Manualparaingenierosmecanicos 130217094219 Phpapp01

ContiTech
Specialist in Rubber Technology
Edition
Conveyor Belting
Manual for
Mechanical Engineers
Continental Aktiengesellschaft
1
ContiTech Specialist in Rubber Technology
CONTI Conveyor Belting

ContiTech manufactures Conveyor Belting for all branches of industry and
for a wide range of applications. The product range comprises Textile-Ply
and Steel Cable Conveyor Belts, as well as Special-Purpose Conveyor Belts
and a versatile range of accessories.
CONTI Conveyor Belt Edition

ContiTech issues a series of informative Conveyor Belt publications on
the subject of conveyor system engineering. Brochures published to date
contain a wealth of general and product-specific information, guidance on
conveyor belt installation and repair, technical data for conveyor system
design and application engineering, plus details on available accessories
and belt types. Other topics are currently in preparation.
Conveyor Belting Manual for Mechanical Engineers

This brochure is the first time concise documentation has been compiled
covering all aspects of a mechanical engineer's working environment.
A thorough understanding and careful monitoring of the system are
essential to ensure reliable operation of a conveyor belt line. Invaluable
information is provided on the structure of a conveyor belt, preparing the
site for belt installation, commissioning, operation, maintenance, repair and
seasonal system shutdown.
ContiTech
Advanced technology in rubber processing and manufacture
Worldwide application
Latest technology in production and development
Responsibilities of the mechanical engineer

Planning
Ordering
Installation
Conti offers
Conti offers
Conti offers
Product information
Quality
Computer service
System design data
Punctual order-servicing
Engineers who provide

expert advice
Technical advice
Project studies
Problem analysis
Research and development
Standardization
Your advantages are
Decision-making aids
the right choice of belt
Low-cost design
optimum economy
Effective standartization
less stock required
Smooth and clean
operation of the
conveyor system
minimal maintenace
Comprehensive range
Site delivery
Packaging
Your advantages are

Pre-shipment release
through a neutral body of
quality assurance
engineers
conformity with agreed
grades of quality
Monitoring of project
schedules
smooth timing
Your advantages are

Recommendations for
optimum belt installation
time and cost-saving
Coordination of delivery
direct delivery of belt
to site; protection from
damage during
transportation
Splicing
Comissioning
Inspection
Conti offers
Conti offers
Conti offers
Optimized splicing systems
Belt approval
Belt inspections
Splicing materials
Troubleshooting guidance
Repair service
Vulcanization
Expert on-site advice
Instruction and training

of vulcanizers and
maintenance staff
Fundamental research
Your advantages are
Splicing materials
specially developed for
each belt type
optimum strength
at splice
Provision of latest
vulcanizing equipment
uniform curing
Own fitters
excellent knowledge of
materials and belts
Your advantages are

Localization and
elemination of trouble
spots
limitation of damage
risk
Belt commissioning
without problems
minimum delay in
starting conveyor service
Your advantages are

Expert opinions and
reports
minimizing of overall risk
Assessment of the belt`s
condition
systematic repairs
Repair materials to suit
each type of belt
optimum service life
Trained maintenance staff
low-cost repairs
ContiTech
Quality assurance
at ContiTech
CONTI Conveyor Belting and

Conveyor Belting Accessories are
state-of-the-art products in every
aspect of material specification and
product design. This is guaranteed
by Continental's in-house quality
assurance experts. All CONTI
products undergo rigid, independent
quality controls throughout and after
manufacturing to ensure uniformity
and a constant high standard of
technical excellence.
Advisory service
at ContiTech
CONTI's Application Engineers
assist in determining the technically
and economically most suitable type
of CONTI product for the specific
application. Backed by the R & D
division of ContiTech, our consultants
are able to provide not only the
optimum solution but one precisely
tailored to end-product service
requirements.
ContiTech
Conveyor Belt Service
Conveyor Belting
Manual for
Mechanical Engineers
Edited by
Dr.-Ing. R. Alles
Dipl.-Ing. G. Bttcher
Obering. W. Ernst
Published by
Continental Aktiengesellschaft, Hannover, Germany
2nd Edition 1990
Structure and identification

of conveyor belts _____________ 2
1.1
1.1.1
1.1.2
1.2
1.2.1
1.2.2
1.2.3
1.2.4
Tension members ____________________ 2

Conveyor belts with textile plies _________ 2
Steel cable conveyor belts _____________ 5
Covers _____________________________ 6
Cover thickness______________________ 6
Cover grade ________________________ 6
Cover reinforcement __________________ 8
Cover patterns ______________________ 8
Ordering and storing _________ 12
2.1
2.1.1
2.1.2
2.2
2.2.1
How to order conveyor belts ___________ 12

Example of how to order______________ 12
Delivery of endless belts _____________ 12
Delivery and storage _________________ 13
Packaging _________________________ 13
Technical data for textile tension
members __________________________ 13
Diagrams showing different roll
diameters ______________________ 14-17
2.2.2 Storage ___________________________ 18
Commissioning _____________ 32
5.1 Tensionieng the belt_________________ 32

5.2 Starting the belt_____________________ 32
5.3 Training the belt ____________________ 33
Operation and problem solving _ 40
6.1 Daily inspection of the conveyor belt;

causes of belt damage _______________ 40
6.2 Dai!y inspection of the system__________ 42
Maintenance and repair _______ 44
7.1 Repair materials ____________________

7.2 Repairing damage with
CONREMA repair materials___________

7.2.1 Repairing damaged covers ___________
7.2.2 Repairing penetrations and damage
to the fabric________________________
3.2 Preparations for pulling the belt onto

the structure _______________________ 23
3.2.1 Hanging the belt roll in let-off stands ____ 23
3.2.2 Pulling in the belt ___________________ 23
Splicing conveyor belts ______ 26
4.1
4.1.1
4.1.2
4.2
Splicing fabric-ply conveyor belts _______ 26

Mechanical splices (detachable) _______ 26
Vulcanized splices (non detachable) ____ 26
Splicing steel cable conveyor belts ______ 29
46
46
48
Seasonal shutdown and

winter operation _____________ 54
Index _________________________ 56
Preparations for installation ___ 20
3.1 Preparing the structure _______________ 20

Drive pulley ________________________ 20
Take-up station _____________________ 21
Idlers and idler sets __________________ 21
Scrapers __________________________ 21
Loading and transfer chutes ___________ 22
CORREX abrasion resistant material ____ 22
44
Conveyor belt systems Troubleshooting guide

(Supplement)
ContiTech

1.1 Tension members
Structure and
identification
of conveyor belts
Aerial cableway is replaced

by a belt conveyor
1.2 Covers
Structure and identification of conveyor belts
Structure and identification

of conveyor belts
Dimensions, test values, designations, etc. of conveyor belts are specified in
the following standards:
DIN 22101 Belt conveyors for bulk materials
DIN 22102 Conveyor belts with textile plies
DIN 22103 Flame resistant conveyor belts
DIN 22104 Antistatic conveyor belts
DIN 22109 Textile-ply conveyor belts for coal mining
DIN 22131 Steel cable conveyor belts
DIN 22129 Steel cable conveyor belts for underground coal mining (draft)
Ordering and delivery of conveyor belts are based on specifications given in
the above standards. Any dimensions or other requirements deviating
from the corresponding standard are subject to special agreement with the
manufacturer.
1.1
Tension members
Conveyor belts are reinforced with one or more plies of special textile fabric
or one layer of adjacent steel cables.
The following code letters denote the type of material used as
reinforcement.
B cotton
Z high-strength viscose staple fibre
R high-strength rayon
P polyamide (trade names such as "Nylon", "Perlon")
E polyester (trade names such as "Trevira", "Diolen")
D aramide (trade names such as "Kevlar, "Arenka")
St steel cables
1.1.1 Conveyor belts with textile plies

In virtually all cases, square-woven fabric of various kinds of weave is used
for conveyor belts. The terms "warp" (running parallel to the length of
the cloth) and "weft" (running across the width of the cloth) have been taken
over from the weaving process.
During the years of pioneering belt development, only cotton was used as a
textile material. The advancement to fully synthetic fibres brought with it
the manufacture of new high-strength types of fabric, leading to a decisive
change and improvement in the structure and performance of conveyor
belts.
Polyester:
Fully synthetic, high strength with low elongation, high workload capacity,
largely resistant to acids and alkalis, unaffected by moisture (at normal
temperatures).
Polyamide:
Fully synthetic, high tear resistance, high elongation, rotproof, resistant to
moisture and chemicals.
Aramide;
Fully synthetic, highly aromatic polyamide fibre with extra high strength and
low elongation; has the advantages of all fully synthetic fibres, is flameresistant without undergoing special treatment and is gaining significance in
the manufacture of high-strength textile-ply belts.
2
Whereas earlier types of conveyor belt used to be reinforced with a

"purebred" fabric, specialists in textile technology have since developed
fabrics with combinations of different materials. Depending on the physical
properties of the warp and weft, these mixed fabrics give the belt the right
properties to meet specific in-service requirements. Textile plies are
identified by two capital letters.The first letter shows the material used in
warp direction and the second letter shows that used in weft direction.
e.g. EP (warp: polyester/weft: polyamide)
Good properties fort he warp are:
High strength, low permanent elongation, hence short take-ups. Strength
and elongation even remain unaffected by wet conditions, rotproof.
Good properties for the weft are:
High elastic elongation, hence good troughability and large filling cross
section, good workload capacity and therefore a good resistance to
mechanical destruction.
In addition, brief reference should also be made at this point to the types of
fabric commonly used for mining service:
e.g. Pb (the second letter is small)
This coding means that two different kinds of material have been twisted
together to form one thread. The capital letter stands for the material giving
the highest measure of strength.
Following the material code is the strength grading in figures according to
DIN 22102 standard specifications. The strength of the textile fabric and that
of the entire belt are stated in N/mm width (previously kg/cm width).
Strength values comply with the R10 standardized series of numbers
contained in DIN 323, i.e. 160, 200, 250, 315, 400, 500, 630, 800,1000,1250,
1600, 2000, 2500, 3150, 4000, 5000, 6300.
Identification coding of a conveyor belt could for instance read as follows:
EP = type of fabric /1000 = overall strength in N/mm belt width /
4 = number of plies
i.e. the belt's tension member with a strength of 1000 N/mm belt width
consists of 4 plies of polyester/polyamide textile fabric, EP 250.
The high strength and ability of fully synthetic blended fabric to withstand
high dynamic stressing enabled the number of plies to be reduced. This led
to the following generation of belts made by Continental:
1-ply belts (only for underground)
CON-MONTEX
2-ply belts
CON-BITEX
Multi-ply belts
Technical Data (guide values)

Type
Nominal
strength at
splice
Elongation at
break (longit.)
Thickness of
tension
member
(belt core)
Tension
member mass
(w/o cover
M or N)
in N/mm
in %
in mm
in kg/m2
2-ply belts (with thick intermediate rubber layer)

CON200/2 200
12-16
3.5
BITEX
250/2 250
3.7
2-ply belts
CONMULTEX
3-ply belts
CONMULTEX
4-ply belts
CONMULTEX
5-ply belts
CONMULTEX
0.6 - 1.2
Minimum
Minimum belt
pulley
width at 30
diameter (drive troughing angle
pulley)
in mm
in mm
250
400
4.1
315
400
315/2
315
3.9
4.3
315
400
400/2
400
4.1
4.6
400
400
500/2
500
4.7
4.8
400
500
630/2
630
5.2
6.1
500
500
800/2
800
6.3
6.4
500
650
1000/2 1000
7.1
7.9
630
800
1250/2 1250
7.7
8.8
800
1000
1.8
1.9
200
400
200/2
100
12-16
250/2
125
2.0
2.3
250
400
315/2
160
2.2
2.4
250
400
400/2
200
2.6
2.8
315
400
500/2
250
3.2
3.2
400
500
630/2
315
3.8
4.2
500
500
800/2
400
4.8
4.8
630
650
1000/2
500
5.8
5.9
630
800
1250/2
630
6.2
6.5
800
800
315/3
200
2.7
2.8
315
400
400/3
250
3.0
3.4
315
400
500/3
315
3.3
3.7
400
500
630/3
400
3.9
4.2
500
500
800/3
500
4.8
4.8
500
650
1000/3
630
5.7
6.4
630
800
1250/3
800
7.2
7.2
800
800
400/4
315
3.2
3.8
400
400
500/4
400
4.0
4.5
500
500
630/4
500
4.4
4.9
500
500
800/4
630
5.2
5.6
630
650
1000/4
800
6.4
6.4
800
800
1250/4 1000
7.6
8.5
800
1000
1600/4 1250
9.6
9.6
1000
1000
4.0
4.7
500
500
12-16
12-16
12-16
0.6 - 1.2
0.6 - 1.2
0.6 - 1.2
500/5
400
630/5
500
5.0
5.7
630
500
800/5
630
5.5
6.1
630
650
1000/5
800
6.5
7.0
800
800
1250/5 1000
8.0
8.0
1000
1000
1600/5 1250
9.5
10.6
1000
1200
2000/5 1600
12.0
12.0
1250
1200
Other types of belt available on request
3.9
Elastic
elongation up
to 10% of minimum breaking
strength
(longit.)
in%
0.6 - 1.2
Aufbau und Kennzeichnung der Frdergurte
1.1.2 Steel cable conveyor belts

All ContiTech Steel Cable Conveyor Belts bear the registered trade name
of STAHLCORD .
Reinforcement for steel cable conveyor belts is in the form of one ply of
high-tensile steel cables embedded in rubber and arranged in one plane
running parallel to each other longitudinally. STAHLCORD Conveyor Belts

are ideally suited to long-distance conveyors due to the high breaking
strength of the steel cables. The belt construction itself plus the high-tensile
steel cables enclosed on all sides by rubber provide STAHLCORD

Conveyor Belts with a high resistance to impact damage at conveyor feed
points, even when handling large lump-size material and where large drop
heights are concerned. STAHLCORD Conveyor Belts also have a good

troughability.
Identification and dimensions are specified in DIN 22131 (Standard
DIN 22129 "Steel cable belts for underground coal mining" is available in
draft version). Coding for the tension member is made up as follows:
St = steel cables / 2000 = overall strength in N/mm belt width
Since only one layer of steel cables is embedded in the rubber according to
DIN 22131, the figure after the oblique which appears in the coding
reference for textile-ply belts does not apply in this case.
Strengths of steel cable conveyor belts currently range from 500 N/mm to
7300 N/mm. The strength of the belt is determined by the strength of the
steel cables and their spacing (pitch).
Grades of strength specified in DIN 22 131 are supplemented by special
versions according to the R 20 series.
Technical Data (guide values)
Type
Nominal
strength
at splice
Pitch
Thickness of
tension
member
(belt core)
Tension member mass

(belt core) without covers
(M or N)
in mm
in kg/m2
(V)
Minimum
pulley
diameter
(drive pulley)
Minimum
cover
thickness
in N/mm
in mm
in kg/m2
in mm
in mm
St 500
500
12.5
2.8
5.3
6.4
500
St
630
630
10
2.8
5.8
6.8
500
St
800
800
12
3.6
7.4
8.8
630
St 1000
1000
12
4.0
8.9
10.4
630
St 1250
1250
14
4.7
10.6
12.3
630
St 1400
1400
4.0
10.3
11.6
630
St 1600
1600
15
5.5
12.8
14.7
800
St 1800
1800
13.5
5.5
13.5
15.4
800
St 2000
2000
12
5.5
14.3
16.2
800
St 2250
2250
11
5.5
15.0
16.8
800
St 2500
2500
15
7.0
18.0
20.3
1000
St 2800
2800
13.5
7.0
19.0
21.3
1000
St 3150
3150
St 3500
St 4000
St 4500
St 5000
St 5400
15
7.8
22.0
24.5
1250
5.5
15
8.2
23.6
26.3
1250
5.5
15
8.8
26.6
29.4
1250
6.5
16
9.6
29.0
32.1
1400
17
10.7
33.0
36.3
1600
7.5
17
11.7
36.2
39.9
1600
18
12.2
40.4
44.0
1600
8.5
19
13.1
43.9
47.7
1800
3500 )
4000 )
4500 )
5000 )
5600 )
St 6300
6300 )
St 7300
7300 )
1) without allowances according to DIN 22101
1.2
Covers
If the reinforcement of a conveyor belt is to retain its strength, it must be

given ample protection from mechanical damage and rotting. The tension
member is therefore provided with a cover on the top or conveying side
of the belt and also on the bottom side.
1.2.1 Cover thickness

Cover thicknesses are generally determined by the anticipated amount of
wear caused by the conveyed material and measure between 0.5 and
20.0 mm. A somewhat thinner bottom cover can be selected in most cases
but the ratio of top to bottom cover thickness should not exceed about 3:1
(cf. DIN 22101). Great differences between the two cover thicknesses can
lead to undesired tensions within the belt and bulging of its edges due to
shrinkage of the rubber following vulcanization.
Minimum cover thicknesses are prescribed for steel cable conveyor belts
(DIN 22101). Special attention when selecting the cover thicknesses can
also optimize the lateral rigidity required for some applications.
1.2.2 Cover grade

It is easy to realize the different types of stressing a conveyor belt is
subjected to when we consider the vast range of materials to be conveyed literally anything from coal to foodstuffs. Similarly, the number of different
cover grades to choose from is high.
Basic qualities and main properties of a cover are specified in corresponding DIN standards and are distinguished by the letters shown below:
Code letters
Property
Fabric-ply belts
(DIN 22 102)
Steel cable belts

(DIN 22 131)
flame resistant
antistatic
flame resistant und antistatic*

self-extinguishing and antistatic*
K
(DIN 22 131)
S
V
resistant to elevated temperatures
resistant to low temperatures
resistant to oil and grease
(DIN 22 109)
belts for foofstuffs
belts for chemical products
belts with fixed mechanical

parameters
special grades
M, N
M, N, P, Q
X
* (Belt cover grades for coal mining service are subject to special conditions of approval
issued by the German mines authorities.)
It is quite possible that several of these properties have to be fulfilled by one

belt, e.g. in the handling of freshly baked bread or confectionary, the
cover may have to be white and resistant to oil and grease as well as higher
temperatures.
When ordering it is therefore extremely important to give a precise definition
of the material to be conveyed and its characteristics.
Properties of the most popular ContiTech cover grades (guide values)

DIN
Code
Continental
equivalent
Density
p
Suitable for
kg/dm3
Permissible temperature**
in C
constant
peak
Resistant
to oil and
grease
Tension
member
Colour
Polymer
min.
max. min.
max.
ATRB
1.09
general conveying
(maximum
requirements)
-50
+60 -55
+70 no
any
type
black
NR
CONTINENTAL 1.13
EXTRA
general conveying
-30
+60 -35
+70 no
any
type
black
NR/
SBR
CONTI-CLEAN 1.12
(dirt repelled)
heavy soiling
-50
(with high moisture
content)
+60 -55
+70 no
any
type
black
BR/NR
N, K
FH
1.24
(flame retardant)
machine belts in
open cast mines
-30
+60 -35
+70 no
any
type
black
NR/BR
S, K
FW (flame
resistant)
1.38
underground and
surface
-30
+60 -35
+70 no
any
type
black
SBR
V
(selfextinguishing)
1.42
1.60
underground
mining (maximum
safety
requirements)
- +110 within
limits
fabric
steel
black
CR
S, T
VULKAN
1.39
spezial
(flame resistant)
VULKAN T 130
VULKAN
extra-T150
- +100
hot materials
with glowing
embers
-30 +110 -30 +130 within

limits
any
type
black
CR
1.13
hot materials
-30 +110 -40 +130 no
any
type
black
SBR
1.13
hot materials
-30 +130 -40 +150 no
any
type
black
SBR
T, C* VULKAN
super - T 180
1.13
hot materials,
also resistant to
acids and alkalis
-30 +160 -40 +180 no
fabric
only
black
IIR
TDAX
1.17
oily, greasy
materials
-10
+70 -20
+90 yes
fabric
only
black
NBR
TBBX
1.13
oil sand
-50
+60 -50
+70 yes
any
type
black
NBR
TDLX
1.21
foodstuffs (oily,
greasy and hot)
-10 +120 -15 +140 yes
fabric
only
white
NBR
X, C* TOWN
1.0
materials with acid

content
-40
+60 -45
+70 no
fabric
only
grey
NR
TBBN
(electrically
conductive)
1.25
potentially
explosive
materials
-30
+60 -35
+70 no
any
type
black
NR
PVC (selfextinguishing)
1.35
underground
-5
+50 -5
+60 yes
fabric
only
brown
PVC
* For applications involving potential chemical attack, we recommend prior consultation

with our Application Engineers.
** These temperature specifications refer to the conveyor belt; maximum temperature loads are
However also subject to the nature of exposure to these temperatures (see also German Rubber
Manufacturers` Association guidelines No. 339).
Details of other cover grades and specifications given on request.
1.2.3 Cover reinforcement

To protect the tension member and give added resistance to impacts, the
cover can be provided with additional transverse reinforcement made of
textile cord or steel strands. This increases the belt's resistance to penetration and reduces the danger of longitudinal slitting.
Transverse reinforcement of the covers
Type
Transverse
reinforcement
Arrangement
Tension member
CONTI-CROSS
T
textile cord
(polyamide)
one side
(top or bottom)
STAHLCORD
(all types)
CONTI-CROSS
T/T
textile cord
(polyamide)
both sides
STAHLCORD
(all types)
CONTI-CROSS
S/S
Steel strands
both sides
STAHLCORD
special-purpose
types
Breaker
fabric
(polyamide)
one side
(top) or both
sides
fabric-ply belts
1.2.4 Cover patterns

To ensure optimum transport of special materials, e.g. on luggage and
parcel conveyors, industrial assembly and sorting conveyors, or when
conveying at a certain gradient, it may be necessary to provide the belt
cover with a pattern. The most popular patterns to improve holding or
eliminate rollback of materials can be seen below.
Coarse cloth impression
Transverse ribbing
Coarse duck impression
Transverse multi-cleats
Herringbone pattern
Longitudinal multi-cleats
The Steep-Angle Conveyor Belt with 15 mm high chevron cleats on the top
cover is designed to carry bulk materials such as coal, sand, gravel, ore
minerals, etc. This belt can be troughed at 45 and is capable of transporting
its load at a gradient of up to about 30 depending on the type of material
handled.
In addition to cover patterns, there are belts with high bonded sections.
Section designs are varied and are vulcanized-on using the cold bonding
process. These belts are named as follows:
Partitioned Belts
Fin-Type Belts
CONTIWELL Box-Section Belts
CONTIWELL Corrugated-Sidewall Belts

Gradients of up to approx. 60 can be achieved using these belts,
depending on the type of belt and the material being conveyed.
Conveyor belts cannot be used for gradients exceeding 60. This is where
it becomes necessary to make use of vertical conveyors or elevator belts.
CONTIWELL Box-Section Belts can also be used for vertical conveying

(with a cover belt if required). Heavy-duty bucket elevators are fitted with
Elevator Belts with fabric or steel cable tension members.
Steep-Angle Conveyor Belt with

chevron cleats
Partitioned Conveyor Belt
Fin- Type Conveyor Belt, 2-section
Fin- Type Conveyor Belt, 3-section
CONTIWELL Box-Section Belt
10

2.1 How to order conveyor belts
2.2 Delivery and storage
Ordering and
storing
Site delivery
Ordering and storage

2.1
How to order conveyor belts
Ordering is done on the basis of standards already named on the previous

pages. In most cases reference can be made to specifications of systems
already in operation when ordering replacement belts.
Based on the DIN standard 22102, an enquiry or purchase order should
include the following information:
a) Extended or unwound length of the belt in m, specifying an "additional
overlap length for splicing", or if the belt is to be delivered in one
continuous length "endless...m". The client is responsible for specifying
the correct length.
b) Type of belt (e.g. steep-angle conveyor belt).
c) Belt width in mm. Standard widths are 300, 400, 500, 650, 800, 1000, 1200
and so on at an increase of 200 mm.
Non-standard widths may be supplied in agreement with the
manufacturer. Continental manufactures belts up to a width of 3200 mm
without a longitudinal joint.
d) Type of reinforcement.
e) Nominal strength of the belt in N/mm.
f) Number of plies.
g) Cover thicknesses (top and bottom) in mm.
h) Cover material (rubber, PVC or the manufacturer's designation).
i) Cover grade, DIN 22102 code, basic properties, resistance requirements
or the trade name if known.
j) Additional information, e.g. type of splice.
2.1.1 Example of how to order

Conveyor belt 40 m inner circumference, 500 mm width, 2 plies polyester/
polyamide, nominal strength 500 N/mm, rubber cover, cover thicknesses top cover 3 mm, bottom cover 2 mm, belt to be supplied unspliced,
additional overlap length for splicing required.
This order is summarized as follows:
40 m CON-BITEX Conveyor Belt + overlap

500 mm wide
EP 500/2
3+2 mm CONTINENTAL EXTRA (N)
If you are ordering for the first time or planning to erect a new conveyor, you
are strongly advised to complete the manufacturer's data sheet giving full
system specifications or ask for one of ContiTech's engineers to pay you a
visit. This is the only way to ensure that you select the right type of belt with
optimum conveying capacity and economy.
2.1.2 Delivery of endless belts

Special-purpose belts and belts for short-distance conveyors can also be
factory spliced to the client's specifications. Delivery of endless belts is
however restricted by methods of transportation and production. Before
ordering an endless conveyor belt, the question of installing it on the belt
conveyor must always be examined. Installation of an endless belt requires
at least prior dismantling of the drive and tail pulleys, as well as the sets of
top run idlers. In addition, the feed and transfer points have to be thoroughly
inspected.
12
The process of dismantling and refitting parts of the structure usually

involves a great deal more work than on-site belt splicing and installation.
ContiTech's specialist engineers can be of help when deciding whether
to select an endless belt or an unspliced one.
A detailed summary of all ContiTech Conveyor Belt types, with descriptions
and information on available sizes can be taken from the CONTI Conveyor
Belt Service Manual, Part C "Conveyor Belting, Product Range".
2.2
Delivery and storage
For long-distance conveyors it is often necessary to divide the total

conveyor belt length into a certain number of part lengths agreed upon
between the client and the manufacturer. The number of part lengths is
always kept as low as possible in order to keep the number of splices at the
installation location to a minimum. Each splicing operation means a loss of
time and money.
Part lengths are usually selected in accordance with the transportation and
installation facilities at the site. Outer dimensions of the conveyor belt roll
and its gross weight must be calculated beforehand when determining the
mode of shipment.
2.2.1 Packaging
Conveyor belts are wound onto wooden cores for shipment. Light belts are
wound onto wooden cores with 400 mm outside diameter and a square
centre hole of 90x90 mm to hold the roll axle; long and heavy belts are
wound on wooden cores with 600 mm outside diameter and a square centre
hole measuring 200x200 mm to hold the axle.
Extra large belt rolls can also be shipped on wooden or steel drums.
When shipping endless belts the inner and outer loops are lined with rollers
to prevent damage to the tension member through sharp kinking.
The thickness of the conveyor belt can be determined by means of the
tables on pages 4 and 5.
Conveyor belt thickness = thickness of tension member +
thicknesses of the two covers
The roll diameter can be taken from the graphs on pages 14 to 17 using the
factors belt thickness and belt length.
The belt weight is determined with the aid of the following tables:
- textile tension member (page 4)
- steel cable belts (page 6)
- cover materials (page 7).
Net Belt weight [kg] =
2
2 .
(cover weight [kg/m ] + tension member weight [kg/m ])
.
belt width [m] belt length [m]
2
Cover weight [kg/m ] =

3 .
density of cover material [kg/dm ] thicknesses of the two covers [mm]
Formlua:
13
Conveyor belt roll diameter with 400 mm core diameter
Roll diameter in mm
30 28
26
24
22
20
19
18
400
500
Belt length in m
3000
Belt thickness in mm
2000
1000
100
14
200
300

22
20 19 18 17
16
15
14
13
12
11
1700
10
1600
9
1500
1400
1300
1200
1100
1000
900
800
700
Roll diameter in mm
30 28 26 24
1800
600
50
100
150
200
Belt length in m
15
Roll diameter in mm
30
28
26
24
22
3000
2000
1000
100
16
200
300
400
500
Belt length in mm

22
20 19 18 17
16
15
14
13
12
1800
11
1700
10
1600
8
1500
7
1400
6
1300
5
1200
1100
1000
900
Roll diameter in mm
30 28 26 24
800
700
600
50
100
150
200
Belt length in m
17

Extra special care must be taken during loading and unloading. On no
account should the belt be tipped from the truck or freight car as damage to
the edges and covers would be inevitable. Lateral slipping of the roll
(telescoping) too would complicate belt installation. If fork-lift trucks are
used for unloading, the sharp-edged forks must be padded (corrugated
cardboard, wood, conveyor belt waste, etc.). A suitable axle and a spreader
must be used for loading and unloading by crane or hoist. If wire cables that
touch the roll edges are being used, boards must be inserted, or better still,
an additional strong wooden board of a length equalling the belt length can
be wedged as a spacer bar between the two cable ends.
If the belt roll has to be rolled, it is essential not to roll it counter to the
winding direction. The roll is otherwise telescoped laterally into a funnel
shape. Wooden boards should be placed underneath for rolling too,
so that the belt is not damaged by stones or building materials.
2.2.2 Storage
If prolonged intermediate storage is necessary, it is advisable to suspend
the rolled belt with one axle in two mobile stands. If this is not feasible, the
roll should be turned at intervals to change the contact surface. Storage
location should be selected so as to avoid heat and direct sunlight. The belt
should also be protected from contact with chemicals, grease or oil.
Premature ageing, cracking, hardening or swelling would affect the service
life of the conveyor belt (cf. DIN standard 7716, May 1982 - Rubber
products: directions for storage, cleaning and maintenance).
In the event of prolonged storage in the open air, the cut edges at the start
and end of the belt have to be protected from moisture. It may be advisable
to coat the edges with ContiTech's CONREMA Solution.
18

3.1 Preparing the structure
Preparations for
installation
Pulling in a STAHLCORD
Steel Cable Conveyor Belt
3.2 Preparations for pulling

the belt onto the structure
Preparations for installation

Installing and splicing a conveyor belt is a job for experts. To give a proper
description of these operations at this point would involve far too much
detail (cf. Conveyor Belt Edition, "Installing and Splicing Conveyor Belts").
3.1
Preparing the structure
11
17
1
2
3
4
5
10
13
15
Feed
Discharge
Head pulley (drive pulley)
Snub or deflector pulley
Tail or bend pulley
(take-up pulley)
6 Top run (tight side)
7 Return run (slack side)
8 Top run idlers
9 16
9
10
11
12
13
14
15
16
17
12
3 14
Return run idlers

Feed rollers
Flat-to-trought transition
Trough-to-flat transition
Feed chute
Belt cleaner (transverve scrapter)
Belt cleaner (plough-type scraper)
Drive unit
Counterweight
A thorough inspection of the entire structure for any defects or damage

should be made before installing a new belt on an existing conveyor system.
It is extremely difficult to check dimensions, take corrective action, replace
damaged parts or do any welding jobs once the belt has been installed.
The structure must be carefully cleaned and feed/discharge points cleared
of any leftover materials. The whole length of the conveyor should be
optimally aligned, i.e. straight-tracked without any twisting.
The drive pulley, tail, snub and take-up pulleys should be set square to the
centre line of the conveyor and be horizontal. If the pulleys are lagged, this
is the best opportunity to inspect the lagging with optimum access to the
pulleys. Various types of rubber lagging can be supplied for various applications.The elasticity of rubber lagging and its grooves serve to effectively
dissipate any moisture, prevent sticky materials from caking, as well as to
cushion and accommodate stones depending on their size thereby keeping
the belt in good working order. Friction grip of the rubber lagging is
maintained.
ContiTech supplies CORREX Rubber Sheeting in different grades and
surface patterns to cater for different needs. Lagging can also be applied to
the pulleys after the system has been in operation.*
* Further details of available types and instructions for lagging pulleys can be found in
ContiTech's brochure, CORREX Rubber Sheeting, Drum Lagging Materials and Abrasion
Resistant Lining Materials.
20
The take-up station with the take-up pulley is positioned for textile fabric
belts at the point of the shortest belt length. After splicing of the belt,
sufficient take-up must be available to offset the belt sag during installation
and its elongation.
Steel cable conveyor belts are low in elongation; the design engineer therefore has to consider a shorter take-up than that for systems fitted with
textile fabric belts. Nevertheless, belt sag during installation must also be
taken into account for steel cable belts.
Once the belt has been adequately tensioned, it is recommended that the
take-up pulley or take-up carriage is adjusted so as to leave enough
belt material for a join in the take-up length. The advantage of this is that it
facilitates dismantling of the pulleys during structure repairs, and in the
event of heavy damage to the belt, the belt can be tightened and a join
made. Spindles, guides, rollers and hoists are to be cleaned and kept
operational.
Idlers and idler sets in top and return runs are centered square to the belt
line. Idlers have to be checked that they are rotating properly and that any
material build-up is removed. Idlers with dented or worn covering, as well as
those with bearing defects are to be replaced. Idlers have to be lubricated
from time to time depending on the type. Self-aligning idlers on the top and
return runs must be cleaned, re-aligned and kept rotating freely. Return
idlers are exposed to heavy soiling and material build-up.
ContiTech Support Rings protect the idlers from wear and material
accumulation; they contribute to the true running of the belt and help to
keep the conveyor clean due to the low belt bearing area.
Scrapers and chuting are always those elements which, together with the
conveyed materials, contribute the greatest amount of wear to the conveyor
belt. Careful thought should be given during the initial phase of designing a
conveyor system to ensure that the belt is subjected to the least amount of
punishment. Deep troughing at the feeding point, restriction of the material
flow and suitable configuration of the belt charging point can nowadays
frequently eliminate the need for chuting or at least enable its positioning so
that it has a protective instead of an abrasive effect on the belt.
Scrapers are made from rubber or plastic according to their intended
application. The scraper material must be compatible with the materials
being conveyed in order to achieve optimum cleanliness and protection
against wear. Scrapers made from old conveyor belt waste, wood, steel or
other materials lead to accelerated and premature wear of the belt.
Weighted or even self-adjusting scrapers are to be checked that they can
move freely. Attachments are to be inspected for signs of damage, loose
bolts or bent parts which could damage the belt.
Rubber scrapers can only be set and adjusted once the belt has already
been installed and tensioned because this is the only way to achieve the
correct contact pressure on the belt cover.
ContiTech supplies Scraper Blades made from different materials suited to
individual requirements of the material conveyed and the conveyor.*
* See details of ContiTech's product range.
21
Loading and transfer chutes, tip chutes as well as hoppers should be

inspected and relined with abrasion resistant material if required. Metal
wearing plates and braces should be firmly seated. Loose plates are
frequently the cause of belt slitting. Excellent results are achieved with
ContiTech's CORREX Rubber Abrasion Resistant Sheeting which can be

subsequently applied using the cold bonding process.*
ContiTech offers a versatile range of materials with different technical
properties to suit various in-service requirements.
CORREX Abrasion Resistant Material with adhesive layer

(guide values)
Type
Specific
gravity
in kg/dm3
Thickness
in mm
6
CORREX
CYCLOP
Hardness
Abrasion
Shore A
(to DIN)
in mm3
10
1.2
70
300
1.1
60
110
CORREX extra
15
1.1
55
55
1.1
45
200
1.0
40
90
1.1
45
200
CORREX super
CORREX red
CORREX beige
CORREX red with

herringbone pattern
1)
L=stock line rolls of 50m, approx. 1200 mm wide. Also spezial-purpose grades,
e.g. V=self-extinguishing, FW=flame resistant, oil resistant within limits, etc., available on
request.
1
) Measured at half load.
Standard sizes:
Thickness
Width
Length
4-15 mm
1200 mm
50 m
16 mm
1400 mm
5m
All safety devices must be carefully inspected! This not only includes
guards around the belt motor drive and the erected awnings, but also all
electrical monitoring systems, visual and acoustic warning signals,
emergency switches, safety lines, belt mistracking and slip monitoring
devices, incorrect loading/spillage control, slit detection systems, etc.
This work should be carried out prior to actual belt installation.
* See also ContiTech's brochure on CORREX Rubber Sheeting, Drum Lagging Materials,
Abrasion Resistant Lining Materials.
22
3.2
Preparations for pulling the belt onto the structure
It is particularly important when setting up a new conveyor system that, prior

to installation, a site inspection plus preliminary discussions on the
procedure take place between engineers in charge from both the conveyor
construction company and the belt manufacturers, as well as competent
maintenance and electrical engineers from the client. During these discussions an installation programme should be established, the provision of
auxiliary equipment and assisting engineers/staff planned, and the different
areas of responsibility determined.
The site for hanging the new belt in let-off stands, the optimum method of
pulling the belt onto the structure and the site for intermediate and final
splicing should also be jointly agreed upon.
3.2.1 Hanging the belt roll in let-off stands

The winding method is governed by local conditions. The belt roll is
suspended in mobile let-off stands, the simplest type of which is fitted with
open U-shaped bearings to support the axle ends. Bearings should be
secured by bolts or stirrups. For small conveying systems, mobile cable reel
jacks are also adequate for hanging in the roll.
For conveying systems over substantially different levels of ground, the belt
must be pulled in upwards using an appropriate hoist or downwards onto
the system by means of suitable braking and intercepting devices capable
of effectively moderating the maximum slope fall.
To ensure the belt is pulled straight onto the system, the roll should as far as
possible be positioned at right angles to the centre line of the system and
centered in front of, behind, below or above the structure. If it is only
possible to pull the belt in from the side, it should be done at an acute angle
to the system. This requires a number of deflection idlers and fender rollers
between the unwinding point and entry onto the structure or groups of
laterally extended troughing idlers to form a lead-in guide onto the centre of
the system. All short twists and bends must be avoided when pulling the
belt onto the structure and particular care should be taken to avoid any
tendency to tear the belt edges.
3.2.2 Pulling in the belt

Before belt installation, all parts of the structure that come into direct contact with it must be cleaned of oils and lubricants. The belt may not be
dragged across sharp-edged steel sections or wall edges. Fender rollers
must be fitted at such points. The process itself of pulling in the belt is also
determined by local conditions. Although small belts can be lifted manually
or with pulling cables or a hoist, long belts require motor-driven cable
winches or cables with corresponding traction vehicles such as trucks,
Unimogs, bulldozers, etc.
Prior to lifting the belt onto the system, a control must be made to ensure
that the top cover of the belt will come to rest upwards in the top run and
downwards in the return run. If the top cover of the belt is not marked with a
stamp, it can be recognized by the cut edge at the beginning of the belt as
the thicker of the two covers.
23
The top cover of a rolled belt usually faces outwards. If the suspended roll is
unwound from above, the outer cover is also on top when the belt enters the
conveyor system.
If the roll is turned so that unwinding is done from below, the outer cover
faces downwards.
If the worn belt of a conveyor system is to be replaced by a new one, the

easiest method is often to attach the new belt to the old cut belt so that
when winding up the old belt the new one is automatically drawn onto the
system.
The method chosen is best left to the discretion of the supervising engineer.
There are a number of different possibilities depending on site conditions,
but it would involve too much detail to explain them all in this brochure.
24

4.1Splicing fabric-ply conveyor
belts
4.2 Splicing steel cable conveyor
belts
Splicing conveyor belts
Hot vulcanizing press

Depending on the length of a conveyor system, the belt is made endless
either by splicing its two ends after it has been drawn onto the structure, or
by suitably splicing the individual part-lengths to form one continuous
length.
4.1
Splicing fabric-ply conveyor belts
There are two methods of splicing fabric-ply belts.
4.1.1 Mechanical splices (detachable)

Detachable splices using mechanical fasteners are recommended
for conveyor belts which have to be frequently replaced, shortened or
lengthened, as in underground mining service.
The mechanical splice is quick to carry out and allows the conveyor to
resume operation after just a short time. Another advantage is the low loss
of belt material - splicing is done with straight, rectangular belt ends and
the fasteners do not extend far into the belt, which means little waste when
making a new splice or replacing a defective one.
Hook fasteners
Utilization of the belt strength varies to a great degree when using

mechanical fasteners. It depends largely on the type of belt, the type of
fabric in particular as well as on the type of fastener, and ranges between
50% and 90%. If a thin, flexible belt is to be joined with mechanical
fasteners, care should be taken that the pulley diameters are suited to the
fastener holding ability.
4.1.2 Vulcanized splices (non-detachable)

The commonest and most successful type of splice for fixed conveyors and
heavy-duty belts is still the hot vulcanized or cold vulcanized splice. If made
properly by an expert, this splicing technique guarantees maximum utilization of the belt strength, longest service life and the best tracking properties
of the belt. These splices also display optimum properties when chuting is
used at loading points or when scrapers are fitted to eliminate material
build-up or clean the belt.
Fabric-ply conveyor belts are normally spliced with staggered steps and
butting of the corresponding fabric plies of the two belt ends.
26
The splice is the weakest point in the entire belt. Due to this method of
stepping the plies, one fabric ply has to be omitted reducing the tensile
strength of the joint by a percentage which is related to the overall number
of plies in the belt. The lower the number of plies, the greater the loss of
strength as a percentage of the overall belt strength.
The high tensile strength of today's fully synthetic fabrics enables conveyor
belts to be manufactured in all strengths up to 1250 N/mm belt width with
just two fabric plies. The special feature of the CON-BITEX Belt is its thicker
rubber interlayer which permits various types of splices to be made.
Two-step splice
Whereas the one-step splice only transmits approx. 50% of the belt
strength, up to 100% of the belt strength can be attained using additional
fabric or the interlaced splice.
The strain on the splice when bending over idlers and pulleys is reduced by
taking a bias length of
.
LA = 0.3 B
The additional belt length for the splice overlap is therefore
One-step splice
LVZ = z LS + LA
for fabric-ply belts with z number of steps.
Step length LS is determined by the strength of the individual fabric plies.
Splice with additional fabric
(CON-BITEX )
Interlaced splice
(CON-BITEX )
27
Splice dimensions for fabric-ply belts

Belt type
CON-MONTEX
Step length
LS in mm
Number of steps
z
Additional belt length for overlap

LVZ in mm
160/1
200
200/1
250
250
250/1
250
250
315/1
300
300
400/1
300
300
500/1
350
350
200
+ 0.3 B
CON-BITEX
one-step or with
additional fabric
.
+ 0.3 B
200/2
180
180
250/2
180
180
360
315/2
180
280
360
400/2
200
200
400
500/2
200
200
400
630/2
250
250
500
800/2
250
200/3
100
EP
200/3
100
200
250/3
150
300
315/3
150
300
400/3
200
400
500/3
200
400
630/3
250
500
800/3
250
500
1000/3
300
600
250
2
200
1250/3
300
250/4
100
EP
400/4
150
450
500/4
200
600
630/4
200
600
800/4
250
750
1000/4
250
750
1250/4
300
900
1600/4
300
900
315/5
100
EP
500/5
150
600
630/5
200
800
800/5
200
800
1000/5
250
800
1250/5
250
1000
1660/5
300
1000
28
two-step or
interlaced
500
.
+ 0.3 B
600
3
300
400
360
+ 0.3 B
+ 0.3 B
+ 0.3
4.2
Splicing steel cable conveyor belts
In a steel cable conveyor belt splice the individual corresponding cables of

the two belt ends are placed side by side alternately and embedded in a
special rubber compound. The type of splice used is predetermined for
each belt strength rating by the diameter and spacing of the cables.
Splicing configurations to DIN 22131 (provisional standard)
one-step splice
two-step splice
three-step splice
Steel cable belts too are normally spliced at a bias of
.
LA = 0.3 belt width B

Right-angle joints are possible if suitable equipment is available.
29
Recommended splice dimensions for steel cable belts to DIN 22131

and special types (guide values)
Belt type
Step length
Number of steps
Additional belt length for

overlap
LS in mm
LVZ in mm + LA
St
500
250
550
St
630
250
550
St
800
300
600
St 1000
300
600
St 1250
350
650
St 1400
350
1000
St 1600
450
750
St 1800
400
1150
St 2000
400
1150
St 2250
400
1150
S1 2500
500
1350
St 2800
600
1550
St 3150
650
1650
St 3500
650
2350
St 4000
750
2650
St 4500
800
2800
St 5000
Splicing system is chosen in accordance with design conditions
St 5400
St 6300
St 7300
Other splicing systems are possible
A great amount of research and testing is invested by ContiTech in the

improvement of splicing methods to achieve optimum splice life and yet
keeping the cost of labour and equipment to a minimum. The importance of
precision and skill during splicing cannot be overemphasized. Further
details are given in the edition "Installing and Splicing Steel Cable Conveyor
Belts".
30

5.1 Tensioning the belt
5.2 Starting the belt
5.3 Training the belt
Commissioning
Long-distance conveyor
in operation
Commissioning
Commissioning
After splicing the conveyor belt, the press, worktop and all auxiliary splicinig
facilities are dismantled and removed. Idler sets are returned to
their positions in the top and return runs, properly aligned and secured.
5.1
Tensioning the belt
It is assumed that the structure will have been erected correctly before belt
tensioning takes place. If using the screw take-up method, the take-up gear
on either side of the take-up pulley is to be adjusted so that the pulley withdraws square to the centre line of the system, thus tensioning the belt. With
a gravity take-up, the supported counterweight is returned to its hanging
position, or alternatively the winch tightened accordingly in the case of
winch tensioning.
The belt must be tensioned so as to ensure that
a) the required tension is available at the drive to effectively transmit the
peripheral force of the drive to the belt. Insufficient tension leads to belt
slip on the pulley, premature wear of both belt and lagging, causing
interference during operation.
b) there is no belt sag between the individual idler sets and that troughing
does not flatten to allow material spillage.
c) the belt shows a good flat-to-trough transition even when running with no
load, thereby gaining enough friction contact with the lateral idlers to
keep it running true. For small conveyor systems, the expert installation
engineer will be able to adjust the correct tension on the basis of
experience. For large conveyor systems, the required tension is predetermined during the design phase, or calculated from the required
tension of the pulley and permissible sag of the belt between idlers.
5.2
Starting the belt
All is now prepared for the initial run, however it is recommended that the
entire system is inspected again before starting the commissioning
operation. Any tools left lying around or parts of the structure, screws, etc.
placed on the return run are to be removed. If necessary, the return run
should be swept clean again. Check that work has been satisfactorily
completed on all parts of the system.
A locking device over the electric switch has proved to be an effective
precautionary measure in this connection. It is secured by each group of
workers with a marked padlock and the conveyor is not released for
commissioning until all padlocks have been removed.
32
Commissioning
If the system has a large centre distance, it is advised that a team of capable
observers be posted at intervals along the conveyor in such a manner as to
enable visual and audible signalling. First of all the belt is switched on
briefly to move it forward about 10 to 15 m depending on the system length.
This makes sure that the belt initially rests properly on the idlers. Then a
second short burst of power is given, after which the supervising engineer
awaits the reaction of his observers. If no problems are reported, the belt
can be run under steady power. Constant monitoring is important to see if
there is a tendency to run out of line, so that corrective action can be taken.
Fabric-ply belts in particular require a certain amount of time before
running with load to allow them to adapt to the system configuration and
troughing. If a belt shows a tendency to run off-centre at the beginning,
there is no reason to interrupt the trial run and expect to find the cause in
the work of the vulcanizers or even a faulty belt. Every start-up operation
needs corrective action. Belt and system must adapt to one other. This is
best done with the belt running, if possible under full load conditions.
5.3
Training the belt
Training a belt, especially on a long conveyor system, requires a great deal

of patience, clear logical thinking and action. If at the beginning the belt
comes into contact with some points of the fixed structure, the conveyor
does not have to be stopped immediately - belt edges do not suffer the
damage that easily. Alignment is only possible when the belt is running,
because it is only during operation that the effect of any adjustment can be
observed. If the belt runs off-centre, correction begins before the point of
misalignment seen in the direction of belt travel.
How can misalignment be corrected?
The drive pulley has been thoroughly checked during preparations for
commissioning: it is horizontal and set square to the belt axle. It has been
cleaned of all caked material. Therefore, this pulley should as far as
possible be left untouched. If the belt does not centralize, the final troughing
idlers before the drive pulley are to be adjusted.
The tail pulley, often designed as a take-up pulley on small conveyors is
usually screw-adjusted. Though it would be preferable to leave the pulley in
the position it was during control of the belt tension, belt tracking can be
corrected at this point if absolutely necessary.
The general rule is:
Conveyor belts enter downwards
33
Commissioning
Conveyor belts enter downwards

A belt always follows the path of reduced tension, i.e. it runs towards the
pulley edge which has retracted as a result of slackening the screw take-up.
Direction of belt travel
Axle position
The troughing idler transoms on the top run are attached to the structure
by means of slots or clamps in such a manner that lateral adjustment is
possible. By tilting the idler sets forwards or backwards, a position is
attained where the friction between idler and belt acts as a steering force on
the belt.
The following rule generally applies in practice:
To bring the belt closer - hammer the group of troughing idlers away from
the direction of belt travel. To push the belt further away - hammer the group
of troughing idlers towards the direction of belt travel.
Direction of belt travel
To push the belt

further away
34
To bring the belt

closer
Commissioning
The following characteristic behaviour should be noted:

The belt always runs towards the point of initial contact with the idler!
Idler adjustment likewise requires a lot of patience and initiative. Three to
four idlers at a time are slightly adjusted and the results are observed
during operation before further alignment is made. Idler adjustment on the
return run is done in the same way as that for the top run.
Centralization of the belt on the return run is substantially more difficult to
control than on the top run. Return idlers in particular and the tendency to
arching of a belt with largely varying cover thicknesses frequently cause
trouble due to the small area of contact between the belt edges and the
idlers, resulting in low forces to steer the belt. It is therefore advisable to
install two-part return idlers at a slight troughing angle on large conveyor
systems.
Return run idlers are in permanent contact with the carrying side of the belt
and are highly vulnerable to soiling and material build-up resulting in
misalignment. ContiTech Support Rings are Rubber-Covered Rollers can be
installed to prevent the material from accumulating on idlers.
It should be remembered though that support rings do not have a cleaning
effect due to the rolling line contact with the belt surface, i.e. care must be
taken to ensure that the structure beneath the conveyor belt is kept as
clean as possible. Rubber sleeves drawn over standard carrying idlers
make better contact with the belt surface due to their flexibility. This in turn
considerably enhances the steering properties needed to minimize belt
training problems. On the other hand, flexing of these sleeves cleans the
belt surface which means that a greater amount of material accumulation
beneath the structure is to be expected.
True running of the return strand just before the tail pulley is of prime
importance. Material feed onto the belt centre is only possible if the belt is
straight when it enters the tail pulley on the return run and this is essential
for straight tracking on the top run. Off-centre feeding can escalate belt
misalignment to such a degree that it may run to one side and curl upwards.
This always leads to heavy damage to the edges and partial destruction of
the fabric plies. Under these circumstances, the tension member of a steel
cable belt can be completely destroyed after curling up and winding around
a pulley.
Effective adjustment can be made at the snub pulley as the area of contact
is particularly high at this point. For this reason the use of conventional
carrying idlers for narrowing down is not recommended, but instead pulleys
with an appropriately large diameter and rubber covering. No support rings
are to be fitted to the snub pulley.
If a long conveyor system has a very unstable return run, belt tracking may
be improved by installing a group of reversed troughing idlers on the return
run. The last set of this idler type should be positioned approx. 4 to 5 m
before bend point so that the steering forces can be fully effective right up
to where the belt enters the pulley.
35
Commissioning
Section A - A
Vertical idlers to restrict the degree of float are only to be considered in an

emergency. They are to be spaced as wide apart as the system allows to
ensure that they are not in constant operation, thereby exerting unnecessary
pressure or causing excessive flexing of the belt edges.
Centre feeding of materials is important to ensure true running of the belt.
A decisive factor is the design of the material loading point. If two conveyors
are erected at an angle to each other, devices should be installed to redirect
material flow so that it enters the belt in the direction of belt travel, i.e.
chutes, troughs, spiral chute feed hoppers, etc. This guarantees proper
loading of materials onto the belt centre and takes care of the conveyor belt.
If connecting structure is not possible for reasons of space, baffles are to be
hung in the trajectory to ensure that the materials bounce off and fall onto
the belt centre.
36
Commissioning
Effects of weathering when exposed to wind, rain, snow and frost can lead
to considerable mistracking if the conveyor is unprotected. Pulleys, idlers
and the return strand are susceptible to moisture on one side, particularly at
the onset of heavy rain when it is slanted by strong winds. This results in
different friction values between the two sides of the belt and the structure
parts and eventually to belt misalignment. Here too, a substantial improvement is achieved by using pulleys with grooved rubber lagging which
squeezes off the film of moisture.
If a conveyor is elevated, e.g. across a valley, the belt may be forced off the
structure by strong gusts of wind. Particularly vulnerable conveyor systems
are therefore fitted with gale shackles.
Long conveyors with a tendency to unstable running due to various
influential factors can be provided with groups of self-aligning idlers for
automatic belt alignment. These are sets of troughing idlers or flat idlers
which are supported in the centre and swivel around a pivot. Various types
are available on the market but they all work according to the same
principle. Two lateral rollers set at right angles to the outer troughing rollers
are connected to the pivoting set of rollers via a lever attachment. If the belt
wanders, its edge is pressed against the lateral roller, which is in turn
pushed forward in the direction of travel together with the set of rollers on
the same side via the lever attachment. The group of rollers turns the
opposite flank against the direction of travel, which brings the belt closer.
The belt realigns automatically. Special care should be taken that selfaligning idlers are positioned somewhat higher than the other groups of
idlers, so that the belt weighs more heavily on them.
Direction of conveying
37
38
ContiTech
6.1 Daily inspection of the conveyor

belt; causes of belt damage
6.2 Daily inspection of the system
Operation and
problem solving
Belt entering
a turnover
Operation and problem solving

If commissioning a new conveyor or installing a new belt on an
already existing conveyor, much of this work can be regarded as normal
maintenance procedure.
The life of a belt is determined by two factors:
a) Aggressiveness of the materials conveyed
b) Maintenance of the structure
A belt takes the greatest amount of punishment from its burden at the
loading point. Once the materials have come to rest properly on the belt and
are accelerated, they cause hardly any wear (except in the case of hot or
chemically aggressive materials).
All other damage is caused mechanically by the structure, i.e. damage to
the structure is reflected in the belt. A regular inspection program by
maintenance staff increases belt life.
6.1
Daily inspection of the conveyor belt
If a replacement belt has been installed, the take-up point is to be closely

monitored. Initial belt stretch requires an increase in the tension.
Belt splices are to be checked for any signs of separation.
Covers of the belt are to be inspected for damage to the carrying and the
bottom side.
The cause of longitudinal grooving, excessive localized wear and chatter
marks can generally be found at the following points:
a) Scrapers:
adjust rubber where needed
b) Structure:
check where the belt is chafing against the structure; the cause of
damage may be protruding bolts, bent bracing or jammed stones
c) Idlers:
missing idlers, belt is rubbing against attachment or structure bracing;
stalled idlers, belt is dragging across idler or material accumulation;
idler shell worn away, open edges cause slitting;
defective bearing, idler out of line, belt chafing and mistracking
d) Feeding and transfer points:
foreign matter and stones lodged in the hopper, over-filling due to faulty
operation or clogging; materials accumulating beside the structure and
falling onto the return run; stones jamming between the bend pulley and
the baseplate
e) Drive pulleys:
damaged pulley shell, material build-up, damaged lagging
f) Inspect coupling, brake adjustment and take-up point; belt slips on
starting and stopping
g) Chuting may be exerting too much pressure; adjust rubber, remove
lodged materials.
Note: Please also see the troubleshooting guide in the back sleeve of this
brochure.
40
The cause of penetrations or holes in the cover should initially be sought at

the feeding point. The source of both these types of damage can usually be
found here.
a) High forces of impact caused by material with a large lump size or falling
from a great drop height. This can be remedied by installing chutes, a
grid, vibration ducts, etc. Whenever possible, load fines first.
Reduce spacing between troughing idlers and equip with ContiTech
Impact Rings. The use of garland idlers which give way has also proved
successful.
b) Material between the belt and pulley. Remedy: Side lining at the loading
point and lateral chuting are to be designed to prevent the material from
spilling or bouncing out. The return strand is to be covered beneath the
feeding point. The plough scraper on the return run must be beyond the
feeding point and fitted closely before the tail pulley. The tail pulley is to
be provided with a cleaner and dirt repellent to ensure that scraped off
material does not drop back onto the return run and is caught up in
circulation.
If cracking on the top side should occur around the area of impact, then the
belt has been exposed to too much heat.
Should swelling show on the cover, this is caused by oil, grease or chemical
attack (excessive lubrication of structure parts should be avoided).
41
Damage to belt edges

Chafing and edge tears require inspection of the entire belt line to check
true running. It may be a case of temporary mistracking due to soiling or
lodged stones, or it could be more permanent due to damaged structure
parts. First priority is to examine the whole return run. Distinct signs of wear
on the attachments of the return idlers denote that the belt is out of line.
Misalignment arises following material build-up and caking, as well as stuck
guide idlers, loose and out-of-true idlers. Abrasion on the sidewalls of the
transfer points is also an indication that the pulley should be inspected for
material accumulation or one-sided wear of the lagging; belt alignment at
the last 10 sets of troughing idlers should also be checked.
6.2
Daily inspection of the system
System inspection entails similar procedures to those for belt inspection

and therefore includes a number of the points given on the previous pages.
In addition, special attention should be paid to inspecting all monitoring and
safety devices. Emergency-off switches, visual and acoustic warning
systems as well as safety guards must be inspected daily prior to starting
the conveyor. Extra care should be taken when doing maintenance work on
the system whilst in operation. Strict observance of current health and
safety regulations is essential.
42

7.1Repair materials
Maintenance
and repair
CONTI STAHLCORD Steel Cable

Conveyor Belt carrying broken limestone
7.2 Repairing damage with
CONREMA Repair Materials
Maintenance and repair

Large companies usually have their own team of maintenance personnel,
including specially trained vuicanizers, who are capable of conducting all
maintenance work.
Maintenance work is often contracted out to vulcanizing specialists who
undertake to procure replacement belts, install them, perform all splicing
jobs, inspect the conveyor system at regular intervals and do repairs when
the conveyor is not in operation. Depending on the size of the company,
a general overhaul on dismantled belts is frequently carried out on the
specialist's own premises.
It is still advisable to repair damaged points as quickly as possible and
avoid damage spreading, even with today's fully synthetic fabrics which are
insensitive to moisture. ContiTech's CONREMA Cold Bonding Repair

Materials were specially developed for the time-saving and reliable repair.
7.1
Repair materials
CONREMA Cold Bonding Repair Materials are designed for conveyor

belts with DIN cover grades M, N, F, S, K and V. They are not suitable for
hot material conveyor belts (max. temperature load is 70 C), foodstuffs
handling belts or oil and grease-resistant belts.
CONREMA Cold Vulcanizing Cement

(approved for use in underground mines in Germany)
CONREMA Cement is mixed with 5% CONREMA Activator Solution

(approved for use in underground mines in Germany). 1 kg and 3 kg packs
are held on stock. CONREMA Activator is portioned in accordance with the
pack sizes of CONREMA Cold Vulcanizing Cement. Larger packs, with or

without activator, are available on request.
CONREMA may only be applied as a mixture (cement + 5% activator). Only

the exact amount required is mixed immediately before use.
Cold Vulcanizing Cement and Activator are easy to mix and are workable for
approximately 2 hours.
CONREMA Patches and Tapes

Type N for the normal cover grade
Type V for coal mining service
(approved for use in underground mines in Germany)
These patches and tapes are packed in protective film to avoid damage to
the cover and adhesive layers. They are tapered off at the edges.
The following sizes are available:
CONREMA Round Patches (contents:10 pcs.)

Patch diameter:
44
50 mm
80 mm
100 mm
120 mm
CONREMA Diamond Patches (contents: 10pcs.)

Diamond sizes:
110 x 135
190 x 245
270 x 345
CONREMA -Repair Tapes (contents: 10pcs.)

Tape sizes
50 x 4000 mm
100 x 4000 mm
150 x 4000 mm
220 x 4000 mm
400 x 4000 mm
CONREMA Repair Sheeting

Types N and V (approved for use in underground mines in Germany)
CONREMA Repair Sheetings is supplied in rolls.

The adhesive layer is covered with protective film
Repair Sheeting is available as follows:
With adhesive layer on one side
Sheeting thickness
Length of roll:
Width of roll:
1.5 mm
2.0 mm
3.0 mm
5.0 mm
10 m
1200 mm*
* also available in other cut-width
With adhesive layer on both sides

Sheeting thickness:
Length of roll:
Width of roll:
1.5 mm
3.0 mm
10 m
1200 mm*
* also available in other cut-width
CONREMA Repair Fabric

This is an EP 200 fabric with adhesive layer on both sides, both covered with
protective film.
Length of roll:
Width of roll:
10 m
1000 mm
CONREMA Adhesive Layer

The adhesive layer is covered with protective film.
Sheet thickness:
Length of roll:
Width of roll:
0.5 mm
5m
1200 mm
45
7.2 Repairing damage to conveyor belts

with CONREMA Repair Materials
Preparing the damaged area
- thoroughly remove any residues of conveyed material
- cover and fabric must be clean and dry
- use hot-air blower or infrared dryer
Treating the damaged area
- slightly roughen the cover and cut edges
- use rotating wire brush, emery cloth or other roughening device
- do not damage the fabric surface
- thoroughly remove buffing dust using a dry process
- first coat of CONREMA Cold Vulcanizing Cement and Activator mixture

must be allowed to dry completely
- allow second coat of CONREMA Cold Vulcanizing Cement and Activator

mixture to dry until tacky
Applying the repair materials
- CONREMA Patches, Sheeting and Tapes must be recessed into the cover
to avoid damage by the belt scraper
- peel off protective film, coat the adhesive surface once with CONREMA
Cold Vulcanizing Cement and Activator mixture
- place the surfaces together, apply firm pressure using a roller and
working from the centre outwards
- moisture and dust on the surfaces impair the level of adhesion obtained
7.2.1 Repairing damaged covers
Repairs with CONREMA Round or Diamond Patches

- clean the damaged area of any residues of conveyed material
- select suitable shape and size of patch
- place patch over damaged area
- mark patch outline on damaged area
- strip cover rubber from damaged area or cut into it using an inclined knife
(approx. 30 to the belt surface)
- pull off cover rubber
- dry the damaged area if necessary
- slightly roughen the cover edge and cut area using a rotating wire brush
Caution! Avoid damaging the fabric or smoothing off the rubber
- remove buffing dust by a dry process
- mix CONREMA Cement with 5% CONREMA Activator
46
- coat cover edge and damaged area with CONREMA mixture

use a short-bristled brush
work well into fabric structure
- allow first coat to dry thoroughly
-
apply second coat to damaged area

peel protective layer from adhesive layer of the patch
coat adhesive layer once
check degree of dryness of the second coat
Caution!
Back to the hand test, i.e. the coat does not dry completely but feels
tacky to touch
- once the stage of feeling tacky has been reached, apply patch with
its adhesive layer on the damaged area and by turning the patch edges
upwards, apply the centre part first
Caution!
Do not try to remove the atch again after it has made contact with
thesurface as this destroys the adhesive layer
press down using a wide hand roller, working from the centre outwards
roll again firmly with a narrow roller
avoid or roll out trapped air
finally roll firmly around the edge of the patch
Repairs with CONREMA RepairTapes
The same procedure is followed to prepare the damaged spots when
repairing cover cracks or chafed areas. CONREMA Repair Tapes are used
to fill out the damaged areas.
When joining a number of repair tapes, the beveled start of the second tape
is overlapped over the beveled end of the first tape.
47
Caution!
When tapes are joined, the direction of taper should be opposite to
that of belt movement, so as to avoid any tendency for the scraper to
"lift" the tape
When repairing long tears the belt can be advanced to reposition the
working area once the first repair tapes have been firmly applied.
Repairs with CONREMA Repair Sheeting

If it is necessary to perform frequent repairs or repairs on damaged areas of
different size or varying cover thicknesses, it is advisable to hold a
permanent stock of CONREMA Repair Sheeting in various thicknesses.

Methods are the same as those described on the previous pages, except
that the patches are cut to size from CONREMA Repair Sheeting in
accordance with the damaged area. As these self-made patches have no
tapered edge, the patch edge is firmly rolled onto the slanted cut edge of
the damaged area and the excess patch edge is trimmed using a inclined
knife.
Steel cable conveyor belts are also repaired with CONREMA Repair
Sheeting following the same procedure. Since it is not possible to remove
the cover from one fabric ply, the cover is sliced or chamfered down to just
above the steel cable layer using a knife held at a slant and then buffed. The
prepared damaged area is then mended using CONREMA Repair Sheeting

as already described.
Where covers are thick or damage is deep, the damaged area is initially
filled in using repair sheeting with adhesive layers on both sides, which is
sandwiched and then covered with ordinary repair sheeting.
7.2.2 Repairing penetrations and damage to the fabric

It is essential to repair a penetration immediately to avoid the fabric tear
extending. CONREMA Repair Sheeting and CONREMA Repair Fabric are

designed for this repair work. The fabric tear may not exceed 25% of the
belt width (danger of the belt ripping apart and risk of belt tracking
problems). If the damaged area is too large, cut the whole section out and
replace it with a new piece of belt.
When repairing fabric damage, the cover and the individual layers are
stepped in length and width at about 30 mm.
Shape of the area to be repaired
Diamond-shaped with the point towards the direction of travel and
longitudinal edge parallel to the belt edge.
- clean the damaged area of any residues of conveyed material
- outline the dimensions of the repair area with rule and chalk on the belt
surface
- cut into the cover as shown with the knife inclined at approx. 30
- cut rounded corners
48
- raise the cover from the fabric around the cut area using a loosening tool
- pull off the cover with saddler's pliers or blunt nipper pliers
- where large areas are involved, cut the cover in strips beforehand using
a ripping knife
mark the first 30 mm wide step on the exposed layer of fabric

cut into the fabric layer with a layer knife
force up the cut edge of the fabric layer with a loosening tool
cut the fabric into longitudinal strips
pull off the fabric strips with saddler's pliers
repeat fabric stepping until all fabric layers have been stepped; only the
bottom fabric layer with the tear remains intact
slightly roughen the slanted cover cut and a 15 mm wide border strip of
the cover using a rotating wire brush
- remove residual rubber on the fabric plies with a rotating wire brush
without impairing the fabric
- remove buffing dust using a dry process
- either turn the belt over, twist or advance it, or continue work on the
bottom side underneath the belt
-
49

- continue work on the bottom side following the methods already described
by cutting a rhombic shape into the cover and pulling it out. The fabric
layer remains intact.
- slightly roughen the slanted cut area of the cover and an approx. 15 mm
wide cover border strip with a rotating raising brush
- remove buffing dust using a dry process
Check the damaged area for moisture; if necessary, dry the fabric
thoroughly using an infrared dryer or hot-air blower.
- if the fabric tear is badly frayed, trim the torn edge with scissors
- coat the prepared area of the bottom side, including the slanted cut in the
cover and the cover border strip with CONREMA mixture

- measure the thickness of the extracted piece of cover
- choose CONREMA Repair Sheeting approx. 0.5 mm thinner

- cut a patch from the repair sheeting, about 10-15 mm wider and longer
than the prepared repair area
- peel the protective film from the adhesive layer
- apply a second coat of CONREMA mixture to the prepared repair area
- the adhesive layer of the patch is also given a coat of CONREMA mixture
- check how dry the second coat is
- once it has reached the tacky stage, apply patch with adhesive layer to
the repair area
- press down patch well with a roller, working from the centre outwards
- trim patch excess at the cover border strip using an inclined knife
- turn belt over again to repair the top cover
- coat repair area and cover border strip with CONREMA mixture
- fill the gap in the bottom fabric ply resulting from trimming the fabric tear
with tie gum
50
- press down the tie gum firmly using a narrow roller
- cut a suitable piece of the CONREMA Repair Fabric for each stepped
area
- coat the bottom fabric ply with CONREMA mixture

- peel off the protective film from one side of the precut piece of repair
fabric and coat this area with CONREMA mixture
- once it has reached the stage of feeling tacky, place the piece of repair
fabric on the bottom fabric ply of the repair area
- press the repair fabric down well using a hand roller

- after rolling, pull the protective film from the upper side of the repair fabric
- coat the next fabric step and the surface of the inserted piece of fabric
with CONREMA mixture

- peel off the protective film from one side of the next precut piece of repair
fabric and coat with CONREMA mixture

- once the repair fabric has reached the tacky stage, position the repair
fabric and roll down firmly
- repeat this procedure until all fabric steps have been filled in
- measure thickness of the extracted piece of cover
- choose repair sheeting approx. 0.5 mm thinner
- cut a patch from the repair sheeting, about 10-15 mm wider and longer
than the prepared repair area
- coat the last step of the repair area, fabric surface and adhesive layer with
CONREMA mixture
- once the tacky stage has been reached, apply the patch to the repair
area, unrolling it from one side
51
- press down the repair sheeting firmly with a roller, working from the centre
outwards
- trim patch excess using an inclined knife
- roll the edge of the patch again firmly along the slanted cut
- coat the patch outline with CONREMA mixture and allow to dry
With steel cable conveyor belts, penetration damage is repaired from the
top and bottom sides in the same way as that done for covers. If more than
one cable has been destroyed, damage assessment should always be
obtained from an expert to see whether the remaining belt strength is
sufficient or whether the belt will have to be cut open and respliced using
the hot vulcanizing process in order to re-establish the full belt strength.
Detailed instructions on repair procedures with CONREMA Repair
Materials are given in ContiTech's brochure: CONREMA "The Repair of

Conveyor Belts using the Cold Bonding Process".
The mechanical engineer is the only person able to decide whether it is
more economical in his particular case to run the installed belt until it is no
longer of use or to keep it serviceable through constant maintenance and
repair work. An invaluable aid in the decision-making process is to set up a
conveyor belt system data index containing all information about the belt
purchase, type, capacity, condition, amendments and repairs, including
those conducted on the structure, as well as the costs involved.
52
ContiTech
Seasonal shutdown
and winter operation
View of a downhill
conveyor
Seasonal shutdown and winter operation
Seasonal shutdown and

winter operation
Conveyor operators who shut down the system at certain intervals are
advised to use these periods of standstill for a thorough overhaul of both
the belt and the system structure.
The belt should be emptied of all materials and properly cleaned. Cleaning
should be done as far as possible using clear water, with perhaps a small
amount of washing agent added. Do not use solvents, diesel oil or petrol.
A final wipe with a mixture of glycerine and spirit likewise does no harm.
The belt must be slackened and all scrapers or cleaners disengaged. No
special treatment of the belt is necessary because an anti-oxidant has
already been applied to the covers.
All structure parts should also be cleaned and inspected as described in
section 3.1 - Preparing the structure.
Where circumstances allow, the conveyor system should be run empty from
time to time in winter during periods of heavy frost. If the belt should slip
due to ice on the pulley, this can be remedied by throwing a few handfuls of
sawdust between the pulley and the belt. Never use sand or grit for this
purpose!
A concise manual such as this cannot possibly cover all likely occurrences,
but we do hope to have provided some useful tips to help enhance
performance and cut costs in the operation of your belt conveyor.
54
55
Index
B
Belt conveyor, layout _____________3.1
Belt damage ____________________6
Belt designation _________________1.1.1/1.1.2
Belt splice ______________________4.1
Belt tension _____________________5.1
Box-section belts ________________1.2.4
C
Changing a belt__________________3.2.2
Chuting ________________________3.1
CON-BITEX (2-ply)
conveyor belts _________________1.1.1/4.1.2
CON-MONTEX (1-ply)
conveyor belts _________________1.1.1
CONREMA repair materials _______7.1

Conveyor belts, endless ___________2.1.1
Conveyor belts, standards _________1
CORREX abrasion resistant

material ______________________3.1
Corrugated sidewall belts __________1.2.4
Covers_________________________1.2.2/6.1
Cover thickness _________________1.2.1
- patterns _____________________1.2.4
- reinforcement_________________1.2.3
- repairs ______________________7.2.1
D
Damage to belt edges_____________6.1
E
Elongation ______________________3.1
F
Fabric-ply belts __________________1.1.1/4.1
Feeding chutes __________________3.1
- hoppers _____________________3.1
- points _______________________3.1/5.3/6.1
Fin-type belt ____________________1.2.4
P
Partitioned belt _________________
Penetrations ___________________
Plough-type scrapers ____________
Pulley lagging __________________
- positioning __________________
1.2.4
6.1
6.1
3.1
5.3
R
Repair ________________________
Repairing penetrations ___________
Repair materials ________________
Repair procedures ______________
Roll axle ______________________
Roll sizes______________________
Rubber sleeves _________________
Running behaviour ______________
7
7.2.2
7.1
7.2
2.2
2.2
5.3
5.3/6.1
S
Safety devices__________________
Scrapers ______________________
Self-aligning idlers_______________
Service life_____________________
Slip __________________________
Splice, detachable
(mechanical fasteners)__________
Splice, non-detachable
(vulcanized) __________________
Splicing fabric-ply belts ___________
Splicing steel cable belts__________
STAHLCORD steel cable belts ____

Steep-angle conveyor belts _______
Storage _______________________
Strength ratings_________________
Support rings___________________
6.2
3.1/6.1
6.1
6
6.1/8
4.1.1
4.1.2
4.1
4.2
1.1.2/4.2
1.2.4
2.2
1.1.1
3.1
Garland idlers ___________________6.1

Guide idlers_____________________5.3
Take-up pulley__________________
Tension member repairs __________
Tension members _______________
Training _______________________
Transportation __________________
Troughing idlers ________________
Idlers __________________________3.1
- impact rings __________________3.1/6.1
- positioning ___________________5.3
- rubber sleeves ________________5.3
- support rings _________________3.1
Impact rings ____________________3.1/6.1
Inspection ______________________6.1
Inspection of belt splices___________6.1
Installation______________________3.1/3.2
Wear _________________________ 6
Weight ________________________ 2.2
Winter operation ________________ 8
M
Material feeding point _____________3.1/5.3/6.1
Mechanical fasteners _____________4.1.1
Misalignment____________________5.3/6.1
Multi-ply conveyor belts ___________1.1.1/4.1.2
O
Order data______________________2.1
56
3.1/5.1
7.2.2
1.1.1
5.3
2.2
5.3
57
ContiTech
Spezialist in rubber technology
Conveyor Belting
Conveyor belt systems Troubleshooting guide
ContiTech has compiled this

problem location table especially
with the conveyor system operator
in mind. It serves as an effective
aid in quickly tracing any problem to
its source.
The conveyor belt must be optimally
matched to the conveyor system to
ensure reliable, problem-free
operation and maximum service life.
Early "problem analysis" can help to
avoid errors and eliminate consequential damage.
If you have any difficulty in locating
the cause of disturbances even after
consulting our table, or if you have
any further technical questions, do
not hesitate to contact ContiTech's
Application Engineers.
Research and Development
Conveyor Belting
Application Engineering
(Dept. 63311)
P.O. Box 1 69
3000 Hannover 1
Germany
Phone: (511) 21 41-1
Fax:
(511) 21 41-5 83
Telex:
9 2 170 con d
ContiTech Specialist in rubber technology
Range
ContiTech
Continental Offices
Conveyor Belts:
Advanced technology in rubber

processing and manufacture
Austria
C.U.P. Gummi
Gesellschaft m.b.H.
Continental
Eisgrubengasse 4
Postfach 13
A-2334 Vsendorf-Sd
(02 22) 69 25 01
Fax (02 22) 69 25 01 37
Fabric Ply Belts

Steep Angel and
Vertical Conveyor Belts
Special Purpose Belts
Special belt types
STAHLCORD (steel cable)

Conveyor Belts
Conveyor Belting Accessories:
Worldwide application
Latest technology in production and
development
Conveyor Belting
Coated Fabrics and Engineered
Products
Industrial and Automotive Hose
Power Transmission Products
Air Springs
CORREX Pulley Lagging with
patterned surface and adhesive layer
CORREX Pulley Lagging and

Abrasion Resistant Materials with
smooth surface and adhesive layer
Anti-Vibration and Sealing Mouled

Products
Extrusions
Footwear Products
Scrapers
CONREMA Cold Bonding Cement
Cushioning Products
France
Continental
Caoutchouc
Industriel
68, Rue de Paris
F-93804 Epinaysur-Seine Cedex
(1) 48.23.46.16
Fax (1) 48.22.28.44
Great Britain
C.U.P. Ltd.
Continental
Technical Products
Division
Cottage Leap
Clifton Road
Rugby
Warwickshire
CV21 3RQ
(0788) 71482-87
Fax (07 88) 53 66 08
Italy
Continental S.p.A.
Divisione Prodotti
Tecnici
Via Marcantonio
Colonna, 42
I-20149 Milano
(02) 33 00 06 27-29
Fax (02)33000632
CONTI PLUS Adhesion Promoter
CONREPA Repair Paste

Cleansing Agent
CONREMA Cold Repair Materials

with adhesive layer
Hot repair and splicing materials for
fabric belts
Hot repair and splicing materials for
STAHLCORD (steel cable) belts

Support and Impact Rings
Corrugated Sidewalls and Extrusions
Geschftsbereich Transportband
Postfach 169
Continental-Haus
D-3000 Hannover 1
Phone (0511) 2141-1
Telex 9 217-0 con d
Telefax (0511) 2141-5 83
Belgium
P.U.E. S.A.
Continental
Noorderlaan 121
Postfach 38
B-2030 Antwerpen
(3) 5413720-27
Fax (3) 5416929
The contents of this publication are

the result of many years of research
and experience gained in application technology. All information is
given in good faith; it does not
represent a guarantee with respect
to characteristics and does not
exempt the user from testing the
suitability of products including
Republic of South Africa

Continental Gummi
(Pty) Ltd.
P.O.Box 76.212
Wendywood
Sandton 2144
(011)8 02-10 44/45/46
Fax (011) 802-4604
Singapore
Continental
Aktiengesellschaft
Singapore Office
10 Collyer Quay
07-07 Ocean Building
Singapore 0104
5 33 86 90/5 33 82 90
Fax 5 33 87 70
Spain
Continental Industrias
del Caucho S.A.
Bruc, 21
E-08010 Barcelona
(93) 41211 20
Fax (93) 4123414
Sweden
C&S Rubber AB
Continental
Box 12 94
S-17125 Solna
(08) 29 04 80
Fax (08) 29 57 58
Switzerland
Continental
Caoutchouc
(Suisse) S.A.
Vogelsangstrasse 28
CH-8307 Effretikon
(0 52) 32 70 21
Fax (0 52) 32 2819
USA
Continental
Products Corporation
1200 Wall Street West
Lyndhurst, N.J. 07071
(2 01) 4 60 02 00
Fax (201) 4608372
checking with respect to industrial property

rights of any third parties. No liability
whatsoever will be accepted for damage,
regardless of its nature and its legal basis,
arising from advice given in this publication.
Products are subject to technical changes
as a result of new developments.
ContiTech
Geschftsbereich Transportband
Postfach 169
Continental-Haus
D-3000 Hannover 1
Phone (0511) 2141-1
Telex 9217-0 con d
Telefax (0511) 2141-5 83
The contents of this publication are

the result of many years of research
and experience gained in application technology. All information is
given in good faith; it does not
represent a guarantee with respect
to characteristics and does not
exempt the user from testing the
suitability of products including
checking with respect to industrial

property rights of any third parties. No
liability whatsoever will be accepted for
damage, regardless of its nature and its
legal basis, arising from advice given in
this publication. Products are subject to
technical changes as a result of new
developments.

Manualparaingenierosmecanicos 130217094219 Phpapp01

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ContiTech

Specialist in Rubber Technology

ContiTech Specialist in Rubber Technology

CONTI Conveyor Belting

CONTI Conveyor Belt Edition

Conveyor Belting Manual for Mechanical Engineers

Responsibilities of the mechanical engineer

Engineers who provide

Your advantages are

Your advantages are

Optimized splicing systems

Expert on-site advice

Instruction and training

Your advantages are

Your advantages are

Specialist in Rubber Technology

CONTI Conveyor Belting and

Specialist in Rubber Technology

Conveyor Belt Service

Structure and identification

Tension members ____________________ 2

Ordering and storing _________ 12

How to order conveyor belts ___________ 12

5.1 Tensionieng the belt_________________ 32

Operation and problem solving _ 40

6.1 Daily inspection of the conveyor belt;

Maintenance and repair _______ 44

7.1 Repair materials ____________________

CONREMA repair materials___________

3.2 Preparations for pulling the belt onto

Splicing conveyor belts ______ 26

Splicing fabric-ply conveyor belts _______ 26

Seasonal shutdown and

Preparations for installation ___ 20

3.1 Preparing the structure _______________ 20

CORREX abrasion resistant material ____ 22

Conveyor belt systems Troubleshooting guide

Specialist in Rubber Technology

Aerial cableway is replaced

Structure and identification of conveyor belts

Structure and identification

1.1.1 Conveyor belts with textile plies

Structure and identification of conveyor belts

Whereas earlier types of conveyor belt used to be reinforced with a

1-ply belts (only for underground)

Structure and identification of conveyor belts

Technical Data (guide values)

2-ply belts (with thick intermediate rubber layer)

Other types of belt available on request

Aufbau und Kennzeichnung der Frdergurte

1.1.2 Steel cable conveyor belts

running parallel to each other longitudinally. STAHLCORD Conveyor Belts

steel cables enclosed on all sides by rubber provide STAHLCORD

heights are concerned. STAHLCORD Conveyor Belts also have a good

Tension member mass

1) without allowances according to DIN 22101

Structure and identification of conveyor belts

If the reinforcement of a conveyor belt is to retain its strength, it must be

1.2.1 Cover thickness

1.2.2 Cover grade

Steel cable belts

flame resistant und antistatic*

resistant to elevated temperatures