conditions!
Mechanical damage is best &revented b' clean desi$n and erection1 6no >a$$ed ed$es5
$ood &ath clearance1 $enerous belt &aths1 re2uent checkin$ and &rom&t remed'in$ o
all aults!
Belt cleaners &erorm a ver' im&ortant role in the &rotection o the belt! ,ro&erl' sited
and itted the' &rotect the belt rom dama$e throu$h(
o Tra&&in$ o material bet/een return belt li$ht and &ulle'!
o Belt /ander throu$h runnin$ o as material orms a cro/n on the &ulle'!
o #ama$e to &ulle' ace throu$h belt ed$e sla&&in$ and $rindin$ at the &ulle' ace
ed$es!
o *&ill rom the return side buildin$ u& under the belt to dama$e both belt and
return idlers!
o Belt cleaners must be selected careull' and deserve re2uent attention!
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,dlers - 3ll nois' idler should be looked at immediatel'! 3ll >ammed or
broken idlers should be removed immediatel'! 4ot idlers should be hosed do/n and
remain under su&ervision /hilst the conve'or is sto&&in$ and do/n to ambient
tem&erature! .t must be removed immediatel' the conve'or is sto&&ed! 3 >ammed idler
causes increased riction resultin$ in e)cess cover /ear hi$her &o/er consum&tion and
ma' create suicient heat to start a ire /hen the belt sto&s!
0lle%s - Material tra&&ed bet/een a &ulle' and the belt ma' cause belt
/ander and i hard lum&s are &resent ma' ru&ture the belt! ,lou$h cleaners should be
itted /herever a s&ill onto the return belt is carried onto a &ulle'! This is crucial at hi$h
tension &ulle's but can lead to trackin$ and loadin$ &roblems ater the tail &ulle'!
'ake-p ma' be a$to)ati" or )a!$al. The 3utomatic Take-u& is the most
desirable as &ro&erl' maintained1 it is able to maintain the correct tension in the belt under all
normal o&eratin$ conditions includin$ startin$1 runnin$1 sto&&in$ and chan$es in belt len$th
caused b' chan$es in ambient and o&eratin$ tem&erature !
. or an' reason the 3utomatic Take-u& travel becomes restricted or >ammed1 belt sli&&a$e at the drive
ma' occur1 this /ill cause e)treme dama$e to the belt!
The Manual Take-A& has the advanta$es o com&actness and lo/ cost1 ho/ever it is unable to
maintain o&timum tension throu$h the normal o&eratin$ conditions includin$ startin$1 runnin$1 sto&&in$
and chan$es in belt len$th caused b' chan$es in ambient and o&eratin$ tem&erature!
Be a;are o abnormal or chan$ed noises emanatin$ rom the conve'or as these1 i let unattended
could lead to a ire1 $earbo) or &ulle' 0 cou&lin$ ailure to name >ust t/o items! The ollo/in$ &lant
items should be re2uentl' listened to and looked at! 3nal'se the &roblem and take maintenance
&recautions!
L$/3,)2 0$,)' ($)S,3&*/',$)S<
(htes, loading boots and skirts - These items are re2uent trouble s&ots /hen itted too closel' to
the belt! The' can cause ra&id localised cover /ear and in e)treme cases1 slit the belt!
Conversel' /hen installed /ith too much clearance1 material is allo/ed to s&ill over1 oten allin$ onto
the return belt and buildin$ u& on the tail &ulle' causin$ trackin$ &roblems in the loadin$ boot urther
e)acerbatin$ the &roblem! . the s&illed material is hard1 the belt ma' also be &unctured!
3lso to be considered is /ed$in$ bet/een a chute /all and the belt! .n the mildest occurrence1 this
/ill accelerate the cover /ear1 in more severe occurrences the belt carcass is &ermanentl' dama$ed!
Most /ear and tear on the belt takes &lace at the loadin$ &oint! The manner o loadin$ ma' inluence
the lie e)&ectanc' o the belt and the com&onents o the loadin$ boot! Boadin$ &oints should be
arran$ed /ith &articular care and the ollo/in$ &oints should be observed(
The material bein$ conve'ed should be ed onto the belt at belt s&eed in the runnin$ direction o the
belt!
The hei$ht o the dro& rom the eedin$ &oint onto the belt should be as small as &ossible!
.m&act idlers should be installed at the loadin$ &oints!
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'he follo;ing sketches sho; some loading point arrangements.
Loading 0oint /rrangements
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*/)3$M &1&)'S /)3 (/+S&S $5 B&L' 3/M/2&
'*/M0 ,*$)
Most ri&s1 some continuin$ the entire len$th o the belt1 are caused b' tram& iron becomin$
/ed$ed into the belt at loadin$ chutes! . this ha7ard is &revalent1 the installation o a
mechanical or ma$netic detector to sto& the belt ma' be >ustiied! #an$erous material can be
ma$neticall' e)tracted or some reliable ri& detection0&rotection device ma' be /arranted!
+ork &ractices and vi$ilance amon$ all em&lo'ees and contractors can also reduce this
&roblem!
M,)$* *&0/,*S
Anless re&aired1 minor tears 2uickl' become ma>or re&airs or catastro&hic ailure! Carl'
detection and &rom&t attention is the best lon$-term strate$'!
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INSTALLATION,
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M AI
STORAGE
New conveyor be! "#o$% be "!ore% $&r'(#! 'n !#e )*c!ory &*c+*(e $n!' $"e%, A coo %ry roo-. )ree
)ro- "$n'(#!. "!e*- &'&e". o' *n% corro"'ve )$-e" '" be"!, /n%er no con%'!'on" "#o$% ro" o) be! be
*'% )*! on * concre!e )oor, Mo'"!$re w' "#r'n+ *ny e0&o"e% )*br'c w#'c# (e!" %*-& )ro- "$c# "!or*(e
*n% !#e be! '" '*be !o bow on one e%(e, /&r'(#! ro" on * %ry woo%en )oor '" reco--en%e%,
HANDLING THE ROLL
1onveyor be!'n( '" c$"!o-*r'y &*c+*(e% 'n cy'n%r'c* ree" or ro" w#'c# -*y be roe% )ro- &*ce !o
&*ce, A ro" *re -*r+e% w'!# *n *rrow "#ow'n( !#e %'rec!'on 'n w#'c# !#ey "#o$% be roe%, 23'(, 14
5o'n( 'n * %'rec!'on o&&o"'!e !o !#*! o) !#e *rrow !en%" !o oo"en *n% !ee"co&e !#e be!,
5ee" or ro" "#o$% never be %ro&&e% )ro- * )re'(#! c*r. !r$c+. or o!#er -e*n" o) convey*nce "'nce
!#e'r we'(#! w' bre*+ !#e &*c+*('n( *n% -*y %*-*(e !#e be!, 5ee" or ro" "#o$% *w*y" be roe% or
&rov'"'on "#o$% be -*%e )or #o'"!'n( !#e-, 3or #o'"!'n(. * b*r '" &*""e% !#ro$(# !#e #oe 'n !#e cen!er
o) !#e ro, 1#*'n" or c*be" oo&e% *ro$n% !#e b*r en%" "#o$% be &rov'%e% w'!# * "&re*%er *bove !#e
ro !o *vo'% %*-*(e !o !#e be! e%(e",
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INSTALLATION
Once the roll of belting has been transported to the point of installation it should be mounted on a
suitable shaft for unrolling and threading onto the conveyor. Conveyor belting is normally rolled at the
factory with the carrying side out. Consequently, in mounting the roll the belt must lead off the top of the
roll if it is being pulled onto the troughing or carrying idlers but off the bottom of the roll if it is being
pulled onto the return idlers. When pulling the belt onto the conveyor, the roll will turn opposite the
direction indicated by the arrows on the crate. ig. ! illustrates a suitable method of mounting as well
as leading off the top of the roll for pulling onto the troughing idlers.
"n some cases, such as in mines where head room does not permit maneuvering a roll, the belt may have
to be pulled off the roll and reefed. #ig. $% &'treme care should be e'ercised to see that the loops have
large bends to avoid (in(ing or placing undue strain on the belt, and no weight should ever be placed on
the belt when it is in this position. )nother method of handling belting under such conditions is to lay
the roll on a turntable with a vertical spindle.
OOTING
INSTALLATION, MAINTENANCE & TROUBLESHOOTING
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TRAINING THE BELT
*raining the belt is a process of ad+usting idlers, pulleys and loading conditions in a manner which will
correct any tendency of the belt to run other than centrally.
When all portions of a belt run off through a part of the conveyor length the cause is probably in the
alignment or leveling of the conveyor structures, idlers or pulleys in that area.
"f one or more portions of the belt run off at all points along the conveyor the cause is more li(ely in the
belt itself, in the splices or in the loading of the belt. When the belt is loaded off,center the center of
gravity of the load tends to find the center of the troughing idlers, thus leading the belt off on its lightly
loaded edge. #-ee ig. .%
*hese are the basic rules for diagnosis of belt running ills. Combinations of these things sometimes
produce cases that do not appear clear,cut as to cause but if a sufficient number of belt revolutions is
observed the running pattern will become clear and the cause disclosed. *he usual cases when a pattern
does not emerge are those of erratic running which may be found on an unloaded belt that does not
trough well or a loaded belt which is not receiving its load uniformly centered.
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FACTORS AFFECTING THE TRAINING OF A BELT
Pulleys and Snubs
/elatively little steering effect is obtained from the crown of conveyor pulleys. Crown is most effective
when there is a long unsupported span of belting, #appro'imately four times belt width% approaching the
pulley. )s this is not possible on the conveyor carrying side, head pulley crowning is relatively
ineffective and is not worth the lateral mal,distribution of tension it produces in the belt.
*ail pulleys may have such an unsupported span of belt approaching them and crowning may help
e'cept when they are at points of high belt tension. *he greatest advantage here is that the crown, in
some degree, assists in centering the belt as it passes beneath the loading point which is necessary for
good loading. *a(eup pulleys are sometimes crowned to ta(e care of any slight mis,alignment which
occurs in the ta(eup carriage as it shifts position
)ll pulleys should be level with their a'is at 00 to the intended path of the belt. *hey should be (ept that
way and not shifted as a means of training with the e'ception that snub pulleys may have their a'is
shifted when other means of training have provided insufficient correction. 1ulleys with their a'es at
other than 00 to the belt path will lead the belt in the direction of the edge of the belt which first
contacts the mis,aligned pulley. When pulleys are not level the belt tends to run to the low side. *his is
contrary to the old rule of thumb statement that a belt runs to the high side of the pulley. When
combinations of these two occur, the one having the stronger influence will become evident in the belt
performance.
Carrying Idlers
*raining the belt with the troughing idlers is accomplished in two ways. -hifting the idler a'is with
respect to the path of the belt, commonly (nown as (noc(ing idlers, is effective where the entire belt
runs to one side along some portion of the conveyor. *he belt can be centered by (noc(ing ahead #in
the direction of belt travel% the end of the idler to which the belt runs. #-ee ig. 2% -hifting idlers in this
way should be spread over some length of the conveyor preceding the region of the trouble. "t will be
recogni3ed that a belt might be made to run straight with half the idlers (noc(ed one way and half the
other, but this would be at the e'pense of increased rolling friction between belt and idlers. or this
reason all idlers should initially be squared with the path of the belt and only the minimum shifting of
idlers used as a training means. "f the belt is over,corrected by shifting idlers it should be restored by
moving bac( the same idlers, not by shifting additional idlers in the other direction.
Obviously such idler shifting is effective for only one direction of belt travel. "f the belt is reversed, a
shifted idler, corrective in one direction, is mis,directive in the other. 4ence reversing belts should have
all idlers squared up and left that way. )ny correction required can be provided with self aligning idlers
designed for reversing operation. 5ot all self,aligners are of this type, as some wor( in one direction
only.
*ilting the troughing idler forward #not over two degrees% in the direction of belt travel produces a self,
aligning effect. *he idlers may be tilted in this manner by shimming the rear leg of the idler stand. 4ere
again this method is not satisfactory where belts may be reversing. *his method is illustrated in ig. 6.
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T#'" -e!#o% #*" *n *%v*n!*(e over +noc+'n( '%er" 'n !#*! '! w' correc! )or -ove-en! o) !#e be! !o
e'!#er "'%e o) !#e '%er. #ence '! '" $"e)$ )or !r*'n'n( err*!'c be!", I! #*" !#e %'"*%v*n!*(e o) enco$r*('n(
*cceer*!e% &$ey cover we*r %$e !o 'ncre*"e% )r'c!'on on !#e !ro$(#'n( ro", I! "#o$% !#ere)ore be $"e%
*" "&*r'n(y *" &o""'be e"&ec'*y on !#e #'(#er *n(e !ro$(#'n( '%er",
S&ec'*. "e)6*'(n'n( !ro$(#'n( '%er" *re *v*'*be !o *""'"! 'n !r*'n'n( !#e be!, 23'(, 74 3or * -ore
co-&e!e %'"c$""'on o) !#e"e '%er" re)er !o !#e Goo%ye*r 7*n%boo+ o) 1onveyor *n% Eev*!or
Be!'n(,
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Return Idlers
/eturn idlers, being flat, provide no self,aligning influence as in the case of tilted troughing idlers.
4owever, by shifting their a'is #(noc(ing%, with respect to the path of the belt, the return roll can be
used to provide a constant corrective effect in one direction. )s in the case of troughing rolls, the end of
the roll toward which the belt is shifting should be moved longitudinally in the direction of return belt
travel to provide correction. #ig. 2%
-elf,aligning return rolls should also be used. *hese are pivoted about a central pin. 1ivoting of the roll
about this pin results from an off,center belt and the idler roll a'is becomes shifted with respect to the
path of the belt in a self,correcting action. #ig. 7% -ome return idlers are made with two rolls forming a
10 to !0 8,trough which is effective in helping to train the return run.
) further aid to centering the belt as it approaches the tail pulley may be had by slightly advancing and
raising the alternate ends of the return rolls nearest the tail pulley. #ig. 0%
Assuring Effectiveness of Training Rolls
5ormally, e'tra pressure is desired on self,aligning idlers and, in some cases, on standard idlers where
strong training influence is required. One way to accomplish this is to raise such idlers above the line of
ad+acent idlers. "dlers or bend pulleys on conve' #hump% curves along the return side have e'tra ressure
due to component of the belt tension and are therefore effective training locations. Carrying side self
aligners should not be located on a conve' curve since their elevated positions can promote idler
+uncture failure of the carcass.
Side Guide Rollers
9uides of this type are not recommended for use in ma(ing belts run straight. #ig. 10% *hey may be
used to assist in training the belt initially to prevent it from running off the pulleys and damaging itself
against the structure of the conveyor system. *hey may also be used to afford the same sort of protection
to the belt as an emergency measure, provided that they do not touch the belt edge when it is running
normally. "f they bear on the belt continually, even though free to roll, they tend to wear off the belt edge
and eventually cause ply separation along the edge. -ide guide rollers should not be located so as to
bear against the belt edge once the belt is actually on the pulley. )t this point no edge pressure can
move the belt laterally.
The Belt Itself
) belt having e'treme lateral stiffness, relative to its width, will be more difficult to train due to its lac(
of contact with the center roll of the carrying idler. /ecognition of this fact enables the user to ta(e
e'tra precaution and, if necessary, load the belt during training to improve its severability. Observation
of troughability design limitations will normally avoid this trouble. #ig. 11%
-ome new belts may tend to run off to one side, in a certain portion or portions of their length, because
of temporary lateral mal,distributions of tension. Operation of the belt under tension corrects this
condition in practically all cases. :se of self,aligning idlers will aid in ma(ing the correction.
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SEQUENCE OF TRAINING OPERATIONS
"nitial installation of conveyor equipment should ensure good alignment of all pulleys, troughing and
return idlers, i.e., they should be placed at right angles to the direction of belt travel, leveled and
centered on a straight line. irst movement of the belt should be slow and intermittent so that any
tendency of the belt to run off may be quic(ly observed and the belt stopped before damage occurs.
When the conveyor is a long center installation, men should be stationed at frequent intervals to observe
the action of the belt. *hey should be provided with an effective method of communication so as to
report their observations and, if necessary, cause the belt to be stopped.
"nitial movement of the belt will provide indication of where corrections of the types described are
required. *he first corrections must be those at points where the belt is in danger of being damaged.
Once the belt is clear of all danger points, a sequence of training operations can be followed. *he best
procedure to use in starting the training sequence is probably to start with the return run and wor(
toward the tail pulley. *his assures early centering of the belt on the tail pulley so that it can be
centrally loaded.
"f the empty belt troughs readily, so that its running tendencies are not erratic, the training can and
should be completed. -hould the belt tend toward stiffness and erratic running, getting some load onto
the belt as soon as the return run has been straightened up and the belt centered on the tail pulley will
help hold the top run.
5ormally, the belt can be trained properly onto the tail pulley by manipulation of return idlers and with
the assistance of self,aligning return rolls. -eldom is any ad+ustment of snub or tail pulley necessary but
the snub can be used as a supplementary training means.
*raining of the top run, with the belt empty, is usually no problem if the belt troughs readily. "n this case
self,aligners on top are not required e'cept as insurance against damage in the region approaching
the head pulley. *here, two self,aligners, placed appro'imately .0 and 70 feet preceding the pulley, will
help re,center the belt if it is ever forced off due to some temporary disturbance.
"t should not be necessary to use the head pulley for training purposes if it has been aligned properly.
;i(ewise, the snub following the head pulley should not be required as a training means. "t is relatively
ineffective as a training device due to the strong influence of the head pulley.
*he ta(e up carriage has a strong influence on the running of the belt at that point and, due to its
movement as belt length changes, is sub+ect to mis,alignment. ) vertical ta(e up carriage, hanging in a
festoon of belt, must be guided in its travel so that the pulley shaft remains hori3ontal. *he belt cannot
be depended upon to center itself on the pulley and, once it moves off center, the pulley will tip out of
hori3ontal if not guided closely on its posts.
) hori3ontal ta(e up carriage is sub+ect to mis,alignment due to loose trac( gauge, fouled rails or even
+umping off the trac(. 8,shaped rails will hold the gauge tight and, with the ape' upward, are self,
cleaning. 4old,down rails above the wheels with sufficient clearance so that they do not touch under
normal operation will help prevent +umping off the trac(. #ig. 1!%
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8'!# !#e e-&!y be! !r*'ne% "*!'")*c!or'y. (oo% o&er*!'on w'!# o*% '" $"$*y *""$re%, 9'"!$rb*nce"
w#'c# *&&e*r w'!# o*% *re $"$*y %$e !o o))6cen!er o*%'n( or !o *cc$-$*!'on o) -*!er'* )ro- !#e
o*% on "n$b &$ey" *n% re!$rn '%er",
8#en e:$'&-en! '" +nown !o be &ro&ery *'(ne%. !r*'n'n( *c!'on "#o$% be !*+en "owy *n% 'n "-*
"!e&" bec*$"e !#e be! re:$'re" "o-e !'-e !o re"&on% !o correc!'ve -e*"$re", I! "#o$% be('n *! "o-e
&o'n! &rece%'n( !#*! w#ere r$n6o)) occ$r" *n% !#en (r*%$*y &rocee% )orw*r%. 'n !#e %'rec!'on o) be!
!r*ve. $n!' !#e r$n6o)) con%'!'on #*" been correc!e%,
/n%er "o-e con%'!'on" o) o&er*!'on w#ere !#e conveyor '" no! eve. '" e0!re-ey "#or! or !oo w'%e !o be
*))ec!e% by &er-'""'be crown'n(. be!" w'!# * "&ec'* ($'%e "!r'& #*ve been $"e%, T#'" ;6($'%e "!r'&
r$n" oo"ey 'n (roove% &$ey *n% '%er ro", G$'%e "!r'&" *re no! reco--en%e% or nece""*ry )or !#e
on( conveyor" nor-*y enco$n!ere% 'n 'n%$"!r'* $"e,
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CLEANING
-pecial care must be e'ercised to (eep the return rolls and snub pulleys clean. <uildup of material on
this equipment has a destructive effect upon training with the result that the belt may run against the
structure and damage itself. "t is adviseable wherever possible that return idlers be suspended far
enough below the structure so that any mis,alignment or dirty idlers can be easily seen.
=eeping the return rolls and snubs clean requires that the belt be clean when it enters the return run.
-craping is the most common method of doing this.
/ubber scrapers can be made by clamping rubber slabs 1>! to 1 thic( #not old belting% between two
metal or wooden bars. &'tend the rubber about twice its thic(ness beyond the bars and suspend the
mechanism with a counter,weight to provide the pressure against the belt. #ig. 1$% /eplace the rubber
when it wears down near the bars. *wo or three such scrapers can be used in succession.
*he most common steel scraper is a series of diagonally set blades mounted on the end of a leaf spring
to maintain pressure against the belt. *hese will scrape stic(y materials which rubber scrapers may ride
over. #ig. 1.%
Washing the belt with a water spray before wiping with a rubber scraper will do a good cleaning +ob on
almost any material, including iron ores and mi'ed concrete.
?ry materials can be cleaned off the belt with rotating bristle or rubber vane brushes, driven at fairly
high surface speed, usually three to five times the belt speed. #ig. 12% *hey wear rapidly, require
considerable maintenance and are li(ely to fill up solid if used with wet and stic(y materials.
"t is preferable to clean +ust after the head pulley and before the snub. )n e'ception to this is that stic(y
material often requires scraping on the head pulley. *his is because a large part of the fine material
stic(s to the belt and must be scraped into the chute.
"n some cases the best possible cleaning is insufficient and steps must be ta(en to compensate for the
effect of a dirty belt. -nub pulleys can be (ept from building up by the use of soft rubber lagging or by
scraping directly against the pulley. ?iagonal grooving will distort and discharge accumulations on
these pulleys. /ubber disc or spiral type return rolls prevent build,up on themselves and thus save a
training problem. #ig. 16 @ 1A%
*he only cleaning required on the pulley side is removal of material, principally lumps, which may fall
or bounce onto the return run, and be carried between the belt and tail pulley if not removed. #ig. !0%
/ubber faced plows immediately in front of the tail pulley are used for this purpose. #ig. 17 @ 10% they
are usually held against the belt by gravity and set at an angle to the direction of belt travel.
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LOADING
5ece'v'n( -*!er'* o)) cen!er w' c*$"e !#e be! !o -ove "'%ew*y" *)!er o*%'n( *" !#e cen!er o) !#e o*%
"ee+" !#e owe"! &o'n! 'n !#e !ro$(#'n( '%er", T#'" c*n be correc!e% by &ro&er c#$!e *rr*n(e-en!
&rov'%e%. o) co$r"e. !#*! !#e be! '" cen!ere% *" '! en!er" !#e o*%'n( &o'n!, 23'(, 44
T#e o*%'n( &o'n! o) *ny conveyor '" ne*ry *w*y" !#e cr'!'c* &o'n!. !#e ')e %e!er-'n'n( &o'n! o) !#e
be!, 7ere !#e conveyor rece've" '!" -*<or *br*"'on. *n% &r*c!'c*y * o) '!" '-&*c!, T#e '%e*
con%'!'on '" !o #*ve !#e -*!er'* &*"" )ro- c#$!e !o be! *! !#e "*-e "&ee% *n% %'rec!'on o) !r*ve *" !#e
be! w'!# * -'n'-$- *-o$n! o) '-&*c!,
T#e "$b<ec! o) c#$!e %e"'(n *n% *rr*n(e-en! '" !oo bro*% !o be %'"c$""e% 'n %e!*' #ere, In 'e$ o) "$c#
%'"c$""'on. !#e )oow'n( "$((e"!'on" *re o))ere%=
T#e w'%!# o) !#e rece'v'n( en% o) !#e o*%'n( c#$!e "#o$% be (re*! eno$(# !o *cce&! -*!er'* y'n( on
!#e e0!re-e e%(e o) !#e &rece%'n( be! or )ee%er. *n% '!" &o"'!'on %e!er-'ne% by !#e !r*<ec!ory o) !#e
-*!er'* co-'n( 'n!o '!, A! no &*ce "#o$% !#e c#$!e be e"" !#*n !w'ce !#e "'>e o) !#e *r(e"! $-&". ')
)'ne" *re &re"en!. *n% 3 1?2 !'-e" !#e "'>e o) $-&". ') $n')or-, T#e %'"c#*r(e w'%!# o) !#e c#$!e !#$"
%e!er-'ne% "#o$% no! e0cee% *bo$! 2?3 o) !#e rece'v'n( be!" w'%!#, 23'(, 214
T#e "o&e o) !#e c#$!e '" %e!er-'ne% by !#e n*!$re o) !#e -*!er'*. '!" en!er'n( veoc'!y *n% en(!# o) !#e
c#$!e, T#'" v*$e v*r'e" w'!# e*c# &*r!'c$*r 'n"!**!'on. b$! *bo$! 35 #*" been )o$n% "*!'")*c!ory )or
-o"! %ry 'n%$"!r'* -*!er'*" "$c# *" co* *n% roc+,
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An *!!e-&! !o *&&ro*c# !#e *bove '%e* con%'!'on "#o$% be -*%e con!'n$*y by *%<$"!'n( !#e c#$!e
*rr*n(e-en!, @&!'-$- o*%'n( *n% !r*n")err'n( !#ro$(# c#$!e" "!' re:$'re" con"'%er*be e0&er'-en!*
*%<$"!-en! 'n !#e )'e%,
S+'r! bo*r%" "#o$% be $"e% !o )$r!#er cen!er *n% "e!!e !#e o*% *" '! e*ve" !#e o*%'n( &o'n!, T#e "!ee
"!r$c!$re o) !#e c#$!e *n% "+'r!" never "#o$% be &*ce% co"er !o !#e "$r)*ce o) !#e be! !#*n 1. !#'"
%'"!*nce !o be -*%e 'ncre*"'n( 'n !#e %'rec!'on o) be! !r*ve !o )ree *ny -*!er'* !r*&&e% be!ween !#e be!
"$r)*ce *n% !#e "+'r!, 23'(, 224 S+'r! bo*r%" *re $"$*y 4 or 5 !'-e" !#e be! w'%!# 'n en(!#. b$! -*y
v*ry con"'%er*by %$e !o be! "&ee%. !y&e o) -*!er'* *n% $-& "'>e, S*-&e "+'r! bo*r% *rr*n(e-en!" *re
"#own 'n 3'(, 23,
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I-&*c! o) -*!er'* be'n( o*%e% on !#e be! '" o)!en !#e c*$"e o) "evere c$!" *n% (o$(e", T#e %e(ree o)
'-&*c! c*n be e""ene% !o "o-e e0!en! by &rov'%'n( * c$"#'on 'n !#e )or- o) r$bber covere% %'"c !y&e or
"e-'6&ne$-*!'c '%er" w#'c# *"o !en% !o &reven! -*!er'* )ro- crow%'n( $n%er !#e "+'r! bo*r%" *! !#e
'n"!*n! o) '-&*c!, 23'(, 244
T#e $"e o) * Gr'>>y. * "'(#!y )*nne% row o) b*r". *! !#e bo!!o- o) !#e !r*n")er c#$!e re%$ce" we*r on
!#e be!, I! %'"!r'b$!e" !#e '-&*c! o) *r(e $-&" by *ow'n( !#e )'ne" !o )* on!o !#e be! )'r"! !o *c! *" *
c$"#'on, T#e )*n "#*&e o) !#e Gr'>>y 'n !#e %'rec!'on o) !r*ve &reven!" <*--'n( o) !#e $-&", 23'(,
254
A ;6"o! c$! 'n !#e bo!!o- o) !#e c#$!e '" *no!#er very "*!'")*c!ory -e!#o% o) *ow'n( )'ne" !o )* on
!#e be! be)ore !#e $-&" *n% !#ereby re%$ce be! we*r *! !#'" &o'n!, 23'(, 264
PULLEY LAGGING
L*(('n( '" reco--en%e% )or %r've &$ey" )or !#e )oow'n( re*"on"=
1, I-&rove% co6e))'c'en! o) )r'c!'on, T#'" &er-'!" * be! !o be %r'ven by ower "*c+ "'%e !en"'on *n%
"o-e!'-e" re"$!" 'n ower !o!* !en"'on,
2, 5e%$c!'on o) "'&&*(e %$e !o we! con%'!'on" ') (roove% *(('n( '" $"e%,
3, Incre*"e% ')e )or &$ey *n% &$ey cover o) be!,
@!#er &$ey" 'n !#e "y"!e-. e"&ec'*y !#o"e con!*c!'n( !#e c*rry'n( "'%e o) !#e be!. *re o)!en *((e% !o
&reven! b$'%6$& o) -*!er'*, Groov'n( '-&rove" ce*n'n( *c!'on on !#e *(('n( *n% !#e be!,
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TYPES OF LAGGING
1. Bo!e% *(('n( '" $"$*y )*br'c re'n)orce%. !#e )*br'c be'n( nece""*ry !o ('ve &ro&er bo!6#o%'n(,
T#'" !y&e #*" no 'nner or &$ey coverA w#ere no (roov'n( '" 'n!en%e%. 1?8 !o& cover '" !#e &ro&er
-'n'-$-. b$! ') !#e *(('n( '" !o be (roove% * -'n'-$- o) 1?4 !o& cover -$"! be $"e%,
Bo!e% *(('n( '" $"$*y *&&'e% 'n !wo or -ore c'rc$-)eren!'* "!r'&". *&&'e% $n%er !en"'on w'!# !#e
&o'n!" 'n !#e %'))eren! "!r'&" "!*((ere% *ro$n% !#e &$ey, 2@n )*!6)*ce% &$ey". one "!r'& !#e w'%!# o)
!#e &$ey -*y be $"e%,4
3or o&en en% &$ey" 5?16 or 3?8 %'*-e!er )*! #e*% eev*!or bo!" w'!# n$!" -*y be $"e%, A!ern*!e
-e!#o%" 'nc$%e "o!!e% bo!" w'!# !*&&e% #oe" or "e) !*&&'n( "crew" )or $"e 'n we%e% "!ee &$ey", I!
'" nece""*ry !#*! !#e bo! #e*%" be "$n+ beow !#e eve o) !#e "$rro$n%'n( *(('n( !o &reven! %*-*(e !o
!#e be! *" '! &*""e" over !#e &$ey, T#'" -*y be *cco-&'"#e% by co$n!er6"'n+'n( !#e #oe" 'n !#e &$ey
or. w#ere !#e *(('n( cover '" (re*!er !#*n *bo$! 1?8. '! '" &o""'be !o "'n+ !#e #e*%" -erey by
!'(#!en'n( !#e bo!",
En%" o) !#e "!r'&" "#o$% be bo!e% 'n * %ove!*' <o'n! *" "#own 'n 3'(, 27, In *%%'!'on. bo!" "#o$% be
$"e% 'n row" r$nn'n( *cro"" !#e )*ce *n% *ro$n% !#e c'rc$-)erence o) !#e &$ey" no )$r!#er !#*n 10
*&*r! 'n e'!#er %'rec!'on, E%(e" o) * "!r'&" "#o$% be bo!e% %own *n% '! '" reco--en%e% !#*! *
e0&o"e% )*br'c e%(e" be ce-en!e% !o +ee& o$! -o'"!$re,
2. ;$c*n'>e% *(('n( '" * "#ee! o) r$bber. $"$*y 1?2 !#'c+. bon%e% %'rec!y !o !#e -e!*, No )*br'c '"
$"e% bec*$"e no bo!6#o%'n( re'n)orce-en! '" nee%e%, I! '" -$c# on(er we*r'n(. #*" be!!er *n% -ore
$n')or- *%#e"'on !o !#e &$ey *n% e'-'n*!e" !#e #*>*r% o) "er'o$" be! %*-*(e %$e !o * oo"e bo!,
T#'" !y&e o) *(('n( c*n be *&&'e% 'n !wo %'))eren! w*y"=
S&'r* -e!#o% (ener*y $"e% )or ower !en"'on *&&'c*!'on", A 4 w'%e "!r'& '" reco--en%e% )or e*"e
o) #*n%'n(, 23'(, 284 T#e en(!# o) !#e "!r'& -*y be c*c$*!e% by !#e )or-$*=
In *&&'c*!'on by !#e "#ee! wr*& -e!#o%. * bevee% *!er* "&'ce '" reco--en%e%, 23'(, 294 T#e !'e ($-
"'%e "#o$% con!*c! !#e bevee% e*%'n( e%(e )or -*0'-$- *%#e"'on *! !#e "&'ce,
3. Groove% *(('n( "#o$% be $"e% on %r've &$ey" ') !#ey *re '+ey !o be we!, T#e (roove" bre*+ !#e
)'- o) -o'"!$re be!ween !#e be! *n% *(('n( !#ereby e'-'n*!'n( "'&&*(e, E'!#er bo!e% or v$c*n'>e%
*(('n( c*n be )$rn'"#e% w'!# (roove", E'!#er !y&e c*n be (roove% 'n !#e )'e% w'!# * !'re6(roover ') !#ere
'" "$))'c'en! r$bber !o &reven! c$!!'n( 'n!o !#e )*br'c c*rc*"" or -e!* &$ey, 7err'n(bone (roov'n( 3?16
%ee& *n% w'%e "&*ce% 1 *&*r! '" reco--en%e%, 23'(, 304
4. A -o%')'e% !y&e o) bo!e% &$ey *(('n( '" *"o *v*'*be w#'c# )e*!$re" re&*ce*be r$bber &*%"
!#*! "'& 'n!o -e!* ($'%e" bo!e% or we%e% !o !#e &$ey, 23'(, 314
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