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TA BLE 11 DRIVE FA CTOR k

Screw Gravity or A utomatic

A ngle 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 Snubbe d 1,1 0,7 0,77 0,450
200 Snubbe d 1,0 0,7 0,72 0,420
210 Snubbe d 1,0 0,7 0,67 0,380
220 Snubbe d 0,9 0,6 0,62 0,350
230 Snubbe d 0,9 0,6 0,58 0,320
240 Snubbe d 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. W he n calculating the driving te nsion re quire d for dual drive units, the drive factor se le cte d m ust corre spond to the
total angle of driving wrap.

2. The drive factors quote d for gravity or autom atic tak e -up
syste m s are m inim um value s base d on the re lationship
be twe e n angle of wrap and coe fficie nt of friction be twe e n
be lt and drum at the point of slip. In the case of scre w
tak e -up units, an adjustm e nt has be e n m ade to the drive factor to allow for the e x tra te nsion which m ay be
induce d in the be lt e ithe r:

a. to com pe nsate for the e ffe ct of be lt e longation whe n the m ate rial is loade d.

b. due to the difficulty in m e asuring the am ount of te nsion applie d.

3. In those case s whe re an e le ctrically or hydraulically loade d winch type tak e -up is use d, whe re the induce d te nsion
can be pre se t and controlle d, the drive factor should be se le cte d to corre spond with a gravity tak e -up syste m .

CONVEYOR BELT SELECTION

Belt carcass selection criteria

In se le cting the optim um be lt construction for a give n application it is ne ce ssary to conside r the following:

Tensile strength
The be lt class re quire d is that which has an ope rating te nsion gre ate r than or e qual to the calculate d m ax im um unit
te nsion T. (Table 12).

Load support
C hoose the lowe st class which m e e ts the te nsile stre ngth re quire m e nt. Look ing at Table 14, de te rm ine which load cate gory
be st de scribe s the load be ing conve ye d i.e . A, B, C , D or E cate gory load. The value obtaine d at the inte rse ction of the
be lt spe cification row and the load cate gory colum n give s the m ax im um width at which that be lt spe cification can be use d.

Number of plies for troughability

The m ax im um num be r of plie s allowable , in orde r to e nsure that the e m pty be lt will conform to the contour of the
troughing idle rs, m ust be che ck e d re fe rring to Table 15. For a particular be lt class the value shown at the inte rse ction of
the be lt width colum n and troughing angle row, is the m ax im um num be r of plie s that should be use d.

Minimum pulley diameters

If the size of the pulle ys is alre ady de te rm ine d, the be lt construction provisionally se le cte d from the pre vious
conside rations can be che ck e d against the re le vant pulle y diam e te rs for suitability. For a ne w installation, the pulle y
diam e te rs should be e qual to or large r than those give n in Table 13 (It should be note d that, in this conte x t, the
diam e te rs quote d re fe r to the m inim um pulle ys around which the particular be lt construction will fle x satisfactorily. The
conve yor de signe r should also tak e into account the ge arbox ratio and re quire d be lt spe e d whe n se le cting the drive pulle y
diam e te r.)

Gauge of covers required

The corre ct gauge of cove r ne ce ssary to give prote ction to the be lt carcass from m ate rial im pact and we ar m ust be
de te rm ine d by conside ration of the size and de nsity of the m ate rial to be handle d. (Table 19).

A dditional Information

Belt modulus
R e fe r to Table 20 for be lt m odulus.

Belt mass
The m ass of a particular be lt construction can be de te rm ine d by adding the carcass m ass found in Table 17 to the
com bine d m ass of cove rs found in Table 18. This will give the m ass pe r unit are a. To calculate the m ass pe r unit le ngth
m ultiply by the be lt width in m e tre s.

Belt thickness
The be lt thick ne ss can be obtaine d from the inform ation give n in Table 16.

TA BLE 12 MA XIMUM RECOMMENDED OPERA TING 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

TA BLE 13 RECOMMENDED MINIMUM PULLEY DIA METERS (mm)

Textile Reinforced Rubber Belting

Steelcord
Solid Woven
Belt Class Pulley Type No. of Plies Reinforced
PVC Belting
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
A 400 500 630 400
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 te nsion pulle ys W rap e x ce e ding 45°
B Low te nsion pulle ys W rap e x ce e ding 45°
or
High te nsion pulle ys W rap up to 45°
C Low te nsion pulle ys W rap up to 45°
He ad, drive & trippe r
Tail, tak e -up, Tak e -up be nd
High te nsion snub or be nd pulle ys
Low te nsion snub or be nd pulle ys

TA BLE 14 LOA D SUPPORT

R e com m e nde d m ax im um be lt width (m m ) for corre ct load support. Multi-ply te x tile re inforce d rubbe r be lting.

Belt Spec A B C D E
Light Duty Light to Medium Duty Medium Duty Heavy Duty Extra Heavy Duty
 Up to 800 kg/m 3 Up to 1200 kg/m 3 Up to 1600 kg/m 3 Up to 2400 kg/m 3 Up to 3000 kg/m 3
- 25mm Lumps - 50mm Lumps - 100mm Lumps - 250mm Lumps + 250mm Lumps
160/2 750 600 500 400 Not R e com m e nde d
200/2 750 600 600 4500 Not R e com m e nde d
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

TA BLE 15 MA XIMUM 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 A ngle

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°
1000 - - - - 4 4 4 4 4 4 4 4 4 4 4 20°
- - - - 2 3 4 4 4 4 4 4 4 4 4 35°
 - - - - 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°
- - - - 3 4 4 4 4 4 4 4 4 4 4 20°
1600
- - - - - 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°

TA BLE 16 CA RCA SS 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 thick ne ss of the cove rs to ge t the total be lt thick ne ss

TA BLE 17 MA SS OF BELT CA RCA SS (kg/m 2)

Textile Reinforced Rubber Belting Solid Woven

No. of Plies PVC Belting Steelcord Reinforced
Belt Class
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 be lt m ass add the m ass of the com bine d cove rs from Table 18.
The m ass pe r unit le ngth is de te rm ine d by m ultiplying the total m ass by the be lt width in m e tre s.
TA BLE 18 MA SS OF COVERS PER mm OF THICKNESS (kg/m 2)

Mass Mass
Grade of Cover Grade of Cover
(kg/m 2) (kg/m 2)
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

RA TE OF WEA R VS THICKNESS OF COVER

The rate at which a be lt cove r we ars is re late d to the thick ne ss of the cove r and to the im pact e ne rgy im parte d by m ate rial
lum ps.

Im pact e ne rgy can be calculate d for any m ate rial of k nown lum p m ass and ve rtical ve locity.

γ - ω x νv J

γ - Im pact Ene rgy (J)

ω - Mass of lum p (k g)
νv - Ve rticle ve locity (m /s)

TA BLE 19 MINIMUM BELT TOP COVER GA UGE GUIDE

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

Non abrasive material A brasive 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

C ycle tim e - 2L/S

TA BLE 20 BELT MODULUS (kN/m)

Multi-ply
Steelcord
Textile Solid Woven
Belt Class 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

TA BULA TOR CA LCULA TIONS

For the purpose s of

1. C alculating ve rtical curve s, or

2. De te rm ining be lt te nsion for conve yors of undulating profile .
It is ne ce ssary to calculate the be lt te nsions at various points on the conve yor.

Calculating the tension at any point along the conveyor.

The tabulation m e thod de scribe d be low is a conve nie nt m e ans of calculating the te nsions at any point on the conve yor.

Blank copie s of the "C onve yor Tabulation She e ts" are available from Dunlop Africa Industrial Products.

The following m e thod is use d to de te rm ine the te nsion at any point along the conve yor:

1. C alculate the le ngth corre ction factor.

2. Look up the m ass of m oving parts in Table 10.
3. C alculate the m ass of the load from the de sign capacity and the be lt spe e d.
4. C alculate the m ax im um e ffe ctive te nsion unde r constant spe e d ope ration. This will always occur whe n all the non-
de cline d se ctions of the conve yor are fully loade d and the de cline d se ctions e m pty.
5. De te rm ine the m inim um value for the slack side te nsion unde r m ax im um load condition.
6. C om m e ncing from im m e diate ly be hind the drive , labe l e ach pulle y, inte rse ction point and loading se ction. Start
and e nd point of e ach of the load le ngths should also be labe lle d.
7. De te rm ine the e ffe ctive te nsion re quire d to ove rcom e the frictional and gravitational re sistance s for e ach of the
se gm e nts of the conve yor by using form ulae on page 4.

The value of 12, de te rm ine d in 5 above , is use d to calculate the

e ffe ctive te nsion to ove rcom e pulle y friction.
8. The e ffe ctive te nsion at any point on the conve yor is the sum of the e ffe ctive te nsions of all pre ce e ding se gm e nts.
The total e ffe ctive te nsion for the conve yor is the sum of the e ffe ctive te nsions for all se gm e nts.
9. The te nsion at any point 'x ' on the conve yor is m ade up of the e ffe ctive te nsion at point 'x ' plus the slope te nsion
at point 'x '. Supe rim pose d on this is the te nsion applie d by the tak e -up syste m . The te nsion applie d by the tak e -
up is give n by the worst case T 2 value i.e . the value of T 2 which

a. pre ve nts slip at the highe st T e value and,

b. lim its sag be twe e n carry idle rs.
It m ay be found that the value of T 2 obtaine d whe n the m ax im um e ffe ctive te nsion has be e n calculate d is diffe re nt to
that use d in the calculations. If this is the case the ne w T 2 value is use d to calculate te nsions at e ach point.

Ste ps 7, 8 and 9 should be re pe ate d for four load case s viz e m pty, fully loade d, non-de cline d se ctions loade d and
de cline d se ctions loade d.

EXA MPLE

Be lt width 1200 m m
C onve yor le ngth 500 m
Lift 45 m
Max capacity 4500 t/hr
Be lt spe e d 3,5 m /s
Sk irt le ngth 3 m
Mate rial conve ye d Iron O re
Lum p size 100 m m
Bulk de nsity 2,4 t/m 3
C arry idle r diam e te r 127 m m
C arry idle r spacing 1,2 m
R e turn idle r diam e te r 127 m m
R e turn idle r spacing 3,6 m
Im pact idle r diam e te r 159 m m
Im pact idle r spacing 0,45 m
Drive wrap 210 de gre e
Drive surface R ubbe r lagge d
Tak e -up type Gravity

Step 1

C alculate the le ngth corre ction factor

L + 70
C =
L
570
=
500
= 1,14

Step 2

From Table 10 the m ass of the m oving parts for a 1200 m m wide conve yor of m e dium duty is 71 k g/m .

Step 3

C alculate the m ass of the load

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

Step 4

C alculate the m ax im um e ffe ctive te nsion whe n the non-de cline d se ctions of the conve yor are all carrying load and the
de cline d se ctions have no load. The total horizontal le ngth of non-de cline d se ctions is 20 + 330 = 350 m .

The ove rall change in e le vation on the non-de cline d se ctions is 70 in. Note that the actual le ngth of the conve yor is use d
to calculate T x and only the loade d le ngth to calculate T y. The le ngth corre ction factor is a constant and is use d to conve rt
the actual le ngth to a corre cte d le ngth. The friction factors are de te rm ine d by the total conve yor le ngth in all case s.

Effe ctive te nsion to m ove the e m pty be lt.

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

Effe ctive te nsion to m ove the load horizontally.

T y = 9,8Q x f y C x L
= 9,8 x 357,4 x 0,020 x 1,14 x 350
= 30745N

Effe ctive te nsion to lift the load.

T z = 9,8Q x H
= 9,8 x 357,4 x 70
= 245176N
Effe ctive te nsion to ove rcom e sk irtboard friction The inte r-sk irtboard width is assum e d to be 2/3 of the be lt width i.e . 0,8
m.

9,8f s x Q x L s
T us =
S x b2
9,8 x 357,4 x 0,020 x 1,14 x 350
=
3,5 x 0,64
= 3050N

The total e ffe ctive te nsion is the sum of the above four.

Te = T x + T y + T z + T us
= 7932 + 30745 + 245176 + 3050
= 286903N

Step 5

The m inim um slack side te nsion to pre ve nt slip is:

Tm = k x Te
k = 0,38 from Table 11 and he nce
T m = 0,38 x 286903
= 109023

The m inim um slack side te nsion to pre ve nt e x ce ssive be lt sag is:

T s = 9,8Sf x (B + Q ) x I d
= 9,8 x 6,3 x (14,8 + 357,4) x 1,2
= 27576N

From Table 8 the e stim ate d be lt m ass is 14,8 k g/m

Since

Tm > Ts

T2 = Tm

i.e . T 2 = 109023N

Step 6

The conve yor is labe lle d from A to 0 as shown on e x am ple she e ts 1 to 4.

Step 7

C alculations of the e ffe ctive te nsion for e ach se gm e nt (or run) is shown on She e t 1 for the e m pty be lt, She e t 2 for the
fully loade d be lt, She e t 3 for the case whe re only non-de cline se ctions are loade d and She e t 4 whe re only the de cline
se ctions are loade d.

Step 8

The accum ulate d e ffe ctive te nsion colum n is the sum of the e ffe ctive te nsions of the curre nt se gm e nt and all pre ce e ding
se gm e nts.

Step 9

The total e ffe ctive te nsion for e ach load case is the value in the last row of the colum n title d 'Accum ulate d Effe ctive
Te nsion'.

For the e m pty be lt T e = 7665N

For the fully loade d be lt T e = 174188N
For all non-de cline s loade d T e = 283609N
For only de cline s loade d T e = -101755N

The re ason for the diffe re nce be twe e n the e ffe ctive te nsion de te rm ine ste p 4 and that on She e t 3 is the m ore accurate
figure s use d for m ass of the m oving parts on the tabulation she e ts.
The te nsion at any point along the conve yor can now be de te rm ine d, all load case s, by adding the e ffe ctive te nsion at the
point to the slope te nsion at the point and the n adding the worst case T 2 value .

The highe st T e value occurs whe n all non-de cline s are loade d. i.e . T e = 283609N

Base d on this value

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

Since T s, calculate d in ste p 5, is le ss than T m

T2 = Tm

i.e . T 2 = 107771N

Thus, for e x am ple , the e ffe ctive te nsion at run L - M tak e s the following value s:

1. Em pty Be lt 4302N
2. Fully loade d - 24577N
3. Non-de cline s loade d 6059N
4. De cline s loade d -26334N

From the se it is de te rm ine d that the te nsion at point M unde r the four case s, give n by

T e + T 2 + T h is

Empty belt

4302 + 107771 + 0
= 112073N

Fully loaded belt

-24577 + 107771 + 0
= 83194N

Non-declines loaded

6059 + 107771 + 0
= 113830N

Declines loaded

-26334 + 107771 + 0
= 81437N

CLIENT NAME CONVEYOR EQUIPMENT NO.

Be lt width W 1200 m m
C onve yor le ngth L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Be lt spe e d S 3,5 m /s
Sk irt le ngth Ls 3 m
Mate rial conve ye d Iron O re Idler Data Carry Return Impact
Lum p size 100 m m Trough Angle 35 0 35 de gre e
Bulk de nsiy 2,4 t/m 3 R oll Diam e te r 127 127 159 mm
Lc Spacing 1,2 3,6 0,45 m
C orre cte d le ngth 570 m
R otating Parts Mass M 19,9 17,1 22,9 k g/se t
C orre ction factor C 1,14

Friction Factors Pulleys Diameter Location

R otating Parts f x 0,020 He ad 630 mm O
Load Friction f y 0,022 Drive He ad mm O
HT Be nd - mm -
Sk irt Friction f s 0,65
Tail 500 mm I
Scrape r Friction f c 0,60
Tak e -up 500 mm E
Drive & Take-up Tak e -up Be nd 500 mm D,F
 Angle of W rap 210° LT Be nd 450 mm B
Trippe r - mm -
Drive Surface Lagge d Bare

Tak e -up Type Gravity Scre w

Drive Factor k 0,38

Idler Tension to Overcome Friction (N) Lift Tension to Effective A ccumulative

Length Belt Load A bsorbed
Mass of Overcome Tension Effective
of Run Mass Mass Power
Run (kg/m) Run Gravity for Run Tension
(m) (kg/m) Idlers Belt Pulley Load (W)
Mr = (kg/m) (m) (N) (N) (N)
Lr B Qr 9,8LrCf xMr 9,8LrCf xB 0,01(do/D)T2 9,8LrCf xQ TeS
M/Id 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.

Be lt width W 1200 m m
C onve yor le ngth L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Be lt spe e d S 3,5 m /s
Sk irt le ngth Ls 3 m
Mate rial conve ye d Iron O re Idler Data Carry Return Impact
Lum p size 100 m m Trough Angle 35 0 35 de gre e
Bulk de nsiy 2,4 t/m 3 R oll Diam e te r 127 127 159 mm
Lc Spacing 1,2 3,6 0,45 m
C orre cte d le ngth 570 m
R otating Parts Mass M 19,9 17,1 22,9 k g/se t
C orre ction factor C 1,14

Friction Factors
R otating Parts f x 0,020
Pulleys Diameter Location
Load Friction f y 0,022
He ad 630 mm O
Sk irt Friction f s 0,65 Drive He ad mm O
Scrape r Friction f c 0,60 HT Be nd - mm -
Tail 500 mm I
Drive & Take-up
Tak e -up 500 mm E
Angle of W rap 210°
Tak e -up Be nd 500 mm D,F
Drive Surface Lagge d Bare LT Be nd 450 mm B

Tak e -up Type Gravity Scre w Trippe r - mm -

Drive Factor k 0,38

Run Length Idler Belt Load Tension to Overcome Friction (N) Lift Tension to Effective A ccumulative A bsorbed
of Run Mass Mass Mass of Overcome Tension Effective Power
Idlers Belt Pulley Load
(kg/m) (kg/m) Run Gravity for Run Tension
9,8LrCf xMr 9,8LrCf xB 0,01(do/D)T2 9,8LrCf xQ
B
 (m) Mr = (kg/m) (m) (N) (N) (N) (W)
Lr M/Id Qr Hr 9,8QHr Ter Te TeS
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 LOA DED BELT

CLIENT NAME CONVEYOR EQUIPMENT NO.

Be lt width W 1200 m m
C onve yor le ngth L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Be lt spe e d S 3,5 m /s
Sk irt le ngth Ls 3 m
Mate rial conve ye d Iron O re Idler Data Carry Return Impact
Lum p size 100 m m Trough Angle 35 0 35 de gre e
Bulk de nsiy 2,4 t/m 3 R oll Diam e te r 127 127 159 mm

Lc Spacing 1,2 3,6 0,45 m

C orre cte d le ngth 570 m
R otating Parts Mass M 19,9 17,1 22,9 k g/se t
C orre ction factor C 1,14

Friction Factors
R otating Parts f x 0,020
Pulleys Diameter Location
Load Friction f y 0,022
He ad 630 mm O
Sk irt Friction f s 0,65 Drive He ad mm O
Scrape r Friction f c 0,60 HT Be nd - mm -
Tail 500 mm I
Drive & Take-up
Tak e -up 500 mm E
Angle of W rap 210°
Tak e -up Be nd 500 mm D,F
Drive Surface Lagge d Bare LT Be nd 450 mm B
Trippe r - mm -
Tak e -up Type Gravity Scre w

Drive Factor k 0,38

Idler Tension to Overcome Friction (N) Lift Tension to Effective A ccumulative

Length Belt Load A bsorbed
Mass of Overcome Tension Effective
of Run Mass Mass Power
Run (kg/m) Run Gravity for Run Tension
(m) (kg/m) (kg/m) Idlers Belt Pulley Load (W)
Mr = (m) (N) (N) (N)
Lr B Qr 9,8LrCf xMr 9,8LrCf xB 0,01(do/D)T2 9,8LrCf xQ TeS
M/Id H r 9,8QH r T er 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 LOA DED

CLIENT NAME CONVEYOR EQUIPMENT NO.

Be lt width W 1200 m m
C onve yor le ngth L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Be lt spe e d S 3,5 m /s
Sk irt le ngth Ls 3 m
Mate rial conve ye d Iron O re Idler Data Carry Return Impact
Lum p size 100 m m Trough Angle 35 0 35 de gre e
Bulk de nsiy 2,4 t/m 3 R oll Diam e te r 127 127 159 mm

Lc Spacing 1,2 3,6 0,45 m

C orre cte d le ngth 570 m
R otating Parts Mass M 19,9 17,1 22,9 k g/se t
C orre ction factor C 1,14

Friction Factors
R otating Parts f x 0,020
Pulleys Diameter Location
Load Friction f y 0,022
He ad 630 mm O
Sk irt Friction f s 0,65 Drive He ad mm O
Scrape r Friction f c 0,60 HT Be nd - mm -
Tail 500 mm I
Drive & Take-up
Tak e -up 500 mm E
Angle of W rap 210°
Tak e -up Be nd 500 mm D,F
Drive Surface Lagge d Bare LT Be nd 450 mm B
Trippe r - mm -
Tak e -up Type Gravity Scre w

Drive Factor k 0,38

Idler Tension to Overcome Friction (N) Lift Tension to Effective A ccumulative

Length Belt Load A bsorbed
Mass of Overcome Tension Effective
of Run Mass Mass Power
Run (kg/m) Run Gravity for Run Tension
(m) (kg/m) (kg/m) Idlers Belt Pulley Load (W)
Mr = (m) (N) (N) (N)
Lr B Qr 9,8LrCf xMr 9,8LrCf xB 0,01(do/D)T2 9,8LrCf xQ TeS
M/Id H r 9,8QH r T er 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 LOA DED

CLIENT NAME CONVEYOR EQUIPMENT NO.

Be lt width W _______ m m
C onve yor le ngth L _______ m
Lift H _______ m
 Max capacity τ _______ t/hr
Be lt spe e d S _______ m /s
Sk irt le ngth Ls _______ m
Mate rial conve ye d _______
Lum p size _______ m m
Bulk de nsiy _______ t/m 3
Lc Idler Data Carry Return Impact
C orre cte d le ngth _______ m
Trough Angle _____ _____ _____ de gre e
C orre ction factor C _______
R oll Diam e te r _____ _____ _____ m m
Spacing _____ _____ _____ m
R otating Parts Mass M _____ _____ _____ k g/se t

Friction Factors
R otating Parts f x _______
Pulleys Diameter Location
Load Friction f y _______
He ad _______ mm _______
Sk irt Friction f s _______ Drive _______ mm _______
Scrape r Friction f c _______ HT Be nd _______ mm _______
Tail _______ mm _______
Drive & Take-up
Tak e -up _______ mm _______
Angle of W rap _______
Tak e -up Be nd _______ mm _______
Drive Surface Lagge d Bare LT Be nd _______ mm _______
Trippe r _______ mm _______
Tak e -up Type Gravity Scre w
Drive Factor k _______

Idler Tension to Overcome Friction (N) Lift Tension to Effective A ccumulative

Length Belt Load A bsorbed
Mass of Overcome Tension Effective
of Run Mass Mass Power
Run (kg/m) Run Gravity for Run Tension
(m) (kg/m) (kg/m) Idlers Belt Pulley Load (W)
Mr = (m) (N) (N) (N)
Lr B Qr 9,8LrCf xMr 9,8LrCf xB 0,01(do/D)T2 9,8LrCf xQ TeS
M/Id H r 9,8QH r T er Te

TENSION TA BULA TOR

VERTICA L CURVES

Design of vertical curves

It is ne ce ssary to calculate the te nsion at the point unde r conside ration following the m e thod de scribe d in Tabulator
C alculations.

Concave curves

The worst condition e x ists whe n the be lt is loade d to the start of the curve and unde r the se conditions the m inim um radius
of curvature to pre ve nt the be lt lifting off the idle rs is

113 T p
R =
B

W he re
R = radius of curvature (m )
T p = Be lt te nsion at the point unde r conside ration (k N)
B = Be lt m ass pe r unit le ngth (k g/m )

Convex curve requirements

The following conditions m ust be satisfie d

1. Minim um radius to pre ve nt ove rstre ss of the be lt e dge s

Sinβ x W x E
R =
4494 (tr - tc)

2. Minim um radius to pre ve nt buck ling

Sinβ x W x E
R =
8988 (tr - 5,2)

3. Max im um allowable change of incline pe r idle r to pre ve nt ove rstre ss of be lt e dge s

5,1 (tr - tc) x 1000

ø =
W x E x Sinβ

4. Max im um allowable change of incline pe r idle r to pre ve nt buck ling

2,55 (tc - 5) x 1000

ø =
W x E x Sinβ

The curve m ust be de signe d with a radius at le ast large e nough to satisfy conditions 1 and 2 and the idle r spacing m ust
e nsure that conditions 3 and 4 are satisfie d.

tr = R ate d be lt te nsion (k N/m )

R = R adius of curvature (m )
β = Troughing angle (de gre e s)
W = Be lt width (m m )
E = Be lt m odulus (k N/m )
tc = Be lt te nsion at the curve (k N/m )

MA XIMUM INCLINE A NGLE

1. C onve ntional sm ooth surface conve yor be lts

2. R uftop pack age handling be lts
3. C he vron top be lts
4. Box e s be lts with fle x ible side walls
5. Sandwich type conve yors
6. Ele vator be lts

GRA PH FOR ESTIMA TING BELT LENGTH/ROLLED BELT DIA METER

Be lt le ngth/rolle d be lt diam e te r
D = rolle d be lt diam e te r (m m )
L = be lt le ngth (m )
t = be lt thick ne ss (m m )
d = core diam e te r (m m )
N = num be r of coils on roll

Belt length:

π(D + d)N
L =
2

Rolled belt diameter:

or
Assum ing the le ngth of be lt is large and the thick ne ss not W he re d 0,3m for ge ne ral stock be lting and up to
abnorm ally sm all, the n the core diam e te r can be ne gle cte d 0,5m for he avy rolls of be lting, such as ste e lcord
in approx im ate calculations. be lting or ve ry wide be lts.

USEFUL DA TA CONVERSION FA CTORS

Imperial to metric

To convert from To Multiply by

in mm 25,4
in cm 2,54
ft m 0,3048
in 2 cm 2 6,4516

ft2 m2 0,0929

ft3 m3 0,0283
ft/m in m /s 0,0051
lb kg 0,4536
lbf N 4,448
lbf/in k N/m 0,1751
lb/in k g/cm 0,179
lb/ft k g/m 1,488
lb/in 2 k g/cm 2 0,0703

lb/ft3 k g/m 3 16,0184

HP kW 0,746
HP W atts 746

Metric to imperial

To convert from To Multiply by

mm in 0,03937
cm in 0,3937
m ft 3,281
cm 2 in 2 0,155
m2 ft2 10,7639

m3 ft3 35,3148
 m /s ft/m in 196,85
kg lb 2,205
N lbf 0,2248
k N/m lbf/in 5,71
k g/cm lb/in 5,6
k g/m lb/ft 0,672
k g/cm 2 lb/in 2 14,2
k g/m 3 lb/ft3 0,0624
kW HP 1,3405
W atts 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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