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TABLE 11 DRIVE FACTOR k

Screw Gravity or Automatic

Angle of Type Take-up Winch Take-up
Belt Wrap of
at Drive Drive Bare Lagged Bare Lagged
Pulley Pulley Pulley Pulley
150 Plain 1,5 1,0 1,08 0,670
160 Plain 1,4 0,9 0,99 0,600
170 Plain 1,3 0,9 0,91 0,550
180 Plain 1,2 0,8 0,84 0,500
190 Snubbed 1,1 0,7 0,77 0,450
200 Snubbed 1,0 0,7 0,72 0,420
210 Snubbed 1,0 0,7 0,67 0,380
220 Snubbed 0,9 0,6 0,62 0,350
230 Snubbed 0,9 0,6 0,58 0,320
240 Snubbed 0,8 0,6 0,54 0,300
340 Dual 0,5 0,4 0,29 0,143
360 Dual 0,5 0,4 0,26 0,125
380 Dual 0,5 0,3 0,23 0,108
400 Dual 0,5 0,3 0,21 0,095
420 Dual 0,4 0,3 0,19 0,084
440 Dual     0,17 0,074
460 Dual     0,15 0,064
480 Dual     0,14 0,056

Notes:

1. When calculating the driving tension required for dual drive units, the drive factor selected must correspond to the total angle of driving
wrap.

The drive factors quoted for gravity or automatic take-up systems are minimum values based on the relationship between angle of wrap
2. and coefficient of friction between belt and drum at the point of slip. In the case of screw take-up units, an adjustment has been made to
the drive factor to allow for the extra tension which may be induced in the belt either:

a. to compensate for the effect of belt elongation when the material is loaded.
b. due to the difficulty in measuring the amount of tension applied.

In those cases where an electrically or hydraulically loaded winch type take-up is used, where the induced tension can be preset and
3. controlled, the drive factor should be selected to correspond with a gravity take-up system.

CONVEYOR BELT SELECTION

Belt carcass selection criteria

In selecting the optimum belt construction for a given application it is necessary to consider the following:

Tensile strength
The belt class required is that which has an operating tension greater than or equal to the calculated maximum unit tension T. (Table 12).

Load support
Choose the lowest class which meets the tensile strength requirement. Looking at Table 14, determine which load category best describes the
load being conveyed i.e. A, B, C, D or E category load. The value obtained at the intersection of the belt specification row and the load category
column gives the maximum width at which that belt specification can be used.

Number of plies for troughability

The maximum number of plies allowable, in order to ensure that the empty belt will conform to the contour of the troughing idlers, must be
checked referring to Table 15. For a particular belt class the value shown at the intersection of the belt width column and troughing angle row, is
the maximum number of plies that should be used.
Minimum pulley diameters
If the size of the pulleys is already determined, the belt construction provisionally selected from the previous considerations can be checked
against the relevant pulley diameters for suitability. For a new installation, the pulley diameters should be equal to or larger than those given in
Table 13 (It should be noted that, in this context, the diameters quoted refer to the minimum pulleys around which the particular belt construction
will flex satisfactorily. The conveyor designer should also take into account the gearbox ratio and required belt speed when selecting the drive
pulley diameter.)

Gauge of covers required

The correct gauge of cover necessary to give protection to the belt carcass from material impact and wear must be determined by consideration
of the size and density of the material to be handled. (Table 19).

Additional Information

Belt modulus
Refer to Table 20 for belt modulus.

Belt mass
The mass of a particular belt construction can be determined by adding the carcass mass found in Table 17 to the combined mass of covers
found in Table 18. This will give the mass per unit area. To calculate the mass per unit length multiply by the belt width in metres.

Belt thickness
The belt thickness can be obtained from the information given in Table 16.

TABLE 12 MAXIMUM RECOMMENDED OPERATING TENSIONS

Textile Reinforced Multi-ply and Steelcord Reinforced Conveyor Belting

Solid Woven Carcass Conveyor Belting
Belt Max recommended Belt Max recommended
Class Operating Tension (kN/m) Class Operating Tension (kN/m)
160 16,0    
200 20,0    
250 25,0    
315 31,5    
400 40,0    
500 50,0 St 500 75,0
630 63,0 St 630 94,0
800 80,0 St 800 120,0
1000 100,0 St 1000 150,0
1250 125,0 St 1250 187,5
1600 160,0 St 1600 240,0
2000 200,0 St 2000 300,0
    St 2500 375,0
    St 3150 472,0
    St 4000 600,0
    St 5000 750,0
    St 6300 945,0

TABLE 13 RECOMMENDED MINIMUM PULLEY DIAMETERS (mm)

Textile Reinforced Rubber Belting

Solid Woven Steelcord
Belt Class Pulley Type No. of Plies PVC Belting Reinforced
Rubber Belting
2 3 4 5
A 315          
160 B 250          
C 200          
A 315          
200 B 250          
C 200          
A 315 400        
250 B 250 315        
C 200 250        
A 315 400     400  
315 B 250 315     315  
C 200 250     250  
 400 A 400 500 630   400  
B 315 400 500   315  
C 250 315 400   250  
A 500 500 630 630 500 500
500 B 400 400 500 500 400 400
C 315 315 400 400 315 315
A 500 630 630 800 500 500
630 B 400 500 500 630 400 400
C 315 400 400 500 315 315
A 630 800 800 800 500 500
800 B 500 630 630 630 400 400
C 400 500 500 500 315 315
A 630 800 1000 1000 630 500
1000 B 500 630 800 800 500 400
C 400 500 630 630 400 315
A   1000 1000 1250 800 630
1250 B   800 800 1000 630 500
C   630 630 800 500 400
A   1000 1250 1250 1000 800
1600 B   800 1000 1000 800 630
C   630 800 800 630 500
A     1250 1400 1000 800
2000 B     1000 1250 800 630
C     800 1000 630 500
A           1000
2500 B           800
C           630
A           1250
3150 B           1000
C           800
A           1250
4000 B           1000
C           800
A           1400
5000 B           1250
C           1000
A           1400
6300 B           1250
C           1000

 
Pulley types   Examples
A High tension pulleys Wrap exceeding 45°   Head, drive & tripper
B Low tension pulleys Wrap exceeding 45°   Tail, take-up, Take-up bend
  or    
  High tension pulleys Wrap up to 45°   High tension snub or bend pulleys
C Low tension pulleys Wrap up to 45°   Low tension snub or bend pulleys

TABLE 14 LOAD SUPPORT

Recommended maximum belt width (mm) for correct load support. Multi-ply textile reinforced rubber belting.

A B C D E
Light Duty Light to Medium Duty Medium Duty Heavy Duty Extra Heavy Duty
Belt Spec
Up to 800 kg/m3 Up to 1200 kg/m3 Up to 1600 kg/m3 Up to 2400 kg/m3 Up to 3000 kg/m3
 - 25mm Lumps  - 50mm Lumps  - 100mm Lumps  - 250mm Lumps  + 250mm Lumps
160/2 750 600 500 400 Not Recommended
200/2 750 600 600 4500 Not Recommended
 250/2 900 750 750 600 500
250/3 1050 900 750 600 600
315/2 900 900 750 600 500
315/3 1200 1050 1050 750 600
400/2 1200 1050 1050 900 750
400/3 1200 1050 1050 900 750
400/4 1500 1500 1350 900 750
500/2 1200 1200 1200 1050 900
500/3 1350 1200 1200 1050 900
500/4 1650 1500 1350 1200 900
500/5 1800 1800 1800 1500 1350
630/2 1200 1200 1200 1050 900
630/3 1650 1350 1200 1050 1050
630/4 1650 1500 1350 1200 1050
630/5 2100 2100 1800 1650 1350
800/2 1650 1500 1500 1350 1200
800/3 1800 1650 1500 1350 1200
800/4 2100 1800 1650 1500 1350
800/5 2400 2400 2100 1800 1500
1000/2 1800 1650 1500 1350 1200
1000/3 2100 1650 1500 1350 1200
1000/4 2400 1800 1800 1500 1350
1000/5 2400 2400 2200 1800 1500
1250/3 2100 1800 1800 1350 1200
1250/4 2400 2200 2200 1650 1500
1250/5 2400 2400 2400 1800 1800
1600/3 2400 2400 1800 1650 1650
1600/4 2400 2400 2200 1800 1800
1600/5 2400 2400 2400 2200 1800
2000/4 2400 2400 2400 1800 1800
2000/5 2400 2400 2400 2200 2100

TABLE 15 MAXIMUM NUMBER OF PLIES RECOMMENDED FOR CORRECT EMPTY BELT TROUGHING

Belt Belt Width (mm) Troughing

Class 350 400 450 500 600 750 900 1050 1200 1350 1500 1650 1800 2100 2200 Angle
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 20°
160
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 35°
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 20°
200
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 35°
- 3 3 3 3 3 3 3 3 3 3 3 3 3 3 20°
250
- 2 2 2 3 3 3 3 3 3 3 3 3 3 3 35°
- 2 3 3 3 4 4 4 4 4 4 4 4 4 4 20°
315
- 2 3 3 3 3 4 4 4 4 4 4 4 4 4 35°
- 2 4 4 4 4 4 4 4 4 4 4 4 4 4 20°
400
- - 3 3 3 4 4 4 4 4 4 4 4 4 4 35°
- - 4 4 4 4 4 4 4 4 4 4 4 4 4 20°
500
- - 3 3 3 4 4 4 4 4 4 4 4 4 4 35°
- - 4 4 4 4 4 4 4 4 4 4 4 4 4 20°
630
- - 2 2 3 4 4 4 4 4 4 4 4 4 4 35°
- - 3 3 4 4 4 4 4 4 4 4 4 4 4 20°
800
- - 2 2 3 4 4 4 4 4 4 4 4 4 4 35°
- - - - 4 4 4 4 4 4 4 4 4 4 4 20°
1000
- - - - 2 3 4 4 4 4 4 4 4 4 4 35°
- - - - 4 4 4 4 4 4 4 4 4 4 4 20°
1250
- - - - 3 3 4 4 4 4 4 4 4 4 4 35°
1600 - - - - 3 4 4 4 4 4 4 4 4 4 4 20°
 - - - - - 3 4 4 4 4 4 4 4 4 4 35°
- - - - - 4 5 5 5 5 5 5 5 5 5 20°
2000
- - - - - - 4 4 5 5 5 5 5 5 5 35°

TABLE 16 CARCASS THICKNESS (mm)

Textile Reinforced Rubber Belting

No. of Plies Solid Woven Steelcord Reinforced
Belt Class PVC Belting Rubber Belting
2 3 4 5
160 2,0          
200 2,6          
250 2,7 3,2        
315 2,8 3,5     4,9  
400 3,0 3,8 5,0      
500 4,0 4,2 5,2 5,9 5,9 3,2
630 4,3 5,2 5,8 6,6 6,2 3,2
800 5,0 6,0 6,9 7,2 6,9 3,7
1000 5,7 6,5 7,6 8,5 7,4 3,7
1250   8,4 9,6 10,0 8,4 3,7
1600   9,5 10,5 11,0 9,9 5,4
2000     12,0 13,0 12,4 5,4
2500           7,0
3150           8,0
4000           9,0
5000           11,0
6300           12,0

Add the thickness of the covers to get the total belt thickness

TABLE 17 MASS OF BELT CARCASS (kg/m2)

Textile Reinforced Rubber Belting Solid Woven

Belt Class No. of Plies PVC Belting Steelcord Reinforced
With Nominal Rubber Belting
2 3 4 5 PVC Coating
160 2,8          
200 3,0          
250 3,1 3,9        
315 3,4 4,2     9,0  
400 3,7 4,4 6,0   9,4  
500 4,3 4,8 6,4 7,5 9,7 7,5
630 4,8 5,2 6,8 8,0 10,5 7,7
800 5,6 6,4 7,2 8,5 11,0 8,2
1000 6,5 7,3 8,5 9,0 11,7 9,0
1250   8,9 9,7 10,5 13,0 9,7
1600   10,7 11,5 12,5 15,0 13,4
2000     14,2 14,9 18,0 15,3
2500           18,7
3150           22,4
4000           28,4
5000           35,1
6300           38,7

To obtain total belt mass add the mass of the combined covers from Table 18.
The mass per unit length is determined by multiplying the total mass by the belt width in metres.

TABLE 18 MASS OF COVERS PER mm OF THICKNESS (kg/m2)

  
Grade of Cover Mass Grade of Cover Mass
 (kg/m2) (kg/m2)
N 1,14 PHR 1,17
M 1,10 SPHR 1,21
OR 1,41 DHR 1,34
GF 1,37 PVC 1,37
FR 1,27 Nitrile 1,32

RATE OF WEAR VS THICKNESS OF COVER

The rate at which a belt cover wears is related to the thickness of the cover and to the impact energy imparted by material lumps.

Impact energy can be calculated for any material of known lump mass and vertical velocity.

γ - ω x νv  J

γ - Impact Energy (J)

ω - Mass of lump (kg)
νv - Verticle velocity (m/s)

TABLE 19 MINIMUM BELT TOP COVER GAUGE GUIDE

Material Class A Material Class B Material Class C Material Class D

Non abrasive material Abrasive material Very abrasive material Very sharp abrasive material
such as lime, charcoal, such as salt, anthracite such as slag, copper ore, such as quartz, some ores,
Cycle wood chips, bituminous coal, phosphate rock, sinter, coke sand, foundry refuse, glass batch,
time coal grain limestone, fullers earth flue dust iron borings
s
Lump size (mm) Lump size (mm) Lump size (mm) Lump size (mm)
dust 12 50 150 dust 12 50 150 dust 12 50 150 dust 12 50 150
to to to and to to to and to to to and to to to and
12 50 150 over 12 50 150 over 12 50 150 over 12 50 150 over
12 2,0 3,0 6,0 8,0 3,0 6,0 10,0 10,0 6,0 10,0 10,0 10,0 8,0 10,0 10,0 10,0
25 2,0 2,5 3,0 5,0 2,5 3,0 6,0 10,0 3,0 6,0 10,0 10,0 4,0 8,0 10,0 10,0
40 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 6,0 10,0 3,0 4,0 8,0 10,0
60 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 5,0 6,0 3,0 3,0 6,0 10,0
90 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 5,0 5,0 3,0 3,0 6,0 6,0
120 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 4,0 5,0 3,0 3,0 5,0 6,0
180 1,0 2,5 3,0 5,0 2,5 3,0 4,0 5,0 3,0 3,0 4,0 5,0 3,0 3,0 5,0 6,0
240+ 1,0 2,5 3,0 5,0 2,0 3,0 4,0 5,0 3,0 3,0 4,0 5,0 3,0 3,0 5,0 6,0

Cycle time - 2L/S

TABLE 20 BELT MODULUS (kN/m)

Multi-ply Steelcord
Belt Class Textile Solid Woven Reinforced
Reinforced PVC Belting Rubber Belting
Belting
160 1060    
200 1330    
250 1660    
315 2070 1750  
400 2950 2220  
500 3330 2800 29000
630 4200 3500 37700
 800 5330 4440 47900
1000 6660 5550 59800
1250 8330 6900 74800
1600 10660 8890 95800
2000 13330 11110 119700
2500     149700
3150     188600
4000     240000
5000     300000
6300     377200

TABULATOR CALCULATIONS

For the purposes of

1. Calculating vertical curves, or

2. Determining belt tension for conveyors of undulating profile.

It is necessary to calculate the belt tensions at various points on the conveyor.

Calculating the tension at any point along the conveyor.

The tabulation method described below is a convenient means of calculating the tensions at any point on the conveyor.

Blank copies of the "Conveyor Tabulation Sheets" are available from Dunlop Africa Industrial Products.

The following method is used to determine the tension at any point along the conveyor:

1. Calculate the length correction factor.

2. Look up the mass of moving parts in Table 10.
3. Calculate the mass of the load from the design capacity and the belt speed.
4. Calculate the maximum effective tension under constant speed operation. This will always occur when all the non-declined sections of
the conveyor are fully loaded and the declined sections empty.
5. Determine the minimum value for the slack side tension under maximum load condition.
6. Commencing from immediately behind the drive, label each pulley, intersection point and loading section. Start and end point of each of
the load lengths should also be labelled.
7. Determine the effective tension required to overcome the frictional and gravitational resistances for each of the segments of the
conveyor by using formulae on page 4.
The value of 12, determined in 5 above, is used to calculate the
effective tension to overcome pulley friction.
8. The effective tension at any point on the conveyor is the sum of the effective tensions of all preceeding segments. The total effective
tension for the conveyor is the sum of the effective tensions for all segments.
9. The tension at any point 'x' on the conveyor is made up of the effective tension at point 'x' plus the slope tension at point 'x'.
Superimposed on this is the tension applied by the take-up system. The tension applied by the take-up is given by the worst case T2
value i.e. the value of T2 which

a. prevents slip at the highest Te value and,

b. limits sag between carry idlers.
It may be found that the value of T2 obtained when the maximum effective tension has been calculated is different to that used in the
calculations. If this is the case the new T2 value is used to calculate tensions at each point.

Steps 7, 8 and 9 should be repeated for four load cases viz empty, fully loaded, non-declined sections loaded and declined sections loaded.

EXAMPLE

Belt width 1200 mm

Conveyor length 500 m
Lift 45 m
Max capacity 4500 t/hr
Belt speed 3,5 m/s
Skirt length 3m
Material conveyed Iron Ore
Lump size 100 mm
Bulk density 2,4 t/m3
Carry idler diameter 127 mm
Carry idler spacing 1,2 m
Return idler diameter 127 mm
Return idler spacing 3,6 m
Impact idler diameter 159 mm
Impact idler spacing 0,45 m
Drive wrap 210 degree
Drive surface Rubber lagged
Take-up type Gravity

Step 1

Calculate the length correction factor

L + 70
C = 
L
570
= 
500
=  1,14

Step 2

From Table 10 the mass of the moving parts for a 1200 mm wide conveyor of medium duty is 71 kg/m.

Step 3

Calculate the mass of the load

τ
Q =  0,278
s
0,278 x 4500
 = 
3,5
 =  357,4 kg/m

Step 4

Calculate the maximum effective tension when the non-declined sections of the conveyor are all carrying load and the declined sections have no
load. The total horizontal length of non-declined sections is 20 + 330 = 350 m.

The overall change in elevation on the non-declined sections is 70 in. Note that the actual length of the conveyor is used to calculate Tx and only
the loaded length to calculate Ty. The length correction factor is a constant and is used to convert the actual length to a corrected length. The
friction factors are determined by the total conveyor length in all cases.

Effective tension to move the empty belt.

Tx =  9,8G x fx C x L
 =  9,8 x 71 x 0,020 x 1,14 x 500
 =  7932N

Effective tension to move the load horizontally.

Ty =  9,8Q x fy C x L
 =  9,8 x 357,4 x 0,020 x 1,14 x 350
 =  30745N

Effective tension to lift the load.

Tz =  9,8Q x H
 =  9,8 x 357,4 x 70
 =  245176N

Effective tension to overcome skirtboard friction The inter-skirtboard width is assumed to be 2/3 of the belt width i.e. 0,8 m.
Tus =  9,8fs x Q x Ls

   S x b2    
9,8 x 357,4 x 0,020 x 1,14 x 350
 = 
3,5 x 0,64
 =  3050N

The total effective tension is the sum of the above four.

Te =  Tx + Ty + Tz + Tus
 =  7932 + 30745 + 245176 + 3050
 =  286903N

Step 5

The minimum slack side tension to prevent slip is:

Tm =  k x Te
k =  0,38 from Table 11 and hence
Tm =  0,38 x 286903
 =  109023

The minimum slack side tension to prevent excessive belt sag is:

Ts =  9,8Sf x (B + Q) x Id
 =  9,8 x 6,3 x (14,8 + 357,4) x 1,2
 =  27576N

From Table 8 the estimated belt mass is 14,8 kg/m

Since

Tm > Ts

T2  = Tm

i.e. T2  = 109023N

Step 6

The conveyor is labelled from A to 0 as shown on example sheets 1 to 4.

Step 7

Calculations of the effective tension for each segment (or run) is shown on Sheet 1 for the empty belt, Sheet 2 for the fully loaded belt, Sheet 3 for
the case where only non-decline sections are loaded and Sheet 4 where only the decline sections are loaded.

Step 8

The accumulated effective tension column is the sum of the effective tensions of the current segment and all preceeding segments.

Step 9

The total effective tension for each load case is the value in the last row of the column titled 'Accumulated Effective Tension'.

For the empty belt Te =  7665N

For the fully loaded belt Te =  174188N
For all non-declines loaded Te =  283609N
For only declines loaded Te =  -101755N

The reason for the difference between the effective tension determine step 4 and that on Sheet 3 is the more accurate figures used for mass of
the moving parts on the tabulation sheets.

The tension at any point along the conveyor can now be determined, all load cases, by adding the effective tension at the point to the slope
tension at the point and then adding the worst case T2 value.

The highest Te value occurs when all non-declines are loaded. i.e. Te = 283609N
Based on this value

Tm =  k x Te
 =  0,38 x 283609N
 =  107771N

Since Ts, calculated in step 5, is less than Tm

T2 = Tm

i.e. T2 = 107771N

Thus, for example, the effective tension at run L - M takes the following values:

1. Empty Belt 4302N

2. Fully loaded - 24577N
3. Non-declines loaded 6059N
4. Declines loaded -26334N

From these it is determined that the tension at point M under the four cases, given by

Te + T2 + Th is

Empty belt

4302 + 107771 + 0
= 112073N

Fully loaded belt

-24577 + 107771 + 0
= 83194N

Non-declines loaded

6059 + 107771 + 0
= 113830N

Declines loaded

-26334 + 107771 + 0
= 81437N

CLIENT NAME CONVEYOR EQUIPMENT NO.

Belt width W 1200 mm
Conveyor length L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Belt speed S 3,5 m/s
Skirt length Ls 3m
Material conveyed   Iron Ore   Idler Data Carry Return Impact  
Lump size   100 mm Trough Angle 35 0 35 degree
Bulk densiy   2,4 t/m3 Roll Diameter 127 127 159 mm
Lc Spacing 1,2 3,6 0,45 m
Corrected length 570 m
Rotating Parts Mass M 19,9 17,1 22,9 kg/set
Correction factor C 1,14  

Friction Factors Pulleys Diameter Location

Rotating Parts fx  0,020 Head 630 mm O
Load Friction fy 0,022 Drive Head mm O
HT Bend - mm -
Skirt Friction fs 0,65
Tail 500 mm I
Scraper Friction fc 0,60 Take-up 500 mm E
Drive & Take-up Take-up Bend 500 mm D,F
Angle of Wrap 210° LT Bend 450 mm B
Tripper - mm -
Drive Surface Lagged Bare
Take-up Type Gravity Screw
 Drive Factor k 0,38

Length Idler Load Tension to Overcome Friction (N) Lift Tension to Effective Accumulative Absorbed
Belt of Overcome Tension Effective
of Run Mass Mass Mass Power
Run (m) (kg/m) (kg/m) (kg/m) Idlers Belt Pulley Load Run Gravity for Run Tension (W)
Lr Mr = M/Id Qr 9,8LrCfxMr 9,8LrCfxB 0,01(do/D)T2 9,8LrCfxQ (m) (N) (N) (N) TeS
B Hr 9,8QHr Ter Te 
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 0 34 10 178 0 0 0 222 3477 12168
K-L 17 16,5 14,8 0 63 56 178 0 0 0 297 3774 13208
L-M 50 16,5 14,8 0 184 165 178 0 -10 0 528 4302 15055
M-N 330 16,5 14,8 0 1217 1091 178 0 70 0 2486 6788 23757
N-O 100 16,5 14,8 0 369 331 178 0 -25 0 887 7665 36829

SHEET 1 - EMPTY BELT

CLIENT NAME CONVEYOR EQUIPMENT NO.

Belt width W 1200 mm
Conveyor length L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Belt speed S 3,5 m/s
Skirt length Ls 3m
Material conveyed   Iron Ore   Idler Data Carry Return Impact  
Lump size   100 mm Trough Angle 35 0 35 degree
Bulk densiy   2,4 t/m3 Roll Diameter 127 127 159 mm
Corrected length Lc 570 m Spacing 1,2 3,6 0,45 m
Rotating Parts Mass M 19,9 17,1 22,9 kg/set
Correction factor C 1,14  

Friction Factors
Rotating Parts fx  0,020
Pulleys Diameter Location
Load Friction fy 0,022 Head 630 mm O
Skirt Friction fs 0,65 Drive Head mm O
Scraper Friction fc 0,60 HT Bend - mm -
Tail 500 mm I
Drive & Take-up
Take-up 500 mm E
Angle of Wrap 210°
Take-up Bend 500 mm D,F
Drive Surface Lagged Bare LT Bend 450 mm B
Tripper - mm -
Take-up Type Gravity Screw
Drive Factor k 0,38

Length Idler Load Tension to Overcome Friction (N) Lift Tension to Effective Accumulative Absorbed
Belt of Overcome Tension Effective
of Run Mass Mass Mass Power
Run (m) Run Gravity for Run Tension
(kg/m) (kg/m) (kg/m) Idlers Belt Pulley Load (W)
(m) (N) (N) (N)
Lr Mr = M/Id B Qr 9,8LrCfxMr 9,8LrCfxB 0,01(do/D)T2 9,8LrCfxQ TeS
Hr 9,8QHr Ter Te 
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
 C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 357,4 34 10 178 264 0 0 485 3740 13090
K-L 17 16,5 14,8 357,4 63 56 178 1493 0 0 1791 5531 19357
L-M 50 16,5 14,8 357,4 184 165 178 4393 -10 -35028 -30108 -24577 -86019
M-N 330 16,5 14,8 357,4 1217 1091 178 28991 70 245196 276673 252096 882335
N-O 100 16,5 14,8 357,4 369 331 178 8785 -25 -8750 -77908 174188 609659

SHEET 2 - FULLY LOADED BELT

CLIENT NAME CONVEYOR EQUIPMENT NO.

Belt width W 1200 mm
Conveyor length L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Belt speed S 3,5 m/s
Skirt length Ls 3m
Material conveyed   Iron Ore   Idler Data Carry Return Impact  
Lump size   100 mm Trough Angle 35 0 35 degree
Bulk densiy   2,4 t/m3 Roll Diameter 127 127 159 mm
Corrected length Lc 570 m Spacing 1,2 3,6 0,45 m
Rotating Parts Mass M 19,9 17,1 22,9 kg/set
Correction factor C 1,14  

Friction Factors
Rotating Parts fx  0,020
Pulleys Diameter Location
Load Friction fy 0,022
Head 630 mm O
Skirt Friction fs 0,65 Drive Head mm O
Scraper Friction fc 0,60 HT Bend - mm -
Tail 500 mm I
Drive & Take-up
Take-up 500 mm E
Angle of Wrap 210°
Take-up Bend 500 mm D,F
Drive Surface Lagged Bare LT Bend 450 mm B
Tripper - mm -
Take-up Type Gravity Screw
Drive Factor k 0,38

Tension to Overcome Friction (N) Lift Tension to Effective Accumulative

Length Idler Belt Load Absorbed
of Run Mass Mass of Overcome Tension Effective Power
Run (m) Mass Run Gravity for Run Tension
(kg/m) (kg/m) (kg/m) Idlers Belt Pulley Load (W)
(m) (N) (N) (N)
Lr Mr = M/Id B Qr 9,8LrCfxMr 9,8LrCfxB 0,01(do/D)T2 9,8LrCfxQ TeS
Hr 9,8QHr Ter Te 
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 357,4 34 10 178 264 0 0 485 3740 13090
K-L 17 16,5 14,8 357,4 63 56 178 1493 0 0 1791 5531 19357
L-M 50 16,5 14,8 0 184 165 178 0 -10 0 528 6059 21205
M-N 330 16,5 14,8 357,4 1217 1091 178 28991 70 245196 276673 282732 989559
 N-O 100 16,5 14,8 0 369 331 178 0 -25 0 877 283609 992631

SHEET 3 - NON-DECLINES LOADED

CLIENT NAME CONVEYOR EQUIPMENT NO.

Belt width W 1200 mm
Conveyor length L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Belt speed S 3,5 m/s
Skirt length Ls 3m
Material conveyed   Iron Ore   Idler Data Carry Return Impact  
Lump size   100 mm Trough Angle 35 0 35 degree
Bulk densiy   2,4 t/m3 Roll Diameter 127 127 159 mm
Corrected length Lc 570 m Spacing 1,2 3,6 0,45 m
Rotating Parts Mass M 19,9 17,1 22,9 kg/set
Correction factor C 1,14  

Friction Factors
Rotating Parts fx  0,020
Pulleys Diameter Location
Load Friction fy 0,022
Head 630 mm O
Skirt Friction fs 0,65 Drive Head mm O
Scraper Friction fc 0,60 HT Bend - mm -
Tail 500 mm I
Drive & Take-up
Take-up 500 mm E
Angle of Wrap 210°
Take-up Bend 500 mm D,F
Drive Surface Lagged Bare LT Bend 450 mm B
Tripper - mm -
Take-up Type Gravity Screw
Drive Factor k 0,38

Tension to Overcome Friction (N) Lift Tension to Effective Accumulative

Length Idler Belt Load Absorbed
of Run Mass Mass of Overcome Tension Effective Power
Run (m) Mass Run Gravity for Run Tension
(kg/m) (kg/m) (kg/m) Idlers Belt Pulley Load (W)
Lr Mr = M/Id Qr 9,8LrCfxMr 9,8LrCfxB 0,01(do/D)T2 9,8LrCfxQ (m) (N) (N) (N) TeS
B Hr 9,8QHr Ter Te 
A-B 2 0 14,8 0 0 7 178 0 0 0 185 185 647
B-C 98 5,7 14,8 0 125 324 0 0 25 0 449 634 2218
C-D 15 5,7 14,8 0 19 50 178 0 -3 0 247 881 3082
D-E 0 0 14,8 0 0 0 178 0 0 0 178 1059 3706
E-F 0 0 14,8 0 0 0 178 0 0 0 178 1237 4330
F-G 330 5,7 14,8 0 420 1091 0 0 -67 0 1512 2749 9621
G-H 50 5,7 14,8 0 64 165 0 0 10 0 229 2978 10422
H-I 20 5,7 14,8 0 25 66 178 0 0 0 270 3248 11367
I-J 2 0 14,8 0 0 7 0 0 0 0 7 3255 11390
J-K 3 50,9 14,8 0 34 10 178 0 0 0 222 3477 12168
K-L 17 16,5 14,8 0 63 56 178 0 0 0 297 3774 13208
L-M 50 16,5 14,8 357,4 184 165 178 4393 -10 -35028 -30108 -26334 -92169
M-N 330 16,5 14,8 0 1217 1091 178 0 70 0 2486 -23848 -83467
N-O 100 16,5 14,8 357,4 369 331 178 8785 -25 -87570 -77907 -101755 -356143

SHEET 4 - DECLINES LOADED

CLIENT NAME CONVEYOR EQUIPMENT NO.

Belt width W _______ mm
 
Conveyor length L _______ m
Lift H _______ m
Max capacity τ _______ t/hr
 
Belt speed S _______ m/s
Skirt length Ls _______ m  
 Material conveyed   _______    
Lump size   _______ mm
Idler Data Carry Return Impact  
Bulk densiy   _______ t/m3
Trough Angle _____ _____ _____ degree
Corrected length Lc _______ m Roll Diameter _____ _____ _____ mm
Correction factor C _______   Spacing _____ _____ _____ m
Rotating Parts Mass M _____ _____ _____ kg/set

Friction Factors
Rotating Parts fx  _______
Pulleys Diameter Location
Load Friction fy _______ Head _______ mm _______
Skirt Friction fs _______ Drive _______ mm _______
Scraper Friction fc _______ HT Bend _______ mm _______
Tail _______ mm _______
Drive & Take-up
Take-up _______ mm _______
Angle of Wrap _______
Take-up Bend _______ mm _______
Drive Surface Lagged Bare LT Bend _______ mm _______
Tripper _______ mm _______
Take-up Type Gravity Screw
Drive Factor k _______

Length Idler Load Tension to Overcome Friction (N) Lift Tension to Effective Accumulative Absorbed
Belt of Overcome Tension Effective
of Run Mass Mass Mass Power
Run (m) (kg/m) (kg/m) (kg/m) Idlers Belt Pulley Load Run Gravity for Run Tension (W)
(m) (N) (N) (N)
Lr Mr = M/Id B Qr 9,8LrCfxMr 9,8LrCfxB 0,01(do/D)T2 9,8LrCfxQ TeS
Hr 9,8QHr Ter Te 
                           
                           
                           
                           
                           
                           
                           
                           
                           
                           
                            
                           
                           
                           

TENSION TABULATOR

VERTICAL CURVES

Design of vertical curves

It is necessary to calculate the tension at the point under consideration following the method described in Tabulator Calculations.

Concave curves

The worst condition exists when the belt is loaded to the start of the curve and under these conditions the minimum radius of curvature to
prevent the belt lifting off the idlers is 

113 Tp
R = 
   B   

Where

R = radius of curvature (m) 

Tp = Belt tension at the point under consideration (kN) 
B = Belt mass per unit length (kg/m)

Convex curve requirements

The following conditions must be satisfied 

1. Minimum radius to prevent overstress of the belt edges

Sinβ x W x E
R = 
4494 (tr - tc)

2. Minimum radius to prevent buckling

Sinβ x W x E
R = 
8988 (tr - 5,2)

3. Maximum allowable change of incline per idler to prevent overstress of belt edges

5,1 (tr - tc) x 1000

ø=
W x E x Sinβ

4. Maximum allowable change of incline per idler to prevent buckling

2,55 (tc - 5) x 1000

ø=
W x E x Sinβ

The curve must be designed with a radius at least large enough to satisfy conditions 1 and 2 and the idler spacing must ensure that conditions 3
and 4 are satisfied.

tr = Rated belt tension (kN/m)

R = Radius of curvature (m)
β = Troughing angle (degrees)
W = Belt width (mm)
E = Belt modulus (kN/m)
tc = Belt tension at the curve (kN/m)

MAXIMUM INCLINE ANGLE

1. Conventional smooth surface conveyor belts

2. Ruftop package handling belts
3. Chevron top belts
4. Boxes belts with flexible side walls
5. Sandwich type conveyors
6. Elevator belts

GRAPH FOR ESTIMATING BELT LENGTH/ROLLED BELT DIAMETER

Belt length/rolled belt diameter

D = rolled belt diameter (mm)

L = belt length (m)
t = belt thickness (mm)

( )
d = core diameter (mm)
N = number of coils on roll

Belt length:

π(D + d)N
L = 
2

Rolled belt diameter:

or

Assuming the length of belt is large and the thickness not abnormally Where d 0,3m for general stock belting and up to 0,5m for
small, then the core diameter can be neglected in approximate heavy rolls of belting, such as steelcord belting or very wide
calculations. belts.

USEFUL DATA CONVERSION FACTORS

Imperial to metric

To convert from To Multiply by

in mm 25,4
in cm 2,54
ft m 0,3048

in2 cm2 6,4516

ft2 m2 0,0929

ft3 m3 0,0283
ft/min m/s 0,0051
lb kg 0,4536
lbf N 4,448
lbf/in kN/m 0,1751
lb/in kg/cm 0,179
lb/ft kg/m 1,488
lb/in2 kg/cm2 0,0703

lb/ft3 kg/m3 16,0184

HP kW 0,746
HP Watts 746

Metric to imperial

To convert from To Multiply by

mm in 0,03937
cm in 0,3937
m ft 3,281
cm2 in2 0,155
m2 ft2 10,7639

m3 ft3 35,3148
m/s ft/min 196,85
 kg lb 2,205
N lbf 0,2248
kN/m lbf/in 5,71
kg/cm lb/in 5,6
kg/m lb/ft 0,672
kg/cm2 lb/in2 14,2

kg/m3 lb/ft3 0,0624

kW HP 1,3405
Watts HP 0,00134

Trigonometrical functions of common angles

Degrees Sin Cos Tan

1 0,0175 0,9998 0,0175
2 0,0349 0,9994 0,0349
3 0,0523 0,9986 0,0524
4 0,0698 0,9976 0,0699
5 0,0872 0,9962 0,0875
10 0,1736 0,9848 0,1763
15 0,2588 0,9659 0,2679
20 0,3420 0,9397 0,3640
25 0,4226 0,9063 0,4663
27 0,4617 0,8870 0,5206
30 0,5000 0,8660 0,5773
35 0,5736 0,8191 0,7002
40 0,6248 0,7660 0,8391
45 0,7071 0,7071 1,0000

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