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Conveyor Belt Design Manual
INDEX
Introduction
Dunlop Conveyor Belting Range
Belting Characteristics
Additional Features
SABS Specifications
Conveyor Belt Design
Step By Step Example of Belt Tension Calculation
Table 1: Table of Symbols
Table 2: Material Characteristics
Table 2(a): Typical Flowability
Determination of Conveyor Capacities
Table 3: Capacities of Troughed Belt Conveyors
Table 4: Recommended Maximum Belt Speed for Normal Use
Table 5: Recommended Idler Spacing
Table 6: Friction Factors
Table 7: Sag Factor

Table 7(a): Recommended Percentage Sag
Table 8: Estimated Belt Mass
Table 9: Typical Mass of Rotating Parts of Idlers
Table 10: Mass of Moving Parts
Table 11: Drive Factor
Conveyor Belt Selection
Table 12: Maximum Recommended Operating Tensions
Table 13: Recommended Minimum Pulley Diameters
Table 14: Load Support
Table 15: Maximum Number of Plies Recommended for Correct Empty Belt Troughing
Table 16: Carcass Thickness
Table 17: Mass of Belt Carcass
Table 18: Mass of Covers per mm of Thickness
Rate of Wear Graph
Table 19: Minimum Belt Top Cover Gauge Guide

Table 20: Belt Modulus
Tabulator Calculations
Sheet 1: Empty Belt
Sheet 2: Fully Loaded Belt
Sheet 3: Non-Declines Loaded
Sheet 4: Declines Loaded
Tension Tabulator
Vertical Curves
Maximum Incline Angle
Graph for Estimating Belt Length/Rolled Belt Diameter
Useful Data Conversion Factors
Conveyor Belting Design Manual
INTRODUCTION
Dunlop Africa Industrial Products is the leading designer and manufacturer of industrial rubber products in South Africa. In fact our belting
systems can be seen on some highly productive plants all around the globe.
What more can you expect, when you consider that our belts have been designed and fabricated by some of the best engineers in the
industry and from only the finest raw materials.
Using the most current technology, many components have taken years of refinement to attain such technological precision. And every belt
is guaranteed to provide maximum performance and maximum life.
http://www.ckit.co.za/Secure/Conveyor/Troughed/belt_tension/Dunlop/Belting%20B... 24/05/2004

And with some 750 000 various specifications available, you can expect to find the right belt for your requirements no matter how
specialised.
This manual contains all the elements, formulae and tables you need to specify the exact belt. It has been compiled for your benefit, as a
quick reference book for easy selection. If however you have an application not covered in the following pages, please contact Dunlop Africa
Industrial Products. A team of experienced and helpful engineers will be pleased to assist you.
Our range of excellent products, competitive pricing and impeccable service, has earned Dunlop Africa Industrial Products the reputation of
being the market's first choice.
DUNLOP CONVEYOR BELTING RANGE
Dunlop Africa Industrial Products manufactures the most comprehensive range of conveyor belting in South Africa.
Multi-ply rubber covered conveyor belting
 XT textile reinforced conveyor belting with grade N covers
 XT textile reinforced conveyor belting with grade M cut resistant covers
 Phoenix heat resistant belting
 Super Phoenix heat resistant belting
 Delta Hete heat resistant belting
 Fire resistant belting
 Rufftop belting
 Riffled concentrator belting
 Grey food belting
 Salmon pink food belting
 Endless belts
 Woodmaster
 Oil resistant belting
Solid woven PVC belting
 Standard solid woven PVC belting
 Nitrile covered PVC belting
Steelcord belting
 Fire resistant steelcord belting
 Steelcord reinforced conveyor belting with cut resistant type M covers
 Steelcord reinforced conveyor belting with type N covers
 Steelcord reinforced conveyor belting with "Ripstop" protection
 Steelcord reinforced conveyor belting with rip detection loops
Flinger belts

 High speed truly endless belting
BELTING CHARACTERISTICS
XT Rubber Conveyor Belting (conforms to SABS 1173-1977)
 From the early days of cotton duck plies, progress has been made in the manufacture of all-synthetic plies offering many
advantages.
 The range of strengths has been greatly increased, with improvements in the flexible structure. The modern multi-ply belt is
manufactured with a synthetic fibre carcass in a wide slab, then slit to width as required for individual orders.
 A wide range of belt specifications is available with current belt constructions having versatile applications.
 The standard XT belting (Grade N) incorporates covers suitable for the handling of most abrasive materials, having a blend of
natural and synthetic rubber.
Cut resistant XT Rubber Belting
 Grade M Belts have covers with high natural rubber content recommended for belts operating under extremely arduous conditions
where cutting and gouging of covers occurs.
Phoenix Heat Resistant Belting
 Phoenix Heat Resistant belting covers are styrene butadiene based and are recommended for belts handling materials with
temperatures up to 1200C.
Super Phoenix Heat Resistant Belting
 Super Phoenix Heat Resistant belts have chlorobutyl covers and are recommended for belts handling materials with temperatures
of up to 1700C.
Delta Hete Heat Resistant Belting
 Delta Hete heat resistant belting with EPDM synthetic rubber covers in a formulation developed to allow conveying materials of
temperatures up to 2000C.
Fire Resistant Belting (conforms to SABS 971-1980)
 Fire Resistant XT belting is manufactured with covers containing neoprene and multi-ply carcass constructions to meet the
stringent standards for safety in all underground mining industries and is therefore particularly suited to shaft applications.
Woodmaster
 This belt has been especially developed for the Timber Industry. The rubber has been compounded to provide resistance to oil and
resin, and is non-staining.
Rufftop Belting
 This is a range of rough top package belting, of two or three ply all-synthetic carcass belts with deep impression rubber covers.
The range is ideal for the packaging and warehousing industries and baggage handling installations such as airports and railway
stations etc.
Riffled Concentrator Belts
 Riffled conveyor belting has raised edges, is 1 500 mm wide and available in endless form. These belts are uniquely applied at
gold mine concentrators.
Food Quality Belting
 Food quality belting is ideal where foodstuffs come into direct contact with the belt surface. This range of belting is manufactured
from non-toxic materials and is resistant to oils, fats and staining, and meets the strict hygiene requirements laid down by the
food processing industry. The two types available are Grey food belting and Salmon pink belting

Endless Belting
 The complete XT range can be made available as factory spliced endless belts. These belts are recommended for short conveyor
installations. (Suitable for lengths up to 50 in.)
Flinger Belts
 Flinger Belts are fitted to flinger conveyors, the primary function of which is to disperse the discharging material over a wide area,
thus minimising heap build-up below the main conveyor. The flinging effect is achieved by running the flinger belt at a high speed
in a U configuration. Flinger belts are built and cured on a drum to eliminate a spliced join.
Solid Woven (PVC) Belting (conforms to SABS 971-1980)
 Commonly known as 'Vinyplast' solid woven PVC. The construction has inherently high fastener holding qualities. The belting is
constructed of polyester and nylon with a cotton armouring, is impregnated with PVC and has PVC covers. These belts have been
specially developed to resist impact, tear, rot and abrasion and to meet the most stringent flame-resistant standards.
Nitrile Covered (PVC) Belting
 The nitrile cover on solid woven PVC belts is specially designed to meet the SABS specifications for use in mines, where a fire
hazard exists. In general the nitrile cover has good flame-retardant properties and oil, abrasion and heat resistance.
Steelcord Belting (conforms to SABS 1366-1982)
 Steelcord conveyor belting is designed for very long hauls where textile reinforcement would either not achieve the requisite
strength or would have too high an elongation at reference load. Resistance to severe shock and exceptional tensile loading is
achieved by the wire reinforcement encased between thick top and bottom covers of the highest quality rubber. These belts are
designed to conform to or exceed the requirements of stringent standards and offer a long belt life.
Fire Resistant Steelcord Belting (Conforms to SABS 1366. 1982 type F).
 Steelcord belting of fire-resistant quality is made with specially compounded rubbers which render it self extinguishing. Fire-
resistant steelcord belting offers great advantages in maintenance-free operation and long belt life for conveyors situated in fiery
mines.
Oil Resistant Belting
 Oil resistant belting provides easily cleanable covers of either nitrile or neoprene on all-synthetic fabric plies. Choice of covers
gives maximum resistance to mineral and vegetable oils thus permitting the user to convey a wide variety of materials containing
mineral and vegetable oils.
ADDITIONAL FEATURES
1. Ri p P rotector
As an additional feature rip protection can be incorporated into the belt by means of arranging strong nylon fibres transversely or
by inclusion of electronic loops. The textile rip protection can be built into the belt in 2-metre lengths at regular intervals or over
the full length of the belt.
2. Shuron Breaker Ply (XT belting)
For applications where the lump size of the material carried is large and where adverse loading conditions exist, an open weave
breaker ply can be incorporated below the top cover as an extra protection for the carcass.
3. Chevron Breaker (XT belting)
This incorporates steel tyre cord in a 'V shape, as a rip protection, at intervals over the belt length. Particularly recommended for
XT belting where arduous conditions are experienced i.e. slag transportation.
4. Belt Edges
Many conveyor belts track off at some stage of their lives, causing edge damage to a greater or lesser extent. Belts can be
supplied with either slit or moulded edges.
Slit edges:
All-synthetic constructed carcasses have good resistance to edge chafing, due to modern fibre construction In addition there is
minimal penetration of moisture to the carcass and therefore no problem with carrying out hot vulcanised splices or repairs.

Moulded edges:
A moulded rubber edge can be provided to protect the carcass from acids, chemicals and oils. In most applications a moulded
edge is unnecessary as synthetic fibres will not rot or be degraded by mildew.
SABS SPECIFICATIONS
Dunlop Africa Industrial Products conveyor belting complies with the stringent standards as laid down by the SABS.
1. SABS 1173-1977 - General purpose textile reinforced conveyor belting.

2. SABS 971-1980 - Fire-resistant textile reinforced conveyor belting.
3. SABS 1366-1 982- Steelcord reinforced conveyor belting.
The above specifications cover the requirements of the various conveyor belts and are classified according to the minimum full thickness
breaking strength of the finished belting in kilonewtons per metre width.
Further information regarding SABS specifications will be supplied on request.
CONVEYOR BELT DESIGN
Introduction
A conveyor belt comprises two main components:
1. Reinforcement or a carcass which provides the tensile strength of the belt, imparts rigidity for load support and provides a means
of joining the belt.
2. An elastometric cover which protects the carcass against damage from the material being conveyed and provides a satisfactory
surface for transmitting the drive power to the carcass.
In selecting the most suitable belt for a particular application, several factors have to be considered:
1. The tensile strength of the belt carcass must be adequate to transmit the power required in conveying the material over the
distance involved.
2. The belt carcass selected must have the characteristics necessary to:
a. provide load support for the duty.
b. conform to the contour of the troughing idlers when empty, and
c. flex satisfactorily around the pulleys used on the conveyor installation.
3. The quality and gauge of cover material must be suitable to withstand the physical and chemical effects of the material conveyed.
Belt Tensions
In order to calculate the maximum belt tension and hence the strength of belt that is required, it is first necessary to calculate the effective
tension. This is the force required to move the conveyor and the load it is conveying at constant speed. Since the calculation of effective
tension is based on a constant speed conveyor, the forces required to move the conveyor and material are only those to overcome frictional
resistance and gravitational force.
Mass of Moving Parts
For the sake of simplicity the conveyor is considered to be made up of interconnected unit length components all of equal mass. The mass
of each of these units is called the mass of the moving parts and is calculated by adding the total mass of the belting, the rotating mass of
all the carrying and return idlers and the rotating mass of all pulleys. This total is divided by the horizontal length of the conveyor to get the
mean mass of all the components. At the outset the belt idlers and pulleys have not been selected and hence no mass for these components
can be determined. Therefore the mass of the moving parts is selected from the tabulated values to be found in Table 10.
Mass of the load per unit length
As is the case with the components the load that is conveyed is considered to be evenly distributed along the length of the conveyor. Given
the peak capacity in ton per hour the mass of the load per unit length is given by:
τ τ
Q = 0,278 or Q=
S 3,600S
The effective tension is made up of 4 components
 The tension to move the empty belt T x

 The tension to move the load horizontally T y
 The tension to raise or lower the load T z
 The tension to overcome the resistance of accessories T u

The effective tension is the sum of these four components
Te = Tx + Ty + Tz +Tu
Tx = 9,8G x f x x Lc
Tz = 9,8Q x H
Various conveyor accessories that add resistance to belt movement are standard on most conveyors. The most common are skirtboards at
the loading point and belt scrapers. Other accessories include movable trippers and belt plows.
Tension required to overcome the resistance of skirtboards Tus
9,8f s x Q x L s
Tus =
S x b²
Tension to overcome the resistance of scrapers
Tuc = A x ρ x f c
In the case of a belt plow the additional tension required to overcome the resistance of each plow is
Tup = 1,5W
Moving trippers require additional pulleys in the system and therefore add tension. If the mass of the additional pulleys has been included in
the mass of moving parts then no additional tension is added. However, if a separate calculation of the tension to overcome the resistance
of the additional pulleys is required this can be determined for each additional pulley as follows
do x T1
Tut = 0,01
Dt
Corrected length Lc
Short conveyors require relatively more force to overcome frictional resistance than longer conveyors and therefore an adjustment is made
to the length of the conveyor used in determining the effective tension. The adjusted length is always greater than the actual horizontal
length.
LC = L + 70
The length correction factor is
Lc
C=
L
All conveyors require an additional tension in the belt to enable the drive pulley to transmit the effective tension into the belt without
slipping. This tension, termed the slack side tension T 2, is induced by the take-up system. In the case of a simple horizontal conveyor the
maximum belt tension T 1 is the sum of the effective tension Te and the slack side tension T 2
ie: T1 = Te + T2
T1 is the tight side tension and 12 is the slack side tension
For a more complex conveyor profile that is inclined, additional tensions are induced due to the mass of the belt on the slope. This tension is
termed the slope tension 'h and increases the total tension.
Thus T 1 = Te + T2 + Th

The slack side tension is determined by consideration of two conditions that must be met in any conveyor. The first condition is that there
must be sufficient tension on the slack side to prevent belt slip on the drive. The second condition is that there must be sufficient tension to
prevent excessive sag between the carrying idlers.
Minimum tension to prevent slip Tm
At the point of slipping the relationship between T 1 and T2 is
T1
= eµθ
T2
Since T1 = Te + T2
1
T2 = Te
eµθ - 1
1
The expression :
eµθ - 1
is called the drive factor k. and the value of T 2 that will just prevent slip is referred to as the minimum to prevent slip T m and therefore
Tm = k x Te
Minimum tension to limit belt sag Ts
The tension required to limit sag is dependent on the combined mass of belt and load, the spacing of the carry idlers and the amount of sag
that is permissable.
Ts = 9,8Sf x (B + Q) x l d
The value of the slack side tension must ensure that both conditions are met and therefore T 2 must be the larger of T m or T s.
Slope tension Th
The slope tension is the product of the belt weight and the vertical lift and has its maximum value at the highest point of the conveyor.
Th = 9,8B x H
Unit tension T
The maximum belt tension T 1 has as its reference width the full width of the belt. Usually this is converted to the tension per unit of belt
width as this is the reference dimension for belt strengths.
T1
T=
W
Absorbed power
The amount of power required by the conveyor is by definition of power equal to the product of the force applied and the speed at which the
conveyor belt travels. The force applied is the effective tension and hence the power required at the shaft of the drive pulley/s is
P = Te x S
STEP BY STEP EXAMPLE OF BELT TENSION CALCULATION
As an example of the application of the formulae the belt tensions for the following conveyor will be determined:
Belt width 900 mm

Co nveyo r Le ngt h 250 m
Lift 20 m

Capacity 400 t/hr

Belt speed 1,4 m/s
Material conveyed ROM coal
Drive 210 degree wrap. Lagged drive pulley.
Take-up Gravity
Idler spacing 1,2 m
Idler roll diameter 127 mm
1. Determine mass of the load per unit length
τ
Q= 0,278
S
0,278 x 400
=
1,4
= 79,4 kg/m
2. Look up the value of the mass of moving parts in Table 10. From the idler roll diameter and the nature of the material conveyed
the application is considered as medium duty. For a 900 mm wide belt the mass of moving parts from Table 10 is 55 kg/m
3. Calculate the corrected length and the length correction factor.
LC = L + 70
= 250 + 70
= 32 0 m
LC
C=
L
320
=
250
= 1, 28
4. Tension to move the empty belt.
TX = 9,8G x f X x LC

= 9,8 x 55 x 0,022 x 320
= 3 794 N
5. Tension to move the load horizontally.
TX = 9,8Q x f Y x LC

= 9,8 x 79,4 x 0,027 x 320
= 6 72 3 N
6. Tension to lift the load.
TZ = 9,8Q x H
= 9,8 x 79,4 x 20
= 15562 N
7. No accessories are present and therefore the tension to overcome the resistance of accessories is zero.
8. Effective tension.
Te = TX + TY + TZ + TU

= 3794 + 6723 + 15562 + 0
= 26079 N
9. The absorbed power
P = Te x S
= 26079 x 1,4
= 36511W
10. The slack side tension.

Slack side tension to prevent slip.
The drive factor for 210 degree wrap and lagged pulley with a gravity take-up, as given in Table 11, is 0,38.
Tm = k x Te
= 0,38 x 36079
= 9 91 0 N
Slack side tension to limit sag to 2%. The sag factor for 2% sag is 6,3 and the estimated belt mass for a medium load and 900
mm belt width, as given in Table 8, is 11,1kg/m.
TS = 9,8Sf (B + Q) x l d
= 9,8 x 6,3 x (11,1 + 79,4) x 1,2

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 T 2 which
a. prevents slip at the highest Te value and,

b. limits sag between carry idlers.
It may be found that the value of T 2 obtained when the maximum effective tension has been calculated is different to that used in the
calculations. If this is the case the new T 2 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 3 m
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 T x and
only the loaded length to calculate T y. 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 f x 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 f y C x L

= 9,8 x 357,4 x 0,020 x 1,14 x 350
= 30745N
Effective tension to lift the load.
Tz = 9,8Q x H
= 9,8 x 357,4 x 70
= 245176N
Effective tension to overcome skirtboard friction The inter-skirtboard width is assumed to be 2/3 of the belt width i.e. 0,8 m.
9,8f s x Q x L s
Tus =
S x b2
9,8 x 357,4 x 0,020 x 1,14 x 350
=
3,5 x 0,64
= 3050N
The total effective tension is the sum of the above four.
Te = Tx + Ty + Tz + Tus
= 7932 + 30745 + 245176 + 3050

= 286903N

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 I d
= 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 T 2 value.
The highest T e value occurs when all non-declines are loaded. i.e. T e = 283609N
Based on this value
Tm = k x Te
= 0,38 x 283609N
= 107771N

Since Ts, calculated in step 5, is less than T m
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 3 m
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 f x 0,020

Pulleys Diameter Location
Load Friction f y 0,022
Head 630 mm O
Skirt Friction f s 0,65 Drive Head mm O
Scraper Friction f c 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

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. Ch ev ro n to p b el ts
4. Boxes belts with flexible side walls
5. Sandwich type conveyors
6. El evator b el ts
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 Where d 0,3m for general stock belting and up to 0,5m for
abnormally small, then the core diameter can be neglected in heavy rolls of belting, such as steelcord belting or very wide
approximate calculations. belts.
USEFUL DATA CONVERSION FACTORS
Imperial to metric
T o co nv er t fr om To M ul ti pl y by
in mm 25,4
in cm 2,54
ft m 0,3048
in2 cm2

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Dunlop Conveyor Belt Design Manual Page 1 of 33

Conveyor Belt Design Manual

Dunlop Conveyor Belting Range

Conveyor Belt Design

Step By Step Example of Belt Tension Calculation

Table 1: Table of Symbols

Table 2: Material Characteristics

Table 2(a): Typical Flowability

Determination of Conveyor Capacities

Table 3: Capacities of Troughed Belt Conveyors

Table 4: Recommended Maximum Belt Speed for Normal Use

Table 5: Recommended Idler Spacing

Table 6: Friction Factors

Table 7: Sag Factor

Table 8: Estimated Belt Mass

Table 9: Typical Mass of Rotating Parts of Idlers

Table 10: Mass of Moving Parts

Table 11: Drive Factor

Conveyor Belt Selection

Table 12: Maximum Recommended Operating Tensions

Table 13: Recommended Minimum Pulley Diameters

Table 14: Load Support

Table 16: Carcass Thickness

Table 17: Mass of Belt Carcass

Table 18: Mass of Covers per mm of Thickness

Rate of Wear Graph

Table 19: Minimum Belt Top Cover Gauge Guide

Sheet 1: Empty Belt

Sheet 2: Fully Loaded Belt

Sheet 3: Non-Declines Loaded

Sheet 4: Declines Loaded

Maximum Incline Angle

Graph for Estimating Belt Length/Rolled Belt Diameter

Useful Data Conversion Factors

Conveyor Belting Design Manual

Dunlop Conveyor Belt Design Manual Page 2 of 33

DUNLOP CONVEYOR BELTING RANGE

Multi-ply rubber covered conveyor belting

 XT textile reinforced conveyor belting with grade N covers

 XT textile reinforced conveyor belting with grade M cut resistant covers

 Phoenix heat resistant belting

 Super Phoenix heat resistant belting

 Delta Hete heat resistant belting

 Fire resistant belting

 Riffled concentrator belting

 Grey food belting

 Salmon pink food belting

 Oil resistant belting

Solid woven PVC belting

 Standard solid woven PVC belting

 Nitrile covered PVC belting

 Fire resistant steelcord belting

 Steelcord reinforced conveyor belting with cut resistant type M covers

 Steelcord reinforced conveyor belting with type N covers

 Steelcord reinforced conveyor belting with "Ripstop" protection

 Steelcord reinforced conveyor belting with rip detection loops

Dunlop Conveyor Belt Design Manual Page 3 of 33

 High speed truly endless belting

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

Cut resistant XT Rubber Belting

Phoenix Heat Resistant Belting

Super Phoenix Heat Resistant Belting