Edition

Conveyor Belt System Design

Service Manual

Conveyor Belt Group

II
Conveyor Belt Service Manual

ContiTech
Specialist in rubber and
plastic technology

Conveyor Belt
System Design
Edited by:
Dr.-lng. Rainer Alles

Contributors:
Obering. W. Ernst
Prof. Dr.-lng. W.S.W. Lubrich
and the following
ContiTech engineers
Dr.-lng. R. Alles
Dipl.-lng. G. Böttcher
Dipl.-lng. H. Simonsen
Dipl.-lng. H. Zintarra

Published by
ContiTech Transportbandsysteme GmbH
Status 1994

Unmodified reprint 2008

The ContiTech Group

is a development partner and
original equipment manufacturer
for numerous branches of in-
dustry with high grade functional
parts, components and systems
It is part of the Continental Cor-
poration with over 26 companies
in Europe specialising in rubber
and plastics technology and uti-
lising their common know-how.

That‘s what the ContiTech brand

is all about.

III
IV
Table of Contents

Page Page

1 Basic expressions and definitions...6 4.3.2 Troughing properties........................ 81

4.3.3 Centre distance and takeups............ 82
2 Stipulation of principal data.............9
4.3.4 Effects of material handled............... 83
2.1 Material handled............................... 10
4.3.5 Feeding strain................................... 85
2.2 Flow of material handled . ................ 12
4.4 Tension member data . .................... 87
2.3 Conveying track............................... 13
4.4.1 Textile tension members................... 90
2.4 Type of belt conveyor......................... 4
4.4.2 Steel cable tension members........... 91
2.4.1 Belt width......................................... 15
4.4.3 Splice dimensions............................ 92
2.4.2 Belt speed........................................ 16
2.4.3 Belt support..................................... 18 5 Selection of covers.........................96
2.5 Conveying capacity.......................... 20 5.1 Cover material.................................. 98
5.2 Cover gauge.................................. 100
3 Calculation of belt conveyor...........27
5.2.1 Abrasion resistance........................ 101
3.1 Masses............................................ 29
5.2.2 Impact resistance........................... 102
3.1.1 Idlers................................................ 30
5.3 Special cover structures ................ 103
3.1.2 Conveyor belt................................... 32
3.1.3 Drive elements................................. 33 6 Steep angle conveyor belts .........105
3.2 Coefficients...................................... 34 6.1 Chevron cleated belt ..................... 107
3.3 Motional resistance.......................... 36 6.2 Box-section belt ............................ 108
3.3.1 Resistive force components.............. 38 6.2.1 Conveying capacity.........................110
3.3.2 Motional resistance of sections......... 39 6.2.2 Constructional data.........................111
3.4 Required power................................ 41 6.3 Fin-type belt and belt with
3.5 Peripheral force................................ 44 bonded partitions............................113
3.5.1 Starting and stopping....................... 47
7 Elevator belts................................ 115
3.5.2 Multiple pulley drive.......................... 50
7.1 Conveying capacity.........................116
3.6 Calculation example......................... 53
7.2 Power requirement and
4 Stipulation of tension member.......56 belt tensions . .................................117
4.1 Belt tensions.................................... 61 7.3 Selection of bucket elevator belts....119
4.1.1 Belt tensions in operation................. 66 7.3.1 Tension member............................ 120
4.1.2 Belt tensions on starting 7.3.2 Covers........................................... 122
and stopping.................................... 68 7.3.3 Buckets and bucket attachments... 123
4.1.3 Belt tensions with regard
8 Piece goods handling and
to sections....................................... 70
belts for sliding bed operation..... 125
4.2 Additional strains.............................. 71
8.1 Conveying capacity........................ 126
4.2.1 Flat-to-trough transition and
8.2 Calculation of required power......... 127
vice versa......................................... 73
8.3 Conveyor belt design...................... 129
4.2.2 Transition curves.............................. 75
4.2.3 Turnover........................................... 75 9 Appendix.......................................130
4.3 Selection criteria............................... 78 9.1 Index.............................................. 131
4.3.1 Pulley diameter................................. 79 9.2 Symbols......................................... 134

1
 An insignificant side-note for all those who are already accustomed to using Sl units or
units derived from them and who take advantage of this “standard” settlement by the
international units system.

For all other readers it is pointed out that an “Act on Units in Measuring Procedure”,
regulating the use of technical units in business and official transactions, was passed on
2nd July 1969 and became mandatory for us when the transitional period expired on 1st
January 1978.

The effects of this Act on materials handling technology are minimal as most of the units
already widely used in this sphere have undergone no change. One essential point is the
uniform stipulation of the
kilogram (kg) as a unit for mass
It was furthermore stipulated that the word “weight” may be used only as a mass quan-
tity. The weights listed in a large number of tables and reference books thus retain their
numerical value. Other units of weight or of mass are the gram (g) and the ton (t).

We recall: one kilogram was accelerated by the gravitational attraction of the earth at
approx. 9.81 m/s2 and thus exercised on the base it is resting upon a weight of one
kilogram-force. In the Space Age we now depart from this unit of force, that applied
solely under the gravitational conditions of the earth, and use exclusively the
Newton (N) as a unit for force
One kilogram is accelerated by one Newton at 1 m/s2 or one kilogram acts under the
influence of the acceleration due to gravity on its base with the force of approx. 9.81
Newton. All forces that were formerly expressed in kilogram-force attain a numerical
value increased approximately by the factor 10 with Newton as a unit.

The breaking strength of a conveyor belt in kilogram-force related to the unit of width
in cm retains approximately its familiar numerical value if the breaking strength in N is
related, as practised below, to the width in mm.
1 kilogram-force/cm ≈ 1 N/mm
It follows from the introduction of the Newton as a unit for force that the acceleration due
to gravity g occurs in all calculation formulae in which weights are determined or other
forces with their origin in weights are calculated. For this purpose
Acceleration due to gravity g = 9.81 m/s2
can be inserted with sufficient accuracy. A simplification results in the calculation of
power in W (Watt) by the multiplication of force in N and speed in m/s. A conversion fac-
tor is then superfluous.

This short introduction is aimed at drawing your attention to the changeover resulting
from these regulations for the following calculation principles and data.

2
D – Conveyor belt calculation

This section of the ContiTech Conveyor Belt Service Manual comprises design funda-
mentals and data design of the belt system and the practical application.

The calculation of the belt conveyor for bulk material set out at the beginning of these
calculation principles is based on specifications contained in DIN standard 22101 (Feb-
ruary 1982) and is supplemented by extending design procedures. Essential calculation
stages not included in the DIN 22101 standard specifications have been described for
instance in publications by Vierling*

The designations of formula quantities have been adapted as far as possible to general
guidelines. Designations already well known from technical literature in this field have
also been used, however, where we felt them to be beneficial.

Only the “statutory units” (Sl units or units derived therefrom) on which the “International
Units System” (Sl) is based are used in the formulae, tables and diagrams. To facilitate
comprehension, the units used in the further course of the calculation are stated after the
respective formulae, whereby the units listed in the index of symbols are to be used. A
brief dimensional consideration helps in cases of doubt. The units to be used are stated
in the case of formulae with conversion factors or dimension-affected constants.

* Vierling, A.: Zum Stand der Berechnungsgrundlagen für Gurtförderer Braunkohle Wärme und Energie
19 (1967) No 9,P 309-315
Vierling, A.: Zur Theorie der Bandförderung Continental-Transportband-Dienst 1972, 3rd edition.
3
 In general, the following data are known before a belt conveyor is designed:
ÂÂ Type of material to be conveyed (e. g. bulk weight, lump size, angle of repose)
ÂÂ Flow of material to be conveyed (e. g. mass flow, volume flow)
ÂÂ Conveying track (e. g. conveying length, conveying height).

These data are a basis for selection of the type of belt conveyor and thus for the type of
conveyor belt. The decision on whether it is a plain standard conveyor belt, a steep-angle
conveyor belt or a special conveyor with the corresponding special-purpose belt serves
as a reference point for the stipulation of the principal data, in particular of conveying
speed and belt width, but may necessitate for instance in addition the stipulation of the
troughing design, the belt surface profile or the pitch of elevator buckets.

The next factors to be determined are motional resistances and required power of the
belt conveyor. If the design is already established, it is the size, position and type of the
driving motors that have to be recorded besides the data stated hitherto, as these may
have a decisive influence on the selection of the conveyor belt. The calculation of the
belt conveyor leads on to the peripheral forces at the driving pulleys. Their magnitude
depends on the extent of the motional resistances but varies for temporary operating
conditions such as starting and stopping.

The design of the tension member in the conveyor belt then follows. Its ten-
sile strength is determined mainly by the magnitude of the belt tensions. Fur-
ther influences result from a variety of criteria relating to operation and design.

As the strength of the tension member must always have a specific safety mar-
gin over the maximum stress, it is essential to stipulate the safety coefficient or
to check the available safety margin on selection of the tension member. Spe-
cial attention must be paid here to the durability of the conveyor belt at the joints.

The tension member of the conveyor belt is enclosed in the covers, which thus form an ef-
fective protection against external influences. For this reason the material and construction
are selected to counteract the effects of the material conveyed and of the environment.
Conformity to the tension member must also be observed on selection of the covers.

Conti conveyor belts are supplied to all parts of the world, using those dispatch fa-
cilities best suited to the destination; the packaging guarantees safe trans-
port even in exceptional cases. The optimum part lengths can be determined for
each particular instance to provide inexpensive shipment and simple assembly.
The thickness, width and weight of the belt are to be given special consideration.

The conveyor belt calculation process described also conforms with the arrange-
ment of the following chapters. The chart shows both the normal sequence of de-
sign stages and the feasibility of starting at any section, provided that specific data
or parameters are known. In general the single chapters go deeper into the re-
spective subject with increasing sub-division, so that a rough assessment of the
belt structure can be made by consulting the general chapter alone. Special refer-
ence is made to those calculation points at which an assessment is recommended.

4
 Basic expressions and
definitions...................................D – 1
 Stipulation of principal data.. . . . D – 2
Material handled.. . . . . . . . . . . . . . . . . . . . 2.1
Flow of material.. . . . . . . . . . . . . . . . . . . . . 2.2
Conveying track.. . . . . . . . . . . . . . . . . . . . 2.3
Type of belt conveyor.. . . . . . . . . . . . . . . 2.4
Conveying capacity.. . . . . . . . . . . . . . . . . 2.5
 Calculation of belt conveyor......D – 3
Masses.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Coefficients.. . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Motional resistance.. . . . . . . . . . . . . . . . . 3.3
Required power.. . . . . . . . . . . . . . . . . . . . 3.4
Peripheral forces.. . . . . . . . . . . . . . . . . . . . 3.5
Calculation example.. . . . . . . . . . . . . . . . 3.6
 Stipulation of tension member.. D – 4
Tensile forces of belt.. . . . . . . . . . . . . . . . 4.1
Additional strains.. . . . . . . . . . . . . . . . . . . 4.2
Selection criteria.. . . . . . . . . . . . . . . . . . . . 4.3
Tension member data.. . . . . . . . . . . . . . 4.4
The staff of the ContiTech with its sophisti-
 Selection of covers.. . . . . . . . . . . . . D – 5 cated research and development resourc-
Cover material.. . . . . . . . . . . . . . . . . . . . . . 5.1 es is available for direct consultation and
Cover gauge.. . . . . . . . . . . . . . . . . . . . . . . . 5.2 to answer any questions. Please address
Special cover structures.. . . . . . . . . . . . 5.3 enquiries to:

 Steep-angle conveyor belts.. . . . D – 6 ContiTech Transportbandsysteme GmbH

P.O. Box 1169, D-37141 Northeim
 Elevator belts.. . . . . . . . . . . . . . . . . . . . D – 7 Breslauer Straße 14, D-37154 Northeim
 Piece goods handling and belts Ph. 05551-702-207
for sliding bed operation.. . . . . . . D – 8 Fax 05551-702-504
[email protected]
 Appendix.. . . . . . . . . . . . . . . . . . . . . . . . . D – 9 www.contitech.de/conveyorbeltsystems

The computer programmes filed in the constantly expanding library of the Department
for Application Technique enable enquiries to be dealt with promptly Apart from specific
individual problems, this facility permits above all extensive calculations and design al-
ternatives to be investigated without loss of time Reference can be made to the currently
complied programmes at those points of the conveyor belt calculation marked with the
key word ‚CONTI-COM‘.

5
 D – 1 Basic expressions and definitions

D – 1 Basic expressions and definitions

Continuous conveyors: Continuous conveyors are mechanical, pneumatic and hydrau-

lic conveying devices with which the material to be handled can be moved continuously
on a fixed conveying track of restricted length from feeding point to discharge point,
possibly at varying speed or in a fixed cycle. These conveyors are available in stationary
or mobile versions and are used for the handling of bulk materials or piece goods.

Belt conveyors: Continuous conveyors whose belts have a tension member consisting
of synthetic fabrics or steel cables with rubber or synthetic covers; the belts are sup-
ported by straight or trough-shaped idlers or have sliding support on a smooth base as
a tension and support member. The actual conveying is done on the top run, in special
cases on the top run and the return run. Belts with cleated top covers, special-purpose
belts or sandwich belts are used for steep-angle conveying.

11 10 1 13 8 6 12 2

17 5 15 7 9 16 4 3 14

1 Feed 9 Return run idlers
2 Discharge 10 Feed rollers
3 Head pulley (drive pulley) 11 Flat-to-trough transition
4 Snub or deflecting pulley 12 Trough-to-flat transition
5 Tail pulley (takeup pulley) 13 Feed chute
6 Top run (tight side) 14 Belt cleaner (transverse scraper)
7 Return run (slack side) 15 Belt cleaner (plough-type scraper)
8 Top run idlers 16 Drive unit
17 Counterweight

Belt-type elevators: Continuous conveyors with buckets or similar containers as car-

riers; these either scoop the material or are filled by metering hoppers and emptied at
specific discharge points. The tension unit consists of belts to which the containers are
attached. Transport is effected at any angle from vertical to horizontal.

Flow of material: Mass or volume of the conveyed bulk material or piece goods per unit
of time in continuous conveying. In contrast, the capacity is not time-related.

Conveying capacity: The volume capacity or capacity of material conveyed that can
be attained with the given conveying speed and the available cross-section area or the
container volume and spacing.

Conveying speed: Speed of the material conveyed. The conveyor belt as the support
member determines the speed of the material on it.
6
D – 1 Basic expressions and definitions

Centre distance: The distance between head and tail pulley of the conveyor. The belt
length as the inside circumference of the endless, slack belt results from this distance
only when the pulley circumference and any belt loops (tension loops, discharge loops
etc.) present are taken into account.

Conveying length: The distance between the centre of the material feeding point and
the axle of the discharge pulley. If the material conveyed is stripped off, the centre of
the material discharge is to be taken instead. In general the conveying length is approxi-
mately equal to the centre distance. The conveying length may, however, be smaller than
the centre distance or be variable during the conveying process.
Discharge

Centre distance
Drive head
Feed with tension
L L4 loop
L3 H4
L0 L2 H3 H
L1 H2

Conveying height: The difference in height between material feed and material dis-
charge. Belt conveyors with sections at different gradients yield the section heights al-
located to the section lengths.

Belt support: The belt is generally supported by fixed idlers or by suspended idlers.
The belt can be flat or troughed by multi-roll idlers. Troughing permits a greater flow of
material and promotes improved belt training. The idler spacing is normally larger on
the return run than on the top run and can also be graduated within one belt conveyor.
Special idler designs or arrangements are frequently selected at the feeding points and
for belt cleaning.

Flat belt V-trough 3-roll troughing 5-part troughing Square-troughing

(with CONTIWELL® belt
side wall)

Conveyor belt: The task of the conveyor belt is to carry the material handled and si-
multaneously to transmit the driving forces to overcome the motional resistances. The
conveyor belt consists in general of the tension member and the top and bottom covers,
which form a core-protecting covering.

Those conveyor belts used in belt conveyors are to be regarded as continuous convey-
ing elements composed of one or more belt sections joined together at their ends. Short
conveyor belts can also be manufactured in endless versions.

7
 D – 1 Basic expressions and definitions

Steel cable belt: Fabric carcass belt:

Cover
top
Covers
Cover Moulded edge
bottom STAHLCORD®- Fabric tension member
tension member

Steep angle conveyor belts: Rollback of the material handled can be prevented by
means of chevron cleats, fins or cross partitions on the carrier side when the conveying
gradient is steep. The design can be adapted to the material to be conveyed and to the
transverse stability required. Cross partitions and corrugated sidewalls can be combined
to form the corrugated box-section belt.

Steep angle HÖCKER® CONTIWELL®

conveyor belt with conveyor belt box-section belt
chevron cleats

Elevator belts: These are used in belt-type bucket elevators and are provided with spe-
cial brackets for the attachment of containers, buckets or belt slings.

Tension member: The task of the tension member is to transmit the forces induced at
the drives for overcoming the system resistances to the point where they are needed.
In the fabric ply belt, the tension member consists of one or more plied fabrics. In the
case of a steel cable belt, the tension member consists of steel cables arranged on a
single plane and running parallel to each other longitudinally; these cables are imbedded
in core rubber.

Core rubber: The core rubber envelops the steel cables of the steel cable tension mem-
ber, providing good adhesion to the Cover material with a high dynamic carrying capac-
ity. The physical properties are maintained even after repeated curing, for instance on
splicing.

Belt covers: The covers protect the tension member from damage and other environ-
mental influences. The top and bottom covers may vary in thickness. The bottom cover
can be omitted from bare-bottom-ply belts for sliding bed operation. Additional elements
designed to increase impact resistance or for monitoring purposes may be located in the
covers. The Cover materials can be selected to suit any application.

Surface patterning: For improved holding of materials on gradients or for special ap-
plications, the top cover can be manufactured in a patterned or a cleated version.

8
D – 2 Stipulation of principal data

D – 2 Stipulation of principal data

 Material handled.. . . . . . . . . . . . . . . . . . 2.1

 Flow of material handled.. . . . . . . . . 2.2
 Conveying track.. . . . . . . . . . . . . . . . . . . 2.3
 Type of belt conveyor.. . . . . . . . . . . . . 2.4
Belt width.. . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1
Belt speed.. . . . . . . . . . . . . . . . . . . . . . . . 2.4.2
Belt support.. . . . . . . . . . . . . . . . . . . . . . 2.4.3
 Carrying capacity.. . . . . . . . . . . . . . . . . 2.5

The designing of a conveyor belt begins with an investigation into the service require-
ments and the stipulation of the principal data characterizing the specific application.
Data already available can be checked against the guide values stated in this section.

The optimum conveyor belt cannot be selected by means of the principal data alone, as
the operating method and the belt conveyor design also have a considerable influence. If
the stress and strain on the conveyor belt are not known in detail, a calculation of the belt
conveyor must be executed with reference to the bulk material transport up to approx.
30° system gradient in section D – 3. Sections D – 6 to D – 8 contain supplementary data
for the calculation of steep-angle conveyors for bulk materials, of elevators and piece
goods conveyors.

9
 D – 2.1 Stipulation of principal data – Material handled

D – 2.1 Material handled

The physical and chemical properties of the material to be handled must be taken into
account when selecting the belt conveyor and designing the conveyor belt.

Properties of material to be handled (guide values)

Possible effect
Bulk Angle of Max. gradient
Material to be handled density ρ repose of fight
δ mech. chem. temp.
in t/m3 in°

Ammonium sulphate 0.75 – 0.95 22 + ++

Artificial fertilizer 0.9 – 1.2 12 12 – 15
Ash, dry 0.65 – 0.75 16 +
Ash, wet 0.9 15 18 +
Asphalt, crushed 0.7 22
Bauxite, crushed 1.2 – 1.4 18 – 20 ++
Bauxite, fine 1.9 – 2.0 18 +
Beet 0.65 – 0.75 10 15 – 17
Beet chip, wet 0.5 18 15 – 17 +
Berry and Lorraine iron,
3.2 15 18
fine
Blast furnace slag 1.2 – 1.4 18 ++ +
Cement 1.2 – 1.5 0 – 10 15 – 20 ++
Cereals (not oats) 0.7 – 0.85 10 – 12 14 +
Clay, damp 1.8 15 – 18 18 – 20
Clinker 1.2 – 1.5 10 – 15 18 ++ ++
Coal, fine 0.8 – 0.9 10 18 – 20
Coal, raw 0.75 – 0.85 18 18 +
Coke 0.45 – 0.6 15 17 – 18 ++ ++
Concrete, wet 1.8 – 2.4 0 – 5 16 – 22 ++
Copper ore 1.9 – 2.4 15 18 ++
Crushed rock 1.5 – 1.8 10 – 15 16 – 20 ++
Felspar, crushed 1.6 18 ++
Fish meal 0.55 – 0.65 25
Flour 0.5 – 0.6 15 15 – 18
Foundry sand 1.2 – 1.3 20 + ++
Foundry waste 1.2 – 1.6 16 ++ +
Fruit 0.35 10 12 – 15 +
Glass, crushed 1.3 – 1.6 12 – 15 ++ +
Granite, crushed 1.5 – 1.6 20 ++
Graphite, powder 0.5 20
Gravel and sand, wet 2.0 – 2.4 15 20
Gravel, graded, washed 1.5 – 2.5 18 12 – 15
Gravel, ungraded 1.8 15 18 – 20
Gypsum, crushed 1.35 18
Gypsum, powdered 0.95 – 1.0 23
Household refuse 0.6 18 – 20 + +
Iron ore 1.7 – 2.5 15 18 ++
Iron ore, pellets 2.5 – 3.0 12 15
Lignite briquettes oval 0.7 – 0.85 15 12 – 13
Lignite, dry 0.5 – 0.9 15 15 – 17

10
D – 2.1 Stipulation of principal data – Material handled

Properties of material to be handled (guide values)

Possible effect
Bulk Angle of Max. gradient
Material to be handled density ρ repose of fight
δ mech. chem. temp.
in t/m3 in°

Lignite, wet 0.9 15 – 20 18 – 20

Lime, lumps 1.0 – 1.4 15 15 – 20 +
Limestone, crushed 1.3 – 1.6 15 16 – 18 +
Maize 0.7 – 0.75 12 15 +
Manganese ore 2.0 – 2.2 15 18 – 22 ++
Matchwood 0.2 – 0.35 22 – 24
Oil cake 0.7 – 0.8 10 15 ++
Oil sand 1.6 – 1.8 15 20 ++
Overburden 1.6 – 1.7 15 17 ++
Peat 0.4 – 0.6 16
Phosphate, crushed 1.2 – 1.4 15 18 – 20 ++
Phosphate, fine 2 12 – 15 18 +
Potash 1.1 – 1.6 15 18 + +
Rock salt 1 – 2 15 18 +
Rubber, pellets 0.8 – 0.9 12 +
Salt, coarse 1.2 15 18 – 20
Salt, fine 1.2 – 1.3 15 15 – 18
Sand, dry 1.3 – 1.4 15 16 – 20 ++
Sand, wet 1.4 – 1.9 15 20 – 25 +
Sandstone, crushed 1.3 – 1.5 ++
Scrap metal 1.2 – 2.0 ++ +
Slag 1.3 18 ++ +
Slate, crushed 1.4 – 1.6 +
Sludge 1.0 0
Soap flakes 0.15 – 0.35 15
Soil, damp 1.5 – 1.9 15 – 20 18 – 20 +
Sugar cane 0.2 – 0.3
Sugar, raw 0.9 – 1.1 15 +
Sugar, refined 0.8 – 0.9 20
Timber, pieces 0.25 – 0.5 20 – 25

Key:
+ medium wear + + heavy wear
chemically aggressive chemically highly aggressive
temperatures above 70° temperatures above 120°C

The dynamic angle of repose is in general lower than the natural angle of incline of the
material handled and depends on the type of material handled, the conveying speed, the
design of the feeding point and the gradient of the system.

It permits an assessment of the cross-sectional form of the bulk material on the belt. The
maximum gradient stated for the flight applies to a standard, uncleated belt surface.

11
 D – 2.2 Stipulation of principal data – Flow of material handled

D – 2.2 Flow of material handled

If a specific quantity of material is to be handled in a prescribed time, the

Mass flow Qm in t/h

results with the mass of the material handled, and the

Volume flow QV = Qm / ρ in m³/h

for bulk materials with bulk density ρ.

The necessary Conveying capacity of the conveyor belt or belt conveyor to be selected
is determined by these two values. To what extent downtime may occur through mainte-
nance, breakdown and repairs and to operation-related interruptions in conveying must
be taken into account when making the selection.
Operating hours per year
Working days per year 1 shift* 2 shift 3 shift
365 2920 5840 8760
250 2000 4000 6000
200 1600 3200 4800
* 1 shift ≙ 8 hours

Guide values for maximum material flows

QV in m³/h Qm in t/h
Belt conveyors approx. 25 000 approx. 40 000
Steep angle conveyor belts approx. 1 400 approx. 3 000
Elevators approx. 1 500 approx. 2 500

12
D – 2.3 Stipulation of principal data – Conveying track

D – 2.3 Conveying track

Owing to its continuous conveying process, the belt conveyor has relatively low flight
loads and can consequently be adapted to any routing. The belt gradient can be changed
at random, which may provide the most economic solution for longhaul conveying sys-
tems in particular. Certain minimum radii of the concave or convex curves must be
adhered to. Laying in horizontal curves is also feasible with belt conveyors. The use of
a high-strength tension member permits considerable conveying lengths and convey-
ing heights to be attained. Centre distances in the magnitude of 5 to 20 kilometres and
conveying heights of up to several hundred meters are no longer a rarity.

Belt conveyors with steep angle belts are normally designed for shorter flights at a very
steep gradient. The belt guidance can be adapted largely to the specific application in
this case too with the use of appropriate supporting elements.

Belt elevators are used almost exclusively for vertical transport with conveying heights of
up to almost 100 meters. The operating principle permits no curves or significant gradi-
ents in the flight. The use of steep angle conveyor belts and elevator belts overlaps in the
range of very steep to vertical transport. Individual adaptation of the conveyor element is
frequently essential in this instance.

13
 D – 2.4 Stipulation of principal data – Type of belt conveyor

D – 2.4 Type of belt conveyor

The transport of bulk material and piece goods on conveyor belts with no surface parti-
tioning or on hugger belts is restricted by the gradient at which the material being han-
dled begins to slip or to roll. Nor is faultless transport guaranteed if starting or stopping
induces this process. The critical conveying gradient angle for a smooth belt is between
15° and 20° for the majority of different types of material handled. Furthermore, special
belts permitting steeper gradients have to be used. The stated guide values apply to
ascending transport.

Stee
6
p an g
5 le 1 Conveyor belts with no surface
co
n ve partitioning (Conveyor belts
yo with cover patterning for bulk
4 r
87° materials)
500 be
400 60°
l
ts 2 Piece goods conveyor belts
300 3 with cover patterning , Rollgurt*
200
100 45° 3 Belts with chevron cleats
0
2
4 Fin belts, box-section belts
35° with corrugated sidewalls
8
6 5 Conveyor belts in sandwich
4
2 20° design
0
1
6 Elevator belts
87°
60° 45° max. edge length
35° approx. 0,3x belt width
20°
0
2
4
6
8

0
100
200
300
400
500

Belt speed Edge length of material

in m/s handled in mm
The maximum gradients are to be selected on the small side, if easily flowing bulk mate-
rial is to be conveyed at an angle on conveyor belts of groups 1,2 or 3. With increasing
surface pattern depth and with transport in buckets etc., the type of material handled is
of essential significance only with regard to granularity or piece size.

The velocity data, too, represent guide values that are intended to help in selecting the
appropriate type of belt but have to be determined more precisely in the subsequent
design. If a steep angle conveyor belt or an elevator belt is found to be suitable for the
application or if belts for piece goods or for sliding bed operation are to be designed,
special attention should be paid to the information in the relevant chapters.

For bulk material transport on conveyor belts with cover patterning (group 1) the maxi-
mum conveying gradients can be set approx. 5° higher than corresponding to the re-
spective angle of the material concerned.

If a control of all requirements has led to the selection of a conveyor with a belt from
groups 2 to 6, the layout information given for these special conveyor belts in Sections
D – 6, D – 7 and D – 8 is to be observed.

* Tubular belt, developed by ContiTech and PWH AS (please ask for special literature).
14
D – 2.4.1 Stipulation of principal data – Type of belt conveyor – Belt width

D – 2.4.1 Belt width

The belt width should be selected as far as possible from standardized or customary
widths as the dimensions of the idlers and other constructional elements of the belt con-
veyor are coordinated with these widths.

Standard belt widths*

300 400 500 600 650 800
Belt width B 1000 1200 1400 1600 1800
in mm 2000 2200 2400 2600 2800
3000 3200

In the case of troughed belts, the belt width must not fall short of certain dimensions,
depending on the lump size (edge length) of the material to be handled, as the material
can otherwise not be transported safely. With strongly eccentric pieces there is further-
more the risk of the belt mistracking and of idlers being damaged by material projecting
beyond the belt.
Minimum belt widths
Size k of lumps Mind. belt width B
in mm in mm
100 400
150 500
200 650
300 800
400 1000
500 1200
550 1400
650 1600
700 1800
800 2000

This data applies to approximately cubic lumps. Narrower widths are also admissible for
oblong lumps (so-called “slabbies“) or when single pieces are imbedded in mainly fine
material.

It is to be observed that the troughability too is influenced by the belt width. The trougha-
bility decreases with diminishing belt width. On final determination of the belt structure,
the troughability (D – 4.3.2) is to be checked.

* ContiTech conveyor belts are currently available in widths of up to 6400 mm. Textile carcass
belts are available from stock in widths of 400 to 2 100 mm.
15
 D – 2.4.2 Stipulation of principal data – Type of belt conveyor – Belt speed

D – 2.4.2 Belt speed

The selection of the belt speed is of decisive significance for the further designing of the
belt conveyor and of the belt.

Application features Conveying speed v in m/s

Special cases, process-related

(e. g. cooling conveyors) 0.5
Small flows of material, protective transport
(e. g. coke bench conveyors) 0.5  –  1.5
Standard application conditions
and material handled (e. g. gravel conveyance) 1.5  –  3.5
Large flows of material, long conveying lengths
(e. g. overburden conveyance) 3.5  –  6.5
Special cases (e. g. jet conveyors) 6.5 and more

In general a more economic design can be achieved with higher conveying speeds. The
greater the conveying lengths and thus the belt lengths, the more significant this is, so
that maximum conveying speeds will be selected especially in such cases. The limits
imposed first and foremost by the type and nature of the material to be handled can be
exceeded in many instances if, for example, additional measures are taken at the feeding
points to eliminate or diminish the drawbacks of high conveying speeds.

Bulk material features

strongly abrasive
fine and light low conveying
fragile speeds
coarse grained (sized) and heavy
slightly abrasive higher conveying
medium bulk weight speeds
medium granularity (unsized)

Increased conveying speed results in an increased Conveying capacity with a constant

belt width. It may thus be possible to select a narrower belt width or a simpler troughing
design for a given flow of material. In addition, reduced drive tractions and consequently
reduced dimensioning of all elements constituting the belt conveyor may result. Draw-
backs are increased belt wear, to which special attention should be paid in short belt
conveyors, an increased risk of damage to the material handled and increasing power
requirements for large capacities.

Reduced conveying speed correspondingly results in a larger belt width or a higher-

capacity troughing design with the given flow of material. The increased drive tractions
are offset by reduced belt wear and a reduced risk of damage to the material handled.

16
D – 2.4.2 Stipulation of principal data – Type of belt conveyor –Belt speed

Belt speeds –
guide values from systems in operation
Bulk materials 1 2 3 4 5 6 7 Application
Coal (fine, dusty) Power stations
Filter ash Refuse dressing
Household refuse
Cement plants
Cement clinker Steel works
Coke Coking plants
Raw salt (fine) Potash industry
Residual salt (damp) Pit and quarry
Gravel, sand industry
Cement, chalk Dressing plants
Limestone (crushed) Grain silos
Cereals
Underground plants
Pit coal (crushed) Power stations
Marl Cement industry
Ore Loading plants
Coal Stockyards
Raw salt (crushed) Long-distance
Bauxite conveying systems
Rock phosphate
Crude lignite (damp) Raw material
Overburden extraction
Concentrated phos- Open cast mines
phate
Belt speed 1 2 3 4 5 6 7 in m/s

Belt speeds of the standard series:

0.42 0.66 1.05 1.68 2.62 4.19 6.6 in m/s
0.52 0.84 1.31 2.09 3.35 5.2 8.4

Standard Possible
conveying speeds conveying speeds

17
 D – 2.4.3 Stipulation of principal data – Type of belt conveyor – Belt support

D – 2.4.3 Belt support

The cross section of the conveyor belt is formed by the arrangement of its supporting
elements - idlers or slip planes - and thus adapted to the application conditions and the
necessary Conveying capacity.

The supporting system is generally effected by idlers with largely standardized lengths
and diameters. The lengths are prescribed so as to ensure reliable belt support even with
the mistracking that is permitted within certain limits. The selection of the idler diameter
is influenced by the conveying speed. Further data to help determine idler weights and
spacings are given in the relevant chapters.

Belts for bulk material transport are supported almost exclusively by rigidly mounted
idlers or suspended (garland) idlers.

Application features for belt support systems

Bulk materials Piece goods
Support
Rollers Plane-borne or rollers
as hopper drawing laterally chuted or with belt width dependent on
device and conveyor corrugated sidewalls as skirting piece goods dimensions
type scales
as belt with corrugated with corrugated side-walls to single piece should not
Flat belt sidewalls increase Conveying capacity project beyond sidewall
as partitioned belt with with transverse partitions or
corrugated sidewalls with corrugated sidewalls
for steep angle trans-
port
for all bulk materials with fins or partitions or with transport of billets or tree
various trough designs patterned cover for steep trunks, reels and barrels to
Troughed angle transport prevent lateral rolling
belt
Trough belt with turned-up sides construction as for bulk
materials

The design of multiple troughs is determined essentially by the troughing angle.

Troughing angle of multiple belt supports

Troughing Top run Return run
for belt widths up to 800 mm. in any width required for better tracking;
Troughing angle up to 30° depending standard troughing angle 10° – 15°
on belt construction. Belt widths up to
V-trough 1200 mm and troughing angle up to 45°
in special cases. With stepped fabric
plies at belt centre where appropriate
Classical version for all belt widths; with double strand, material and
standard troughing angle: passenger transport with the
3-part 20° – 30° – 35° – 40° – 45° conventional top run troughings
“Deep trough” with shortened centre idler
In top run, preferred as close-set garland
idler assembly in the material feeding
5-part area. Troughing angle dependent on load
distribution, belt rigidity and belt tension:
25°/55° or 30°/60°

18
D – 2.4.3 Stipulation of principal data – Type of belt conveyor – Belt support

Troughing designs
(The clearance d must not exceed 10 mm; from 2000 mm belt width it must not exceed
15 mm.)

Standard idler tube lengths in mm

Troughing Belt width B in mm
design 300 400 500 600 650 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200
flat I 380 500 600 700 750 950 1150 1400 1600 1800 2000 2200 2500 2800
V-trough I 200 250 315 340 380 465 600 700 800 900 1000 1100 1250 1400 1500 1600 1700 1800
3-part I 160 200 250 250 315 380 465 530 600 670 750 800 900 950 1050 1120 1150
3-part I1 200 250 315 380 465 530 600 640 670 700 800 900 900
(deep
I2 380 465 550 600 670 700 800 900 1000 1100 1150 1150 1250
trough)
5-part I 165 205 250 290 340 380 420 460 500 540 580 640 670

When selecting the idler diameter, care should be taken that no excessively high numbers of
revolutions result from the belt speed. 600 – 700 r. p. m. should not be exceeded.

Standard idler diameter in mm

Carrier idlers 88.9 108 133 159 193.7
Impact idlers 156 180 215 250 290
Return run support discs 120 133 150 180 215 250 290

Idler speed
v · 60
nR = in min-1 DR in m
π · DR

The economic efficiency of a belt conveyor can be considerably influenced by the selection
of an optimum idler spacing in the top and the return run. The capital expenses and the
maintenance expenditure are also reduced by a smaller number of idlers. Approximate
standard values of the idler spacing lo in the top run can be calculated from the empirical
relationship

max. grain size k in mm

I 0 ≤ 5 ∙ ( k ∙ ρ)
-0.2 in m
bulk density ρ in t/m3

The idler spacing in the return run should be about 2 or 3 X IO.

A detailed investigation, e. g. towards graduating the idler spacings when centre distances
are greater, may be advisable and can be undertaken at any time by the staff of the
ContiTech Transportbandsysteme GmbH Application Technique Department.

* The following effects should be observed in particular: Loading capacity of the idlers
(Service life of the idler depending on bearing load and axial deflection)
Troughing properties of the belt (Safe material intake and adequate belt support)
Drive traction and belt sag (cf. D – 4.1) (Prevention of shear vibrations of the belt and exces-
sive motional resistances due to higher flexing stress)
19
 D – 2.5 Stipulation of principal data – Conveying capacity

D – 2.5 Conveying capacity

The Conveying capacity of the belt conveyor is determined by the filling cross-section
area A and the conveying speed v. The theoretical volume capacity thus amounts to
Q V th = A · v · 3600 in m³/h
and the theoretical capacity to

Q m th = A · v · 3600 · ρ in t/h

A = A1 + A2
in m2

The filling cross-section area A is based on the effective belt width

b = 0.9 · B – 50 mm für B ≤ 2000 mm
b =  B – 250 mm für B > 2000 mm
For belts with corrugated sidewalls the maximum effective belt width amounts to
b eff = B – 100 mm for a corrugated sidewall height h K ≤ 80 mm
b eff = B – 120 mm for a corrugated sidewall height h K > 80 mm
which is reduced by the corresponding amount for a plain skirting zone. The effective fill-
ing height h n is approx. 0.9 · h K.

With feeding rate φ1 the effective Conveying capacity amounts to

Q V eff = A · v · 3600 · φ1 in m³/h
or

Q m eff = A · v · 3600 · ρ · φ1 in t/h

The deviation of the filling cross-section form from the straight-side fill assumed with
angle β, which occurs above all in non-horizontal transport, can be taken into account
with feeding rate φ1.
Guide values for φ1 in non-horizontal transport
Gradient in ° 2 4 6 8 10 12 14 16 18 20
H/L 0.035 0.070 0.105 0.140 0.174 0.208 0.242 0.276 0.310 0.342
Feeding rate φ1 1.0 0.99 0.98 0.97 0.95 0.93 0.91 0.89 0.85 0.81

The values stated apply only to strongly troughed conveyor belts and bulk material with
high internal friction. For untroughed belts and V-troughs in particular, non-horizontal
transport results in considerably reduced feeding rates φ1 that have to be calculated by
the approximation method* or determined empirically.

* A mathematical formulation is given for instance in DIN 22 101

20
D – 2.5 Stipulation of principal data – Conveying capacity

Gradients exceeding 20° can generally be attained only with conveyor belts with a par-
titioned or patterned cover. The stated values of φ1 apply with the same restrictions as
above.
Guide values for φ1 with gradients exceeding 20°
Gradient in ° 21 22 23 24 25 26 27 28 29 30
H/L 0.358 0.375 0.391 0.407 0.423 0.438 0.454 0.469 0.485 0.500
Feeding rate φ1 0.78 0.76 0.73 0.71 0.68 0.66 0.64 0.61 0.59 0.56

Short flights deviating in their gradient from the overall conveying angle of the belt con-
veyor need not be taken into account with reduction factor φ1 unless the filling cross-
section changes on a brief run-through.

The necessary filling cross-section results from the above equations with a given flow of
material Qm (mass flow in t/h) and taking into account where relevant a uniformity coef-
ficient φ2 ≥ 1 in feeding, in

Q m · φ2
A = in m2
v · 3600 · ρ · φ1

and thus enables the trough design to be selected from the tables showing the values
for A with the corresponding parameters
b2 hn I hn
A = · tan  β in m2 A = (I + ) · hn +( + ) 2 · tan  β in m2
4 tan  λ 2 tan λ

Flat Square trough ( λ = 80º)

hk* = 100 mm
Belt width Belt width
B in mm
Angle of repose β B in mm
Angle of repose β
5º 10º 15º 20º 5º 10º 15º 20º
300 0.0010 0.0021 0.0032 0.0044 400 0.0171 0.0183 0.0194 0.0207
400 0.0021 0.0042 0.0064 0.0087 500 0.0258 0.0282 0.0306 0.0332
500 0.0034 0.0070 0.0107 0.0145 650 0.0397 0.0447 0.0499 0.0554
650 0.0062 0.0126 0.0191 0.0260 800 0.0546 0.0633 0.0723 0.0817
800 0.0098 0.0197 0.0300 0.0408 1000 0.0759 0.0911 0.1067 0.1231
1000 0.0158 0.0318 0.0483 0.0657 1200 0.0990 0.1224 0.1466 0.1719
1200 0.0232 0.0467 0.0710 0.0965 1400 0.1239 0.1573 0.1918 0.2279
1400 0.0320 0.0645 0.0980 0.1332 1600 0.1505 0.1957 0.2423 0.2911
1600 0.0422 0.0851 0.1294 0.1758
hk* = 150 mm
1800 0.0539 0.1086 0.1651 0.2242 Belt width
2000 0.0669 0.1350 0.2051 0.2786 B in mm Angle of repose β
2200 0.0831 0.1676 0.2547 0.3459 5º 10º 15º 20º
2400 0.1011 0.2037 0.3096 0.4206 650 0.0499 0.0534 0.0569 0.0606
800 0.0717 0.0783 0.0851 0.0922
1000 0.1024 0.1147 0.1273 0.1406
1200 0.1347 0.1545 0.1750 0.1964
1400 0.1689 0.1980 0.2279 0.2594
1600 0.2048 0.2449 0.2863 0.3296
* h n = h k + 25 mm 21
 D – 2.5 Stipulation of principal data – Conveying capacity

b 2eff
A = b eff · h eff + · tan β in m2
2

Corrugated sidewall
Angle of repose β = 0˚ Angle of repose β = 10˚
Belt width Height of corrugated Height of corrugated
B in mm sidewalls hk in mm sidewalls hk in mm
60 80 125 160 60 80 125 160
300 0.0097 0.0129 0.0180 0.0230 0.0111 0.0143 0.0191 0.0241
400 0.0151 0.0201 0.0292 0.0374 0.0185 0.0236 0.0322 0.0404
500 0.0205 0.0273 0.0405 0.0518 0.0268 0.0337 0.0462 0.0575
650 0.0286 0.0381 0.0573 0.0734 0.0410 0.0505 0.0688 0.0849
800 0.0367 0.0489 0.0742 0.0950 0.0571 0.0693 0.0934 0.1142
1000 0.0475 0.0633 0.0967 0.1238 0.0816 0.0974 0.1293 0.1564
1200 0.0583 0.0777 0.1192 0.1526 0.1097 0.1291 0.1687 0.2021
1400 0.0691 0.0921 0.1417 0.1814 0.1413 0.1643 0.2117 0.2514
1600 0.0799 0.1065 0.1642 0.2102 0.1764 0.2031 0.2582 0.3042
1800 0.0907 0.1209 0.1867 0.2390 0.2151 0.2453 0.3082 0.3605
2000 0.1015 0.1353 0.2092 0.2678 0.2573 0.2911 0.3617 0.4203
2200 0.1123 0.1497 0.2317 0.2966 0.3030 0.3404 0.4188 0.4837
2400 0.1231 0.1641 0.2542 0.3254 0.3522 0.3933 0.4794 0.5505

Angle of repose β = 15˚ Angle of repose β = 20˚

Belt width Height of corrugated Height of corrugated
B in mm sidewalls hk in mm sidewalls hk in mm
60 80 125 160 60 80 125 160
300 0.0118 0.0151 0.0197 0.0247 0.0126 0.0159 0.0203 0.0253
400 0.0203 0.0254 0.0337 0.0419 0.0222 0.0272 0.0354 0.0435
500 0.0301 0.0370 0.0491 0.0605 0.0336 0.0404 0.0522 0.0636
650 0.0474 0.0569 0.0747 0.0908 0.0541 0.0637 0.0810 0.0971
800 0.0676 0.0799 0.1034 0.1242 0.0787 0.0910 0.1138 0.1346
1000 0.0993 0.1152 0.1462 0.1733 0.1179 0.1338 0.1640 0.1911
1200 0.1364 0.1558 0.1945 0.2279 0.1644 0.1838 0.2214 0.2548
1400 0.1788 0.2019 0.2480 0.2877 0.2182 0.2412 0.2862 0.3258
1600 0.2266 0.2532 0.3070 0.3530 0.2792 0.3058 0.3582 0.4041
1800 0.2797 0.3100 0.3713 0.4236 0.3475 0.3777 0.4374 0.4897
2000 0.3382 0.3721 0.4409 0.4995 0.4231 0.4569 0.5240 0.5826
2200 0.4021 0.4395 0.5160 0.5809 0.5059 0.5434 0.6178 0.6827
2400 0.4713 0.5123 0.5963 0.6675 0.5961 0.6371 0.7190 0.7901

22
D – 2.5 Stipulation of principal data – Conveying capacity

b2
A =
4
· cos λ · sin λ + ( b
2
)
· cos λ 2
· tan β in m2

V-trough
Angle of repose β = 0˚ Angle of repose β = 10˚
Belt width
B in mm Troughing angle λ Troughing angle λ
20˚ 30˚ 35˚ 40˚ 45˚ 20˚ 30˚ 35˚ 40˚ 45˚
300 0.0038 0.0052 0.0056 0.0059 0.0060 0.0057 0.0068 0.0071 0.0072 0.0071
400 0.0077 0.0104 0.0112 0.0118 0.0120 0.0114 0.0135 0.0141 0.0143 0.0141
500 0.0128 0.0173 0.0187 0.0196 0.0199 0.0190 0.0226 0.0235 0.0238 0.0235
650 0.0229 0.0309 0.0336 0.0352 0.0357 0.0341 0.0404 0.0420 0.0426 0.0420
800 0.0360 0.0485 0.0527 0.0552 0.0561 0.0535 0.0634 0.0660 0.0668 0.0660
1000 0.0580 0.0782 0.0848 0.0889 0.0903 0.0861 0.1020 0.1062 0.1076 0.1062
1200 0.0852 0.1148 0.1246 0.1305 0.1326 0.1265 0.1499 0.1559 0.1580 0.1559
1400 0.1176 0.1584 0.1719 0.1802 0.1830 0.1746 0.2068 0.2152 0.2181 0.2152
1600 0.1552 0.2091 0.2269 0.2378 0.2415 0.2304 0.2730 0.2840 0.2878 0.2840
1800 0.1980 0.2668 0.2895 0.3034 0.3081 0.2939 0.3483 0.3624 0.3671 0.3624
2000 0.2460 0.3315 0.3597 0.3769 0.3828 0.3652 0.4327 0.4503 0.4562 0.4503
2200 0.3055 0.4116 0.4466 0.4680 0.4753 0.4535 0.5373 0.5591 0.5664 0.5591
2400 0.3714 0.5004 0.5429 0.5690 0.5778 0.5513 0.6532 0.6796 0.6886 0.6796

Angle of repose β = 15˚ Angle of repose β = 20˚

Belt width
B in mm Troughing angle λ Troughing angle λ
20˚ 30˚ 35˚ 40˚ 45˚ 20˚ 30˚ 35˚ 40˚ 45˚
300 0.0067 0.0076 0.0078 0.0078 0.0076 0.0077 0.0085 0.0086 0.0085 0.0082
400 0.0134 0.0152 0.0156 0.0156 0.0152 0.0154 0.0169 0.0171 0.0169 0.0163
500 0.0223 0.0253 0.0259 0.0259 0.0253 0.0257 0.0282 0.0285 0.0282 0.0272
650 0.0399 0.0453 0.0464 0.0464 0.0453 0.0459 0.0505 0.0510 0.0505 0.0488
800 0.0626 0.0711 0.0729 0.0729 0.0711 0.0721 0.0792 0.0801 0.0792 0.0765
1000 0.1007 0.1145 0.1173 0.1173 0.1145 0.1161 0.1275 0.1289 0.1275 0.1231
1200 0.1479 0.1681 0.1723 0.1723 0.1681 0.1704 0.1872 0.1893 0.1872 0.1808
1400 0.2042 0.2320 0.2377 0.2377 0.2320 0.2352 0.2584 0.2613 0.2584 0.2496
1600 0.2695 0.3062 0.3137 0.3137 0.3062 0.3104 0.3410 0.3449 0.3410 0.3294
1800 0.3438 0.3906 0.4003 0.4003 0.3906 0.3961 0.4350 0.4400 0.4350 0.4202
2000 0.4272 0.4853 0.4973 0.4973 0.4853 0.4921 0.5405 0.5467 0.5405 0.5221
2200 0.5304 0.6026 0.6175 0.6175 0.6026 0.6110 0.6711 0.6788 0.6711 0.6483
2400 0.6448 0.7326 0.7507 0.7507 0.7326 0.7428 0.8156 0.8252 0.8158 0.7881

23
 D – 2.5 Stipulation of principal data – Conveying capacity

A = I+ ( b-I
2
· cos λ ·) b-I
2
· sin λ + ( I+ ( b - I ) ·cos λ
2
) 2
· tan β in m2

3-part
Angle of repose β = 0˚ Angle of repose β = 10˚
Belt width
B in mm Troughing angle λ Troughing angle λ
20˚ 30˚ 35˚ 40˚ 45˚ 20˚ 30˚ 35˚ 40˚ 45˚
400 0.0059 0.0084 0.0095 0.0104 0.0112 0.0099 0.0121 0.0130 0.0138 0.0144
500 0.0100 0.0143 0.0161 0.0177 0.0191 0.0166 0.0204 0.0220 0.0232 0.0242
650 0.0187 0.0266 0.0299 0.0328 0.0353 0.0305 0.0374 0.0402 0.0425 0.0443
800 0.0292 0.0415 0.0468 0.0514 0.0552 0.0477 0.0586 0.0630 0.0666 0.0694
1000 0.0482 0.0685 0.0771 0.0845 0.0907 0.0780 0.0958 0.1029 0.1087 0.1131
1200 0.0705 0.1002 0.1128 0.1237 0.1327 0.1143 0.1403 0.1507 0.1592 0.1657
1400 0.0987 0.1401 0.1576 0.1727 0.1852 0.1590 0.1953 0.2097 0.2214 0.2302
1600 0.1312 0.1860 0.2092 0.2291 0.2455 0.2106 0.2587 0.2778 0.2931 0.3047
1800 0.1682 0.2384 0.2680 0.2935 0.3144 0.2694 0.3310 0.3553 0.3749 0.3896
2000 0.2086 0.2957 0.3325 0.3641 0.3901 0.3344 0.4108 0.4410 0.4654 0.4837
2200 0.2635 0.3731 0.4191 0.4584 0.4905 0.4194 0.5153 0.5529 0.5830 0.6052
2400 0.3179 0.4503 0.5061 0.5539 0.5930 0.5076 0.6236 0.6693 0.7060 0.7333
2600 0.3849 0.5446 0.6116 0.6687 0.7152 0.6111 0.7508 0.8054 0.8490 0.8811
2800 0.4501 0.6373 0.7159 0.7831 0.8380 0.7167 0.8805 0.9448 0.9963 1.0344
3000 0.5256 0.7440 0.8356 0.9138 0.9775 0.8356 1.0265 1.1013 1.1611 1.2052
3200 0.6143 0.8682 0.9742 1.0641 1.1368 0.9702 1.1917 1.2778 1.3460 1.3956

Angle of repose β = 15˚ Angle of repose β = 20˚

Belt width
B in mm Troughing angle λ Troughing angle λ
20˚ 30˚ 35˚ 40˚ 45˚ 20˚ 30˚ 35˚ 40˚ 45˚
400 0.0119 0.0140 0.0148 0.0155 0.0160 0.0141 0.0160 0.0168 0.0173 0.0177
500 0.0201 0.0236 0.0250 0.0261 0.0269 0.0237 0.0270 0.0282 0.0291 0.0297
650 0.0366 0.0431 0.0456 0.0475 0.0490 0.0431 0.0490 0.0512 0.0528 0.0538
800 0.0574 0.0675 0.0714 0.0745 0.0767 0.0675 0.0768 0.0802 0.0828 0.0844
1000 0.0935 0.1100 0.1163 0.1212 0.1247 0.1097 0.1249 0.1304 0.1344 0.1369
1200 0.1370 0.1612 0.1705 0.1777 0.1828 0.1608 0.1831 0.1911 0.1970 0.2007
1400 0.1903 0.2240 0.2368 0.2467 0.2536 0.2231 0.2540 0.2651 0.2732 0.2781
1600 0.2519 0.2965 0.3134 0.3264 0.3355 0.2951 0.3361 0.3507 0.3613 0.3677
1800 0.3220 0.3791 0.4007 0.4173 0.4287 0.3772 0.4295 0.4482 0.4616 0.4697
2000 0.3998 0.4706 0.4974 0.5181 0.5323 0.4683 0.5333 0.5565 0.5732 0.5833
2200 0.5005 0.5892 0.6224 0.6477 0.6649 0.5854 0.6666 0.6953 0.7155 0.7273
2400 0.6062 0.7136 0.7541 0.7850 0.8062 0.7095 0.8080 0.8429 08678 0.8826
2600 0.7287 0.8579 0.9061 0.9427 0.9673 0.8519 0.9701 1.0117 1.0409 1.0576
2800 0.8553 1.0069 1.0638 1.1071 1.1365 1.0005 1.1394 1.1884 1.2232 1.2434
3000 0.9966 1.1733 1.2394 1.2896 1.3235 1.1654 1.3271 1.3841 1.4243 1.4475
3200 1.1551 1.3597 1.4356 1.4925 1.5300 1.3489 1.5359 1.6009 1.6460 1.6709

24
D – 2.5 Stipulation of principal data – Conveying capacity

(
A = I1 +
b - I1
2
·cos λ ·
2
)
b - I1
· sin λ + ( I 1 + ( b -I 1) ·cos λ
2
) 2
· tan β in m2

3-part (deep trough)

Angle of repose β = 0˚ Angle of repose β = 10˚
Belt width
B in mm Troughing angle λ Troughing angle λ
20˚ 30˚ 35˚ 40˚ 45˚ 20˚ 30˚ 35˚ 40˚ 45˚
1000 0.0545 0.0764 0.0853 0.0925 0.0980 0.0837 0.1025 0.1095 0.1147 0.1180
1200 0.0795 0.1116 0.1246 0.1353 0.1435 0.1225 0.1501 0.1604 0.1681 0.1732
1400 0.1092 0.1534 0.1713 0.1861 0.1976 0.1685 0.2066 0.2208 0.2316 0.2388
1600 0.1423 0.2001 0.2238 0.2435 0.2590 0.2207 0.2708 0.2897 0.3042 0.3142
1800 0.1811 0.2548 0.2851 0.3102 0.3300 0.2813 0.3451 0.3693 0.3878 0.4006
2000 0.2242 0.3156 0.3532 0.3845 0.4092 0.3487 0.4279 0.4580 0.4812 0.4972
2200 0.2812 0.3953 0.4420 0.4807 0.5109 0.4355 0.5341 0.5713 0.5997 0.6190
2400 0.3455 0.4850 0.5416 0.5883 0.6243 0.5327 0.6529 0.6978 0.7317 0.7542
2600 0.4162 0.5834 0.6510 0.7063 0.7486 0.6395 0.7832 0.8365 0.8763 0.9022
2800 0.4854 0.6815 0.7612 0.8269 0.8777 0.7488 0.9178 0.9811 1.0289 1.0607
3000 0.5597 0.7867 0.8795 0.9564 1.0164 0.8665 1.0627 1.1367 1.1931 1.2314
3200 0.6531 0.9161 1.0227 1.1103 1.1776 1.0053 1.2316 1.3160 1.3793 1.4209

Angle of repose β = 15˚ Angle of repose β = 20˚

Belt width
B in mm Troughing angle λ Troughing angle λ
20˚ 30˚ 35˚ 40˚ 45˚ 20˚ 30˚ 35˚ 40˚ 45˚
1000 0.0989 0.1161 0.1221 0.1262 0.1284 0.1148 0.1303 0.1353 0.1383 0.1394
1200 0.1448 0.1701 0.1789 0.1851 0.1886 0.1682 0.1910 0.1984 0.2030 0.2048
1400 0.1994 0.2343 0.2466 0.2552 0.2602 0.2317 0.2632 0.2735 0.2800 0.2826
1600 0.2615 0.3075 0.3240 0.3358 0.3429 0.3042 0.3460 0.3598 0.3688 0.3729
1800 0.3333 0.3919 0.4130 0.4282 0.4373 0.3878 0.4411 0.4588 0.4704 0.4757
2000 0.4134 0.4862 0.5125 0.5314 0.5430 0.4812 0.5474 0.5695 0.5841 0.5909
2200 0.5157 0.6063 0.6386 0.6616 0.6752 0.5997 0.6818 0.7090 0.7264 0.7341
2400 0.6300 0.7401 0.7790 0.8062 0.8217 0.7319 0.8316 0.8640 0.8843 0.8924
2600 0.7555 0.8870 0.9329 0.9647 0.9820 0.8771 0.9958 1.0340 1.0573 1.0657
2800 0.8857 1.0406 1.0954 1.1338 1.1558 1.0291 1.1694 1.2151 1.2438 1.2555
3000 1.0260 1.2061 1.2703 1.3161 1.3431 1.1931 1.3564 1.4103 1.4450 1.4601
3200 1.1882 1.3956 1.4683 1.5191 1.5474 1.3800 1.5674 1.6280 1.6656 1.6799

25
 D – 2.5 Stipulation of principal data – Conveying capacity

A = ( I 1 + I 2 · cos λ1 ) · I 2 · sin λ1

+ [ I 1 +2I 2 · cos λ1 + ( b - I 1 - 2I 2

2
) · cos λ ] ·
2 
( b - I 1 - 2I 2) · sin λ2
2

+ [ I1
2
+ I 2 · cos λ1 + ( b - I 1 - 2I 2
2
) · cos λ ] 2 
2
· tan β in m2

5-part
Troughing angle λ1/ λ2
Belt width 25˚/55˚
B in mm Angle of repose β
0˚ 10˚ 15˚ 20˚
1000 0.0958 0.1181 0.1297 0.1418
1200 0.1402 0.1730 0.1901 0.2080
1400 0.1949 0.2399 0.2633 02878
1600 0.2541 0.3143 0.3455 0.3783
1800 0.3262 0.4025 0.4421 0.4837
2000 0.4073 0.5016 0.5506 0.6019
2200 0.5106 0.6264 0.6866 0.7497
2400 0.6254 0.7649 0.8374 0.9134
2600 0.7516 0.9171 1.0031 1.0932
2800 0.8892 1.0892 1.1835 1.2890
3000 1.0228 1.2512 1.3698 1.4942
3200 1.1909 1.4498 1.5844 1.7254

Troughing angle λ1/ λ2

Belt width 30˚/60˚
B in mm Angle of repose β
0˚ 10˚ 15˚ 20˚
1000 0.1021 0.1224 0.1329 0.1439
1200 0.1496 0.1794 0.1949 0.2112
1400 0.2076 0.2484 0.2696 0.2918
1600 0.2714 0.3261 0.3546 0.3843
1800 0.3480 0.4172 0.4532 0.4909
2000 0.4340 0.5195 0.5639 0.6104
2200 0.5427 0.6475 0.7020 0.7590
2400 0.6634 0.7895 0.8550 0.9236
2600 0.7960 0.9453 1.0229 1.1042
2800 0.9406 1.1151 1.2058 1.3008
3000 1.0851 1.2914 1.3987 1.5110
3200 1.2595 1.4928 1.6140 1.7410

26
D – 3 Calculation of belt conveyor

D – 3 Calculation of belt conveyor

 Masses.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Idlers.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1
Conveyor belt.. . . . . . . . . . . . . . . . . . . . . 3.1.2
Drive elements.. . . . . . . . . . . 3.1.3  –  3.5.1
 Coefficients.. . . . . . . . . . . . . . . . . . . . . . . . 3.2
 Motional resistance.. . . . . . . . . . . . . . . 3.3
Resistive force components.. . . . . . 3.3.1
Motional resistances of sections.. 3.3.2
 Required power.. . . . . . . . . . . . . . . . . . . 3.4
 Peripheral forces.. . . . . . . . . . . . . . . . . . 3.5
Starting and stopping.. . . . . . . . . . . . 3.5.1
Multi-pulley drive.. . . . . . . . . . . . . . . . . . 3.5.2
 Example of calculation.. . . . . . . . . . . 3.6

When designing conveyor belts for low-powered conveyor systems, a rough calculation
of the belt conveyor may be adequate in many cases. For this purpose it is quite suf-
ficient to work with the standard formulae and guide values given in the main chapters
of this section. The guide values listed there can also be used to achieve an initial rough
assessment of the belt structure, the data of which can then be applied in the more pre-
cise calculation. It is therefore advisable to observe the main chapters of Sections D – 4
(tension members) and D – 5 (covers) prior to the more detailed investigations in the sub
chapters.

The technical staff of the ContiTech Transportbandsysteme GmbH guarantee to under-

take a meticulous investigation of both simple and extremely intricate applications at any
time. The prompt preparation of a quotation can be facilitated considerably by use of the
questionnaire attached in the appendix (D – 9).

27
 D – 3 Calculation of belt conveyor

An essential step in conveyor belt calculation is the determination of the power require-
ments from the overall motional resistances, taking into account where relevant tempo-
rary operating conditions such as starting, stopping or section loading in systems with
varying gradients.

Motional resistances of a belt conveyor

1 Rolling resistance of idlers

2 Belt flexing resistance
3 Flexing resistance of material conveyed
4 Feeding resistance
5 Skirting friction resistance
6 Scraper friction resistance
7 Belt deflection resistance at pulleys
8 Gradient resistance

The different components of the motional resistance can in general be calculated com-
prehensively by means of empirical coefficients. In special cases, however, it may be
advisable to ascertain the essential components of the motional resistance individually.

The size of the drives and their quantity, if the power is to be generated by more than one
drive, can be determined from the required power. A statement on the optimum arrange-
ment too can be made as soon as the motional resistances have been ascertained.
When the number of drives and their arrangement have been stipulated, the peripheral
forces acting on the drive pulleys and having a decisive effect on the extent of the belt
tensions can be determined.

28
D – 3.1 Calculation of belt conveyor – Masses

D – 3.1 Masses *

In order to calculate the motional resistance, the sum total of all masses moved on the
flight must be determined. These include not only the load mass but also the belt mass
and the rotating idler parts. A more precise investigation of the intermittent operating
conditions in starting and stopping furthermore involves reducing all rotating masses,
including the masses of rotating drive parts, to the pulley circumference.

The mass mLI of the material handled, burdening one meter of the flight, amounts from
the capacity and the conveying speed to
Qm
m LI = in kg/m
3.6 · v
If transport is effected on the top and return runs simultaneously, the mass mLI is to be
ascertained from the sum total of the two capacities.

Mass flow Qm in t / h

Mass in mIL in kg / m

In cases where the belt structure has not yet been assessed or further data on the in-
tended design of the conveying system are not yet available, guide values for the mass
mGI of the belt and mRI of the rotating idler parts can be inserted according to the loading
of the system.

Guide values for the mass (2 m G I + m R I ) of the moving parts of a belt conveyor in kg/m
B in mm 300 400 500 650 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 3000 3200
light systems 8.5 15.0 18.5 22.5 30 37 54 63 81 106 118 128 140 161 180 200
standard system 10 16.5 21 25.5 35 52 77 89 130 154 192 207 242 256 302 345
heavy-duty system 13.0 18 24 28.5 40 67 100 115 179 202 266 287 344 371 425 490

* In general usage the term “weight” can also be used for “mass”. In all instances, however,
it Is only the unit “kilogram” (kg) that is admissible.
29
 D – 3.1.1 Calculation of belt conveyor – Masses – Idlers

D – 3.1.1 Idlers

In order to ascertain with precision the mass of all moving idler parts, related to 1 m of
the centre distance, the mass of one idler or idler trough set is to be taken from the table
below and to be divided by the respective idler spacing lo or lu. If the idler spacings are
graduated, the average idler spacing is to be taken as a basis.

m Ro m Ru
m RI = + in kg/m
Io Iu

Guide values for masses of rotating parts of idlers (trough assemblies)

Belt width Idler diameter Mass in kg
B in mm in mm 1-part V-trough 3-part 5-part
300 88.9 3.2 4.1
88.9 3.9 4.7 5.4
5.9 6.6 7.3
400 108 7.6 8.7 9.6
133
88.9 4.5 5.5 6.1
500 108 6.6 7.8 8.4
133 8.9 10.4 11.1
88.9 5.5 6.3 7.0
650 108 8.0 9.0 9.8
133 10.8 12.1 13.1
88.9 6.7 7.4 8.3 9.0
800 108 9.8 10.6 11.6 12.4
133 13.3 14.2 15.6 16.3
108 11.7 13.2 13.6 14.2
1000 133 15.9 17.8 18.2 18.9
159 21.9 24.7 26.3 28.0
108 14.2 15.0 16.3 16.3
1200 133 19.3 20.5 22.3 21.7
159 26.1 28.0 29.8 31.9
133 21.8 23.3 25.0 24.3
1400 159 29.3 31.6 35.5 35.0
133 25.1 26.5 28.0 28.5
1600 159 33.4 35.0 38.7 39.3
133 27.6 29.1 30.7 31.5
1800 159 37.8 39.5 42.4 42.5
133 30.2 31.8 33.3 33.5
2000 159 40.2 43.3 47.0 46.5
193.7 69.1 76.4 80.1 89.5
159 46.5 49.0 50.1 49.5
2200 192.2 77.8 82.6 93.2 95.5
159 50.7 51.5 53.5 53.0
2400 193.7 86.6 91.4 93.2 100.5
159 55.1 57.5 56.5
2600 193.7 97.2 97.6 107.0
159 58.5 59.1 60.0
2800 193.7 103.0 106.4 113.0
159 63.0 65.5 65.0
3000 193.7 109.0 112.5 121.5
159 70.0 71.5 68.0
3200 193.7 120.0 123.0 126.5

30
D – 3.1.1 Calculation of belt conveyor – Masses – Idlers

Idlers with supporting discs are frequently used in the return run in order to keep the
system clean.
Masses of rotating parts of return run idlers with supporting discs in kg
Belt width Tube diameter Disc diameter 1-part 2-part
B in mm in mm in mm
400 51 120 4.0 5.0
500 57 133 5.7 6.8
650 51 133 6.8 8.1
800 63.5 150 11.7 13.2
1000 63.5 150 13.0 14.5
1200 88.9 180 22.2 23.9
1400 88.9 180 24.2 25.9
180 31.9 33.9
1600 108 215 42.0 44.5
180 34.3 36.3
1800 108 215 44.9 47.3
100 31.3 39.3
2000 198 215 48.8 51.8
215 59.8 62.8
2200 133 250 73.8 76.8
215 62.4 67.2
2400 133 250 77.5 82.3
215 68.7 71.7
2600 133 250 84.9 87.9
2800 159 290 130.6 138.2
3000 159 290 138.4 146.3
3200 159 290 146.2 154.4

In the case of heavy-duty systems with centre distances below 80 m, the masses of
the feeding idlers that may be fitted with impact rings are to be given special consid-
eration where applicable.
Masses of rotating parts of feeding idlers with impact rings
Belt Tube Impact idler Mass in kg
width B diameter diameter
in mm in mm in mm 1-part 3-part
1000 88.9 156 19.1 21.1
1200 108 180 30.8 32.8
1400 108 180 35.7 40.5
1600 108 180 42.2 45.0
1800 133 215 67.1 71.1
2000 133 215 73.6 77.6
2200 133 215 80.1 84.1
2400 159 250 117.5 127.5
2600 159 250 127.3 137.5
2800 193.7 290 201.0 221.0
3000 193.7 290 214.0 234.0
3200 193.7 290 230.0 252.0

As the mass of the rotating idler parts is concentrated mainly in the idler tube, the idler
mass reduced to the belt speed amounts approx. to

m RI red = 0.9 · m RI in kg/m

and
m R red = m RI red · L in kg 31
 D – 3.1.2 Calculation of belt conveyor – Masses – Conveyor belt

D – 3.1.2 Conveyor belt

The mass of the conveyor belt results from the mass m IIZ of the tension member and the
mass mo of the covers. If the type and structure of the conveyor belt are not stated, the
belt construction must first be assessed. For this purpose an estimated calculation can
be executed as described earlier, using the standard formulae and guide values stated
in the main chapters.

Guide values to determine the tension member mass

Strength grade of belt in N/mm

Steel cable tension memeber

Textile tension member

Mass m Z II of tension member (belt core) in kg/m 2

The mass m IID depends on the density of the cover compound and on the thickness of
the top and bottom covers. For standard applications, the mass with cover thickness s2
or s3 in mm amounts approx. to

m IID = ρD · (s 2 + s 3) in kg/m²

A density of ρD = 1.1 kg/dm 3 can be assumed in cover rubber compounds for stand-
ard application.

materials designed for the handling of material containing oil, for hot materials or for ap-
plication in underground mining. The precise values are stated in Section D – 5.1.

The belt weight mGI with B in m consequently amounts to

m GI = (m II
Z + m IID ) · B in kg/m

For conveyor belts with a special structure and for special applications, the precise data
are to be obtained from the manufacturer. If it becomes apparent in the course of contin-
ued calculation or designing that a deviating belt structure has to be selected, the value
of mGI is to be corrected where applicable.
32
D – 3.1.3 Calculation of belt conveyor – Masses – Drive elements

D – 3.1.3 Drive elements

The masses of the drive elements such as motor armature, clutch, brakes, gear
mechanism and pulleys are not taken into account in the calculation of the motional
resistance of a belt conveyor.
The operating conditions on starting and stopping (D – 3.5.1) may, however, be consid-
erably influenced by the masses as these also have to be accelerated or decelerated
by the starting or braking torque. The mass moments of inertia must be reduced to
the pulley circumference and, if they attain a significant quantity in comparison with the
other moving masses, must be taken into account in the calculation of the peripheral
forces.
The mass of a drive element rotating at speed n in min-1 reduced to the pulley circum-
ference rotating at belt speed v is

m red = J · ( v
n
) ·(
2 2 π
60
) 2
in kg

with the mass moment of inertia J = GD²/4g in kgm². In obsolescent catalogues GD² is
frequently still stated as a so-called “flywheel effect” in kpm².

If the masses of the individual drive elements cannot be reduced separately, the mass
m E red of a drive pulley with clutches and possibly with a brake results approximately
from the mass moment of inertia of the motor J M, the motor speed n M and a standard
factor K M

m E red = K M · J M · ( nM 2
v
) (
·
2 π
60
2
) in kg

Rotational inertia coefficient K M

Slipring motor Squirrel-cage motor
Drive with brake 0.58 1.2
Drive without brake 0.28 0.65

Guide values of mass moments of inertia for electromotors with a rated speed of
1000 min-1
Mass moment of inertia JM in kg m2
70

60
Slipring motors
50

40

30

Squirrel-cage
20
motors

10

0
100 200 300 400 500 600 700
Engine output PM in kW

33
 D – 3.2 Calculation of belt conveyor – Coefficients

D – 3.2 Coefficients

The resistance coefficient f, resulting from a correlation between the weights and the
motional resistances, yields the primary resistances FH of the belt conveyor. The f-values
take into account the sum of the motional resistances in the top run and the return run
and are applicable approximately in the range from 70% to 110% rated load.
Guide values for f+
Conveying systems ascending, f with v in m/s
horizontal or slightly descending
transport (motor-driven) 1 2 3 4 5 6
Standard version Handling of material
0.016 0.0165 0.017 0.018 0.02 0.022
with average internal friction
Well laid-out and with
smoothly rotating idlers.
0.0135 0.014 0.015 0.016 0.017 0.019
Handling of material with
low internal friction
Unfavourable operating
conditions.
0.023 to 0.027
Handling of material
with high internal friction

The guide values of f+ include a safety margin for the design as the actual motional
resistances are dependent on numerous factors, some of which cannot be precisely
determined. A safety margin is also to be taken into account in the designing of braked
systems for descending transport. In this case, however, the resistance coefficient is to
be assumed to be not larger but correspondingly smaller.
Guide values for f –
Conveyor systems for steeply descending
f
transport (generator-induced braking)
Well laid-out conveying systems with normal operating
conditions. 0.012 to 0.016
Handling of material with low to medium internal friction

Special account can be taken of certain limiting quantities. The guide values stated are
based on a minimum belt sag of approx. 1 % so that the f-values can be reduced where
applicable when the sag: idler spacing ratio is low, i. e. when the belt tensions are high.
Overdimensioned idler diameters also lead to lower f-values.

Quantatively the influence of the outdoor temperature can be taken more exactly into
consideration, provided that f-values not deviating considerably from the guide values
result from the multiplication of f by factor CT.
Influence of outdoor temperature
Temperatur in °C +20 +10 +0 -10 -20 -30
Factor c T 1 1.01 1.04 1.10 1.16 1.27

34
D – 3.2 Calculation of belt conveyor – Coefficients

The secondary resistances FN are determined by the length coefficient

FH + FN
C =
FH
the accuracy of which, however, is adequate only for conveying systems with centre
distances or conveying lengths exceeding 80 m.
Length coefficient C* depending on conveying length L
L in m C L in m C L in m C L in m C
3 9.0 80 1.92 250 1.38 700 1.14
4 7.6 90 1.86 300 1.31 800 1.12
6 5.9 100 1.78 350 1.27 900 1.10
10 4.5 120 1.70 400 1.25 1000 1.09
16 3.6 140 1.63 450 1.22 1500 1.06
20 3.2 160 1.56 500 1.20 2000 1.05
25 2.9 180 1.50 550 1.18 2500 1.04
32 2.6 200 1.45 600 1.17 5000 1.03
40 2.4
50 2.2
63 2.0

Coefficient C*
2.0

1.9

1.8

1.7

1.6

1.5

1.4

1.3

1.2

1.1

1.05
1.03
1.0
80 100 200 300 500 1000 2000 5000
Conveying length L in m

* For conveying lengths below 80 m and In individual cases for relatively high secondary
resistances, it is advisable to check and, where relevant, to correct coefficient C in the light
of the secondary resistance components.
35
 D – 3.3 Calculation of belt conveyor – Motional resistance

D – 3.3 Motional resistance

The motional resistance F of a belt conveyor is calculated with the coefficients C and f.

F = C ·f ·L · [ m RI + ( 2 ·m GI + m LI ) · cos δ] · g +H ·m LI ·g in N

In the case of conveying systems with slighter gradients ( δ < 18°) cos δ can be
equated with I as an approximation.

The motional resistance F consists of various components.

Primary resistance F H

F H = f ·L · [ m RI + ( 2 ·m GI + m LI ) ·cos δ ] ·g in N

The primary resistance is that resistive force component that occurs in the top run and
in the normally unloaded return run, irrespective of conveying height H. It is equivalent
to a frictional force.

Secondary resistance F N*

FN = ( C - 1) · FH in N

The secondary resistance is due mainly to frictional and acceleration forces in the feed-
ing area and can generally be expressed with sufficient accuracy by the coefficient C as
a fraction of the primary resistance for belt conveyors with a conveying length in excess
of 80 m.

* When ascertaining the secondary resistances precisely, it is above all the following
components that have to be taken into account:

Acceleration resistance FNa at the feeding point

Qm
F Na = · ( v - v o) in N
3.6
In this equation VO is the relative speed of the material handled on feeding.

Frictional resistance F Nsch at the feeding chute

F Nsch = 2000 · v 2· h 2sch · ρ in N
In this equation hsch is the height in m of the material filling between the chute sidewalls.

The frictional resistance of belt cleaning equipment can be taken into account by
F Nr ≈ 1500 · B in N
with belt width B in m. This component, however, does not normally occur in concentrated
form at the feeding point.

The precise determination of F N is thus based on

F N = F Na + F Nsch + F Nr
36
D – 3.3 Calculation of belt conveyor – Motional resistance

Gradient resistance F St
F St = H · m LI · g in N

Considering the belt conveyor as a whole, the gradient resistance results solely from the
drop forces of the load masses, as the forces from the downward pressure of the con-
veyor belt (top run against return run) are counterbalanced.

As a further component of motional resistance F, special resistances FS may occur; these

are due, for example, to tilted idlers* skirtboards located on the flight or to scrapers for
discharging the material conveyed. Their magnitude can be ascertained in individual
cases from data in technical literature.

With the stated components, the overall motional resistance becomes

F = F H + F N + F St + F S
and must be overcome in operation by a peripheral force FU generated at one or more
than one drive pulley.

The conveying height H is to be inserted with a positive sign for ascending transport
and with a negative sign for descending transport. When the gradient of the conveying
system is slight, a prediction cannot always be made in the latter case as to whether a
positive or a negative overall motional resistance will result. The calculation must then
be executed with the selected values f(+) and f(-) respectively. The largest numerical value
then states the decisive (positive or negative) motional resistance for further calculation.

In a borderline case, operation of the belt conveyor with no load may lead to the maxi-
mum motional resistance. A calculation of the motional resistances in no-load operation
too is therefore essential for low-gradient downhill conveying systems.

The layout of the belt conveyor in accordance with this schedule can be executed by
means of the table used in the calculation example in Section D – 3.6 (cf. also D – 9.3).
If a precise investigation of the belt tension is to be made in the further course of the
calculation, possibly with starting and stopping taken into account, the motional resist-
ance can no longer be considered totally but must be allotted to top run and return run
according to its origins.

It is also in the investigation of belt conveyors with an alternating flight gradient or vary-
ing section loads that the motional resistances have to be determined separately and
allocated locally to the individual sections of the conveying system in order to ascertain
the exact belt tensions (D – 3.3.2).

* According to Vierling, the tilt resistance for 3-part (roughing sets In the top run and 2-part (roughing
sets in the return run can be determined as follows (with μ = 0 3 to 0.4):

F So = L · c · µ ( m GI + m LI ) · g · cos  δ · sin ε in N and

F Su = L · µ · m GI · g · cos  λ· cos  δ · sin ε in N

In these equations, the trouhing factor is c = 0.4 for 30°-troughing,
c = 0.3 for 45°-troughing and ε the angle of tilt.
37
 D – 3.3.1 Calculation of belt conveyor – Motional resistance – Resistive force components

D – 3.3.1 Resistive force components

Components of the primary resistance F H occur in the top run and in the normally un-
loaded return run of the belt conveyor. The resistance coefficients f O or f U to be inserted
for this purpose can be set at approximately equal to f.
F Ho = f o · L · [ m R oI + ( m GI + m LI ) · cos δ] · g in N

F Hu = f u · L · ( m RI u + m GI · cos δ) · g in N
with
fo ≈ fu ≈ f
For loading states deviating considerably from the rated load or from noload operation of
the belt, the values of f can be corrected in accordance with an empirically determined
correlation.
Resistance coefficient
1,0f

0.8f

0.6f

0.4f

0.2f

0
Nominal load mLnom in %
If the return run is also used for transport, the load mass m LU is to be taken correspondingly
into account in component F HU. The secondary resistance F N is determined separately
from the individual components or calculated with coefficient C from the primar y
resistance FH

FN = ( C - 1) · FH

and can be allocated locally to the feeding point with sufficient accuracy. The gradient
resistances are also to be considered separately for top run and return run, so that
F Sto = H · ( m GI + m LI ) · g in N
and
F Stu = -H · m GI · g in N
now results with regard to belt mass m I
In this case too the load mass m LU I is to
G.
be taken into account where relevant in component F Stu if the return run is used for
transport.

The tabular schedule shown in the calculation example can be used in allocating the
motional resistances. FHO and FSto or FHU and FStu are combined in the schedule.

F o = f o ·L · [ m R oI + ( m GI + m LI ) · cos δ] · g + H · ( m GI +m LI ) · g in N
and
F u = f u ·L · ( m RI u + m GI · cos δ) · g - H · m GI · g in N
38
D – 3.3.2 Calculation of belt conveyor – Motional resistance – Motional resistances of sections

D – 3.3.2 Motional resistances of sections

If the motional resistances, the required power and the belt tensions of a belt conveyor
with a layout including sections with varying gradients or loads are to be determined, a
division into section lengths LN and corresponding section heights HN is undertaken in
order to obtain more accurate results. Those sections too that result from variable feed-
ing or discharge points are also to be distinguished in this process.

In order to facilitate recognition of critical operating conditions, those section lengths

that have an approximately constant gradient or at least run at a continuous upward or
downward inclination are selected. Initial feeding of the belt conveyor or interruptions in
transport may result in loading states that lead to higher or lower motional resistances in
conveying systems with such layouts than when loading is continuous. In addition, the
motional resistances at vertices or saddle points of the system layout may lead to critical
belt tensions that do not emerge from a calculation with the overall conveying height H.
This calculation, however, must nevertheless be executed in order to determine whether
the conveying system is to be regarded as braked or motor-driven in normal operation
with continuous loading. In accordance with this, either the large or the small f-value is
to be inserted uniformly in the subsequent calculation of the motional resistances by
sections.

The motional resistance in the top run or return run of a section n results with primary
resistance FHN and gradient resistance FStn as
F n = f · L n [ m R In+ ( m GI + m Ln
I ) · cos δ ] · g + H* · ( m I + m I ) ·g
n  n G Ln in N
Any special resistances present must be taken into account additionally. The same
f-value can be assumed here too for the loaded or unloaded belt if no data of greater
accuracy are available.

The secondary resistances FN amounting from the calculation executed above to

FN = ( C - 1) · FH
or needing to be determined in special cases from the individual components, can be
added with sufficient accuracy to the section at the beginning of which the material is
loaded onto the belt.

The chart shown in chapter D – 3.6 can be used for the systematic recording of all cal-
culated values. It is advisable to calculate first the values of the sections for the normal
loading state and for unloaded operation, beginning with the return run in the belt driving
direction, as the critical operating instance can frequently not be recognized from the
outset. For this reason the moving masses required for calculation of intermittent operat-
ing states are to be determined at this point.

m n = ( m RI n + m GI + m LI n ) · L n in kg

If the reduced masses mEred of the drive elements or pulleys are not negligible in relation
to the moving masses of the flight, they are to be recorded at the point at which they are
effective.

* For sections of the return run, Hn is to be inserted with an inverse sign

(negative for ascending transport).
39
 D – 3.3.2 Calculation of belt conveyor – Motional resistance – Motional resistances of sections

Apart from the normal case, in which the conveying flights are continuously loaded,
further operating states arise from the section loads that may be critical for design and
that lead to the largest or smallest (i. e. negative) motional resistances. The respective
loading states are identified as follows.

a continuously loaded

b continuously non-loaded

c transport starting

d transport ending

Whilst these loading states are to be taken into account in all instances, there is a slight
probability of extreme operating conditions occurring through accidental interruptions
in the feeding of the conveyor. Such cases, that might lead to considerably increased
dimensioning, can be prevented with appropriate control systems.

e loaded on uphill gradient

f loaded on downhill gradient

Low-gradient sections with a positive motional resistance even when loaded are to be
regarded as loaded in case e and as unloaded in case f.

The maximum motional resistance to be taken into account in the design results from the
sum total of the motional resistances.

F max = F N + F n + F (n+1) + F (n+2) + ...

F N  = 0 is to be set in the consideration of the critical case with the smallest, i. e. negative
motional resistances (mainly loading of downhill sections).

40
D – 3.4 Calculation of belt conveyor – Required power

D – 3.4 Required power

The power required by a belt conveyor that has to be transmitted to the conveyor belt by
one or simultaneously by more than one drive pulley amounts from the motional resist-
ance F to
F
P Tr = · v in kW
1000

The power capacity PM to be installed for driven conveying systems (with positive F) re-
sults from the power required PTr with the mechanical efficiency η
P M = P Tr / η+
for braked conveying systems (with negative F)
P M = P Tr · η-

Guide values for mechanical efficiencies

Efficiency Driven conveying system Braked conveying
η+ η+ -
system η
Single-pulley drive Multiple pulley drive
Drive with pulley motor 0.96
Drive via secondary transmission 0.94 0.92
via secondary transmission 0.9 0.85 0.95 – 1.0
and fluid clutch
with pump / hydraulic motor 0.86 0.80

Whilst the mechanical efficiency leads to the power to be installed PM having to be

greater in the case of a positive power PTr on the pulley, braked conveying systems can
possibly be provided with a drive whose output PM is equal to or slightly lower than the
required power PTr on the drive pulley. For safety reasons a somewhat higher efficiency
factor is assumed on braking.

The power capacity of the motors to be provided for the drive is furthermore influenced
by the ambient temperature (coolant temperature) and the altitude above mean sea level
(coolant density). The instructions of the specific manufacturer should be observed. For
air-cooled motors, standard conditions imply a coolant temperature of between 30 and
40°C and installation altitudes of up to 1000 m above mean sea level. Where relevant,
special requirements concerning starting-up of the system or extreme power peaks due
to section loading are to be taken into account in selection of the motor construction.

41
 D – 3.4 Calculation of belt conveyor – Required power

Selection from the rated output values (acc. to DIN 42 973 standards)
Output in kW Output in kW Output in kW
1.5 22 160
2.2 30 200
3 37 250
4 45 315
5.5 55 400
7.5 75 500
11 90 630
15 110
18.5 132

In order to attain favourable starting and operating properties, the type of motor (squirrel
cage rotor or slipring rotor) and of clutch are to be adapted to the specific application.
The decisive factor here is starting factor KA, by which the ratio of maximum starting
torque to rated torque is determined, so that the maximum torque on starting amounts
to
M max = K A · M nom
The magnitude of the rated driving torque is determined by the engine size
selected or - when a fluid clutch is used - by the clutch size selected. In order not
to generate any unnecessarily high belt tensions on starting, it is advisable to coor-
dinate the motor or clutch size as precisely as possible with the required power P M.
Guide values for starting factors K A
Drive Application Starting factor
Squirrel cage motor with Large-scale conveying 1.2
special-purpose fluid clutches systems
Slipring motor or Medium to large-scale 1.2 – 1.4
thyristor controlled start-up conveying systems
Squirrel cage motor Standard conveying systems 1.5
with fluid clutch (from approx. 30 kW per motor)
Squirrel cage motor with Only for conveying systems 1.6
Y-delta connection starting up unloaded
Squirrel cage motor with Small-scale conveying systems 2.0 – 3.0
full-voltage starting (up to approx. 30 kW)
The torque required for the breakaway and acceleration of a belt conveyor on start-up,
which must normally be somewhat greater than the load torque in operation, can be
designated by the so-called breakaway factor.
Guide values for breakaway factor K I
Downhill conveying systems, long-distance systems, systems starting up unloaded below 1,3
Standard systems 1.3 – 1.5
Heavy-running systems with high friction above 1.5

For conventionally designed conveying systems KA > KI is to be selected. If, however, a

higher power capacity is installed (PM nom > PM) for reasons of drive uniformity or owing
to only one specific size of drive being available, the starting factor can be determined
with the equation
PM
KA ≥ KI · and can be reduced if necessary by the selection
P M nom of an appropriate fluid clutch or starting circuit.
42
D – 3.4 Calculation of belt conveyor – Required power

In the case of drives with more than one motor, the start-up can be influenced by switch-
ing on the individual motors with time delay The start-up of conveying systems is dealt
with in detail in Chapter D – 3.5.1.

When considering sections, the rating of the drives to be installed is to be laid out in
the light of the maximum required power, i.e. in accordance with the criteria set out in
Chapter D – 3.3.2.
F max
P Tr max = · v in kW
1000
and when F max is positive
P M max = P Tr max / η+
or when F max is negative
P M max = P Tr max · η-

In the least favourable case a start-up process may coincide with the motional resist-
ances Fmax, resulting in the starting factor
(K I - 1) · P M + P M max
KA ≥
P M nom

43
 D – 3.5 Calculation of belt conveyor – Peripheral force

D – 3.5 Peripheral force

The peripheral forces occur at the driven or braked drive pulleys and are transmitted
there to the belt to overcome all motional resistances acting on the conveyor belt.
The peripheral forces can act on the belt at one pulley or distributed over a number of
pulleys.
P Tr
FU = F = · 1000 in N
v

The belt tensions on the entry side and the leaving side of the drive pulleys are of decisive
significance for further calculation. On the one hand the greater belt tension, generally
T1 on the entry side, affects the tensile strength calculation of the conveyor belt; on the
other hand the height of the smaller belt tension, generally T2 on the leaving side, deter-
mines whether power transmission is feasible at all. The target of the calculation is thus
to determine the necessary magnitude of the belt tension on the entry side and the leav-
ing side. These belt tensions are the outcome of this chapter.

Regardless of whether it is a driving or braking drive mechanism that is being investi-

gated, whether the operating state concerned is starting or stopping, or whether it is
a Multiple pulley drive that is under consideration, the following designation should be
retained under all circumstances.

in operation T2
Belt tension at the leaving side of the belt
from the last pulley at the head On Starting
T 2A
of the conveying system (start of return run)
On braking
T 2B

Setting out from this belt tension that is designated with T2, T2A oder T2B the level of the
further belt tensions is to be determined in the following section D – 4. A design of the
tension member in the conveyor belt based on belt tension T1 or T1A sufficiently accurate
only for the standard case of a horizontal or constant-gradient belt conveyor, ignoring
stopping and any additional strains in the case of exclusive head drive.

In the case of a driven belt, the peripheral force FU is positive; thus T1 is greater than T2.
In the case of negative peripheral forces, i. e. of a braked belt, T2 is greater than T1.

44
D – 3.5 Calculation of belt conveyor – Peripheral force

For the case of a driven conveyor belt, the belt tensions required for friction transmission
of peripheral force FU result from marginal condition
T1
≤ e µα
T2
In this formula µ is the friction coefficient between the pulley circumference and the belt
surface and the degree of wrap round the pulley in radian measure. When the transmis-
sion potential is fully exploited, the necessary belt tension on the leaving side of the belt
becomes
1
T2 = FU · c2 with drive factor c 2 =
e µα
-1

The belt tension T1 at the entry side of the belt becomes

1
T1 = FU · c1 with drive factor c 1 = 1 +
e µα
-1
The peripheral force ist accordingly
FU = T1 - T2
In the case of a braked conveyor belt, the equation apply according to the retroacting
peripheral force.
Values for c 1*
Angle of wrap Friction coefficient μ
α in º 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
170 3.90 2.78 2.23 1.91 1.69 1.54 1.44 1.35 1.29
175 3.80 2.72 2.19 1.87 1.67 1.52 1.42 1.34 1.28
180 3.70 2.66 2.15 1.83 1.64 1.50 1.40 1.32 1.26
185 3.62 2.60 2.10 1.80 1.61 1.48 1.38 1.30 1.25
190 3.55 2.55 2.06 1.77 1.59 1.46 1.36 1.29 1.23
195 3.47 2.50 2.02 1.74 1.56 1.44 1.34 1.28 1.22
200 3.41 2.45 1.99 1.71 1.54 1.42 1.33 1.26 1.21
205 3.32 2.41 1.96 1.69 1.52 1.40 1.31 1.25 1.20
210 3.28 2.36 1.93 1.67 1.50 1.38 1.30 1.24 1.19

If the belt tensions in the conveying direction are designated continuously as Tn and
T(n+ 1), general equations that are also valid for drives at the rear end of the conveying sys-
tem can be drawn up for the case of full exploitation of the transmission potential.
Entry side Leaving side
Peripheral force eµα
belt tension T n belt tension T (n+ 1)

Belt driven, Tn
positive peripheral force T n =F U ·c 1 T (n+1) =F U ·c 2 F U =T n -T (n+1)
T (n+1)

Belt braked, T (n+1)

negative peripheral force T n =F U** ·c 2 T (n+1) =F U** ·c 1 F U =T n -T (n+1)
Tn

* Values for c2 result from c2 = c1 – 1

** FU is to be inserted as a positive factor
45
 D – 3.5 Calculation of belt conveyor – Peripheral force

Friction coefficient µ between drive pulley and rubber conveyor belt

(60 to 65 Shore A hardness) with Grimmer
Rubber wrapped Polyurethane extruded
herringbone herringbone grooves
grooves Ceramic porous
Steel pulley hardness:
hardness: herringbone
Operating bare 79 Shore A
60 Shore A grooves
conditions smooth Lagging surface:
Lagging surface: Lagging thickness:
rust-free lightly corrugated
smooth 11 mm
Lagging thickness:
Lagging thickness: 11 mm
8 mm
Dry operation 0.35 – 0.4 0.4 – 0.45 0.35 – 0.4 0.4 – 0.45
Clean, wet 0.1 0.35 0.35 0.35 – 0.4
operation (water)
Loam- or
clay-soiled wet 0.05 – 0.1 0.25 – 0.3 0.2 0.35
operation

The friction coefficient µ is also influenced by the surface pressure between the con-
veyor belt and the pulley. The values stated are valid for a mean surface pressure of
10 N/cm2.

Friction coefficient µ
0.8
Bare steel pulley
0.6 Dry operation
0.4
(T1 + T2)sin α/2
0.2 pm = 
DTR � B

0 2 4 6 8 10 12 14 16
Mean surface pressure p m in N/cm 2

Non-ope Service angle αn

rat 500°
in
Friction coefficient 0.25
g

400° µ = 0,2
arc

0.3
300°
0.35
200°

Service arc
100°

0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Ratio T1 / T2

The law of friction transmission represents an extreme condition that is not precisely
fulfilled in every instance. If T1/T2 is less than eµα, the transmission potential of the drive
pulley is not fully exploited. Power is transmitted only on the service arc of the angle
of wrap α, whereas the non-operation arc represents a reserve for the transmission of
higher peripheral forces or for a possible drop in the friction coefficient μ.
The ratio T1/T2 produces specific service angles αn with the value of µ varying.

46
D – 3.5.1 Calculation of belt conveyor – Peripheral force – Starting and stopping

D – 3.5.1 Starting and stopping

Starting and stopping are temporary operating conditions in which the belt velocity
changes as a result of a supposedly constant acceleration or deceleration. Apart from
the motional resistances of the steady state condition, the inertia forces of the moving
masses are to be supplied by peripheral forces FUA tor starting or FUB for stopping (brak-
ing). The breakaway resistance component is regarded as negligible in this case.

The peripheral force FUA on starting is stipulated by the size of the motor or clutch select-
ed when the drive is being designed and by starting factor kA, provided that the starting
process is effected by switching on the corresponding drives.
P Mnom · η
F UA = ·K A ·1000 in N
v

This is based on the fact that the drive is restricted by a control mechanism or slip clutch
on acceleration to a torque corresponding to the multiple rated torque determined by
starting factor K A. It is only when the design corresponds precisely to the required power
P M that F UA = F ·K A.

The expression “sequence starting” can be used when the belt conveyor is driven by a
number of motors that are switched on with a time lag. The optimum time sequence is
generally found by trial and error. A calculation is possible only when the dynamic proc-
esses are taken into account. If start-up is regarded as a quasi-stationary process, on
the other hand, the peripheral force F UA and the resulting drive tractions are determined
from the capacity of the motors that are switched on on start-up.

The necessary belt tension results from the marginal value for fractional force transmis-
sion with negligible slip
T 2A = F UA · c 2 and T 1A = T 2A + F UA
Determination of the friction coefficient µ is generally based on values that provide for a
certain safety margin against belt slip, i. e. incomplete utilization of the angle of wrap α.
In order to calculate T2A, therefore, a somewhat greater value of µ may be inserted if an
increased utilization of the angle of wrap or a temporarily increased slip is permitted.

47
 D – 3.5.1 Calculation of belt conveyor – Peripheral force – Starting and stopping

The acceleration aA of the belt conveyor amounts from motional resistance F and the
sum of the accelerated masses to

F UA - F
aA = in m/s2
(m I
L +m I
R red + 2 ·m I
G ) ·L

Any relatively large reduced masses of rotating drive elements are to be taken into
account too. The acceleration is approximately

F UA - F
aA = in m/s2
(m I
L +m I
R red + 2 ·m I
G ) ·L + m E red + m red*

Experimental values for acceleration a A in m/s 2

Type of conveyor system No load Full load
Small-scale systems (L < 50m; B < 800mm) 0.75 0.5
Medium systems (50m < L < 500m; 1000mm < B < 1600mm) 0.6 0.1
Large-scale systems (L > 500m; B > 1800mm) 0.5 0.075

The peripheral force FUB for stopping generally depends on the required run-down time
tB of the belt conveyor, which must not exceed a specific value in emergency cutouts
or to prevent overfilling. The necessary deceleration follows from this with an assumed
constant braking torque as
v
aB = - in m/s2
tB
with the leaving flight
v · tB
LB = in m
2
and the possibly resulting overfilling
m LI
V = ·L B in m3
ρ

* In this equation mred are the reduced masses of non-driven rotating parts of the
belt conveyor, such as deflection rollers or pulleys.
48
D – 3.5.1 Calculation of belt conveyor – Peripheral force – Starting and stopping

The peripheral force occurring on stopping becomes

F UB = a B · ( m LI +m RI red + 2m GI ) ·L +F in N

If significant reduced masses are accelerated, these must be taken into

F UB = a B · ( m LI +m RI red + 2m GI ) ·L +F +a B ·m red in N

The necessary belt tension for transmission of the negative peripheral force FUB occurs
on the entry side of the belt and is, in the case of a braked pulley,
T 1B = F UB* · c 2

The drive traction (or, where relevant, the tensioning force) on the leaving side of the
braked pulley becomes

T 2B = T 1B - F UB
For ascertainment of the belt tensions on starting or stopping, the mass flight LB may re-
sult in very high belt tensions that would lead to unjustified overdimensioning of the belt.
In this case the transmittable peripheral force can be determined with the belt tension
T2B = Tadmissible given (possibly for other operating conditions).
F UB = - T 2B · c 1
This yields the deceleration
F UB - F
aB = in m/s²
( m LI +m RI red + 2m GI ) ·L
an the run-down time
v
tB = - in s
aB
The non-braked run-down results from F UB = 0.

For ascertainment of the belt tensions on starting or stopping, the mass forces of iner-
tia resulting from the acceleration aA or the deceleration aB are to be determined.
Mass forces of inertia in N
Starting Stopping
Top run F ao = a A ·(m R red o +m G +m L ) F bo = a B ·(m R red o +m Go +m L )
Return run F au = a A ·(m R red u +m G ) F bu = a B ·(m R red u +m G )
Peripheral force** F aU = a A ·m red F bU = a B ·m red

For the investigation of sections, the mass forces of inertia of a section n amount to
Fa n = aA · mn in N
Fb n = aB · mn in N

* F UB is to be inserted as a positive factor.

** The peripheral forces resulting from the mass forces of inertia occur only at tail pulleys,
i. e. on rotating parts of the belt conveyor that are not directly driven or braked.
49
 D – 3.5.2 Calculation of belt conveyor – Peripheral force – Multiple pulley drive

D – 3.5.2 Multiple pulley drive

The magnitude of the belt tensions is decisive for the conveyor belt design. In general,
very high belt tensions occur on the entry side of the drive pulley. This belt tension, that
is designated T1 and depends on drive factor c1 with a given peripheral force, can be
reduced by increasing the angle of wrap. Values exceeding 230° can be attained by us-
ing multiple pulley drives.
v

T1
Drive
pulley 1 T1/2
α1 Drive pulley 2
FU1 α2 FU2
T1/2

T2
Drives that are arranged separately as a head and a tail drive and have only one drive
pulley each are not to be regarded as multiple pulley drives, although in this case too the
peripheral force is transmitted by an enlarged angle of wrap and the belt tensions can
consequently be reduced.

The total transmitted peripheral force is

F U1 P Mnom1
F U = F U1 + F U2 with ≈
F U2 P Mnom2

for a two-pulley drive.

Belt tension T2 is necessary for the transmission of peripheral force FU2. For the trans-
mission of peripheral force FU1, the belt tension on the leaving side of pulley 1 results
from this as
Drive factor c1 c2
T 1/2 = T 2 + F U2 4 3
Angle of wrap α

3 2 160°
180°
210°
230°
2 1 280°
340°
420°

1 0

0 0.1 0.2 0.3 0.4

50
Friction coefficient µ
D – 3.5.2 Calculation of belt conveyor – Peripheral force – Multiple pulley drive

The smallest belt tensions are attained with a given peripheral force FU when the trans-
mission potential of the drive pulleys is fully exploited and the peripheral forces of series
mounted drive pulleys are in a specific ratio to one another.
T1 = FU · c1 and T2 = FU · c2 with α = α1 + α2
The distribution of the peripheral forces, at which the lowest belt tensions are yielded,
follows from the equation
F U1 e μα1 - 1
= · e μα2
F U2 e μα2 - 1
This optimum ratio cF can be approximated by the provision of differing power outputs
at pulleys 1 and 2 in the ratio of
P Mnom1
≈ cF
P Mnom2
For a friction coefficient μ = 0.25 and the angle of wrap α1 =180° or α2 =210°, the fre-
quently executed drive arrangement, for instance, results in the ratio 2/1.
Ratio c F
Angle of wrap α1
μ = 0.25
160° 170° 180° 190° 200° 210°

160° 2.0 2.2 2.4 2.6 2.8 3.0

170° 1.9 2.1 2.3 2.48 2.67 2.86
180° 1.83 2.02 2.2 2.38 2.57 2.75
α2
190° 1.77 1.95 2.12 2.3 2.48 2.65
200° 1.71 1.89 2.06 2.23 2.4 2.57
210° 1.67 1.83 2.0 2.17 2.33 2.5

μ = 0.3 160° 170° 180° 190° 200° 210°

160° 2.31 2.53 2.76 3.0 3.26 3.53

170° 2.22 2.43 2.66 2.89 3.14 3.4
180° 2.15 2.35 2.57 2.79 3.03 3.28
α2
190° 2.08 2.28 2.48 2.7 2.93 3.18
200° 2.02 2.21 2.41 2.62 2.85 3.08
210° 1.97 2.15 2.35 2.55 2.77 3.0

μ = 0.35 160° 170° 180° 190° 200° 210°

160° 2.66 2.92 3.2 3.51 3.84 4.18

170° 2.56 2.82 3.1 3.39 3.70 4.03
180° 2.48 2.74 3.0 3.29 3.59 3.91
α2
190° 2.41 2.66 2.92 3.19 3.48 3.8
200° 2.35 2.58 2.84 3.11 3.39 3.7
210° 2.29 2.52 2.77 3.03 3.31 3.61

51
 D – 3.5.2 Calculation of belt conveyor – Peripheral force – Multiple pulley drive

When the conveyor belt revolves round pulley 1, the belt tension and thus the service
elongation of the belt declines in part. With equal pulley diameters, this results in a
slightly lower speed at pulley 2 than at pulley 1, that may lead to a relatively high strain on
this drive. Unless this is compensated by special measures, optimum power distribution
PM nom1/pM nom2 is always slightly above the value cF.
Necessary belt tension on the leaving side of the belt
(on transmission of positive peripheral forces)
Power distribution
P M nom1/P M nom2 Belt tension T 2 Remarks

> cF F U1 · ( e μα1
1
-1
)* - F U2
Full exploitation of transmitting potential
at pulley 1

· ( )*
1 Full exploitation of transmitting potential
≤ cF F U2 at pulley 2
e μα2
-1

T 1 =T 2 +F U

Necessary belt tension on the entry side of the belt

(on transmission of negative peripheral forces)
Power distribution
P M nom1/P M nom2 Belt tension T 1 Remarks

≥ cF F U1** · ( e μα1
1
-1
)* Full exploitation of transmitting potential
at pulley 1 or at both pulleys

· ( )* - F
1 Full exploitation of transmitting potential
< cF F U2** U1** at pulley 2
e μα2 -1

T 2 =T 1 - F U

In the case of belt conveyors with separately located drive pulleys (head and tail drive)
the peripheral forces are distributed in approximately the ratio of the drive powers. The
optimum distribution in these cases is yielded by a comparison of the motional resist-
ances in the top run and the return run. A distribution in which the specific component
is taken over by the head or the tail drive is of advantage.

* corresponding to drive factor c2 of the respective pulley

** The peripheral forces are to be inserted as a positive factor.
52
D – 3.6 Calculation of belt conveyor – Calculation example

D – 3.6 Calculation example

An example is given below to elucidate the procedure on calculation of a belt conveyor.

For this purpose a schedule is used which permits basic quantities and calculation re-
sults to be entered. The most important calculation formulae are also listed once again.
The calculation of the belt conveyor extends to determination of the peripheral forces.
The adjacent calculation sheet accordingly contains all steps required to reach this point.
A calculation taking sections into account can be undertaken by means of the expanded
schedule attached in the appendix.
The determination of the belt tensions is continued for the selected example in the
corresponding sections. For this purpose too a tabular schedule can be used; in its ex-
panded form attached in the appendix it can also serve for calculations taking sections
into account.
All tabular schedules can be obtained as printed forms from ContiTech’s Application
Technique Advisory Service.
Calculation of belt conveyor Form 1
Sketch of conveying system:

T1 1st drive
pulley
Feeding point
T1/2
T5 T2
T4 2nd drive pulley

T3

Principal data Material handled Raw salt

D – 2.1 Bulk density ρ 1.2 t/m³
D – 2.1 Angel of repose β 15 °
D – 2.2 Flow of material Qm 225 t/h
Qv 188 m³/h
D – 2.4.1 Max. lump size k 200 mm

Sections cf. Form 3 Conveying length L 439 m

D – 3.3.2 Conveying height H 138 m
Gradient δ +18 °

D – 2.4.1 Belt width B 800 mm

D – 2.4.2 Belt speed v 2.09 m/s

D – 2.4.3 Troughing angle λ 20 °

Idler spacing lO 1.25 m
lU 2.5 m

Calculation data Degree of fill φ 0.85 –

1
D – 2.5 Q m · φ2 Degree of uniformity φ 1 –
2
A =
v·3600·φ1 ·ρ Filling cross section A 0.03 m²

Qm Load mass m LI 30 kg/m

D – 3.1 m LI
3.6 ·v Idler weight m RI 13.5 kg/m
m Ro m Ru m GI kg/m
D – 3.1.1 m RI +
Belt weight 8
IO Iu

F H +F N Resistance coefficient f 0.0165 –

D – 3.2 C =
FH Length coefficient C 1.23 –
53
 D – 3.6 Calculation of belt conveyor – Calculation example

Motional resistance
D – 3.3 Motional resistance F 45617 N
F = C ·f · L [m RI + (2 · m GI + m LI ) · cos δ] · g + H ·m LI · g Primary resistance FH 4068 N
Secondary resistance FN 936 N
Distribution cf. Form 3 Gradient resistance FSt 40613 N
D – 3.3.1 Special resistance FS – N

Power F·v Efficiency η 0.85 –

D – 3.4 PTr = Required power PTr 95 kW
1000
PTr PM 112 kW
PM = (PTr > 0) PMnom
η Installed power kW
Start-up factor KA 1.5 –
PM = PTr · η (PTr < 0)
Peripheral force Friction coefficient µ –
D – 3.5
c1 =1 +
1 Angle of wrap α °
eμα -1 c1
Drive factor –
1
c2 = c2
eμα -1 –

FU = F FU
Peripheral force N

T1 =FU ·c1
T2 =FU ·c2 Belt tension T1 N
T2 N

Starting and stopping Peripheral force FUA N

D – 3.5.1 PMN · η · KA Belt tension T1A N
FUA = v 1000 T2A N
Multiple-pulley drive cf. Form 4 Peripheral force FUB N
D – 3.5.2 Belt tension T1B N
T2B N
FUA - F
aA =
(m L + m R red + 2 · m GI ) ·L
I I Acceleration aA 1.798 m/s²
FUB - F aB m/s²
aB =
(m L + m R red + 2 · m GI ) ·L
I I

m RI red ≈ 0,9 · m RI

Calculation of belt conveyor (sections) Form 3

Section L H δ Top run Return run
Top Return in mm in mm in º IO m LI I
m RO IU I
m RU m GI
run run
in m in kg/m in kg/m in m in kg/m in kg/m
1 2 439 138 + 18 1.25 30 9.3 2.5 4.2 8

54
D – 3.6 Calculation of belt conveyor – Calculation example

Motional resistances F o =f o · L ·[ m Ro

I + ( m I +m I )  · cos δ]  · g+H ( m I +m I ) ·  g
G L G L
D – 3.3.1 F u =f u · L · ( m Ru
I +m I  · cos δ)  · g – H · m I  · g
G G

Section Top run Return run

FO m R red o mG mL F ao F bo Fu m R red u F au F bu
Top run Top run
in N in kg in kg in kg in N in N in N in kg in N in N
1 2 54 673 3 674 3 512 13 170 36 592 – -9 991 1 659 9 295 –

Mass inertia forces F ao = a A ·(m R red o +m G +m L)

D – 3.5.1 F bo = a B ·(m R red o +m G +m L)
F au = a A ·(m R red u +m G)
F bu = a B ·(m R red u +m G)
Calculation of belt conveyor (Multiple pulley drive) Form 4
D – 3.5.1/3.5.2 cF head 1 : 1 –
Power Distribution cF tail – –

Drive pulley 1. 2. 3. 4.
Operation PM nom 75 75 kW
FU 22808 22808 N
μ 0.3 0.3 –
α 180 210 º
c1 1.64 1.5 –
c2 0.64 0.5 –

1. 14597 N
Belt tension 2. 11404 N
(leaving side) 3. N
Starting 4. N
D – 4.1.2 FaU =aA · m red Drive pulley 1. 2. 3. 4.
FUA 45753 45753 N
FaU – – N
1. 29282 N
Belt tensions 2. 22877 N
(leaving side) 3. N
4. N
Stopping Drive pulley 1. 2. 3. 4.
D – 4.1.2 FbU =aB · m red FUB – – N
FbU – – N

1. – N
Belt tensions 2. – N
(leaving side) 3. N
4. N 55
 D – 4 Stipulation of tension member

D – 4 Stipulation of tension member

 Belt tensions.. . . . . . . . . . . . . . . . . . . . . . . 4.1

Belt tensions in operation.. . . . . . . . 4.1.1
Belt tensions on starting
and stopping. . . . . . . . . . . . . . . . . . . . . . 4.1.2
Calculation with sections.. . . . . . . . 4.1.3
 Additional strains.. . . . . . . . . . . . . . . . . 4.2
Flat-or trough and
trough-to-flat transition.. . . . . . . . . . . 4.2.1
Transition curves.. . . . . . . . . . . . . . . . . . 4.2.2
Turnover.. . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.3
 Selection criteria.. . . . . . . . . . . . . . . . . . 4.3
Pulley diameter.. . . . . . . . . . . . . . . . . . . 4.3.1
Troughing properties.. . . . . . . . . . . . . 4.3.2
Centre distance and takeups. . . . . 4.3.3
Effects of material handled.. . . . . . . 4.3.4
Feeding strain.. . . . . . . . . . . . . . . . . . . . . 4.3.5
 Tension member data.. . . . . . . . . . . . 4.4
Textile tension members. . . . . . . . . . 4.4.1
Steel cable tension members.. . . . 4.4.2
Splice dimensions........................ 4.4.3

The tension member of a conveyor belt is designed in general so as to withstand with

adequate certainty the maximum tensile strains that may occur on operation of the belt
conveyor. The operational and construction-related effects must, however, also be taken
into account on selection, as these may lead to a different dimensioning of the tension
member or to an adaptation to operating conditions.

56
D – 4 Stipulation of tension member

Properties and possible applications of textiles and steel cables as load

carrying elements in conveyor belts
Material
constituting Properties and possible Types most
Symbol
load carrying applications widely used
element
Cotton B Natural fibre, thus susceptible to moisture and less (B 18)
suitable for wet operation; relatively low strength and B 60
elongation, not suitable for heavy loads, and now
rarely used (only in certain cases such as for bare-
bottom-ply belts)

Aramid D Fully synthetic, highly aroma tic polyamide fibre

(Kevlar) with extra high strength and low elongation (similar to
steel) and tested so far in special cases of application;
shares most of the advantages of fully synthetic fibres,
is noninflammable without special treatment and gains
significance in high-strength textile belts*

Polyester E Fully synthetic, high strength with good elongation EP 63

(Diolen, Trevira) properties, large working capacity, largely acid and EP 100
alkali resistant, unaffected by moisture; processed EP 125
with polyamide, an ideal fabric for conveyor belts and EP 160
suitable for handling hot materials EP 200
EP 250
EP 315
EP 400
EP 500
EP 630
(E 100)
Polyamide P Fully synthetic, resistant to moisture and chemicals, Pb 315
(Nylon, Perlon) processed primarily as union thread or in the weft; Pb 400
less suitable as sole tension member material for fully Pb 500
loaded belts and large centre distances owing to Pb 630
excessive takeups

Rayon R Semi-synthetic, high strength, but now rarely used

(artificial silk) owing to detrimental properties - loss of strength and
shrinkage through moisture
Steel cables St Anticorrosive-treated, in various types ideal for belt Special conveyor
conveyor systems of all kinds; high strength and low belt steel cables
elongation, of advantage with large centre distances for
in particular, good troughing properties and high load St 630
capacity St 800
St 1600
St 2500
St 3150
St 4000

* Available on request
57
 D – 4 Stipulation of tension member

Conveyor belts with textile plies and steel cable conveyor belts conform in certain ver-
sions to standard specifications and are marked correspondingly.

In the case of textile belts, the

Nominal belt strength k nom in N/mm

is marked after the symbol representing the ply material or, in special-purpose versions,
after the type designation.

Example EP 500/4
Polyester in warp
Polyamide in weft
Nominal belt strength in N/mm
Number of plies

For steel cable conveyor belts the nominal belt strength is also stated after the symbol
representing the ply material.

Example St 3150
Steel cables in longitudinal direction
Nominal belt strength in N/mm

STAHLCORD®- Special versions not conforming to standard specifications are marked

with a letter/number combination separated by a dash.

The different tension members have preferential applications depending on the

strength grading and belt width.

CON-MONTEX®
CON-BITEX®
Multi-ply belt
(EP)
STAHLCORD®
Nominal strength of splice in N/mm
Belt width B
in mm

up to up to
5600 mm 6400 mm
58
D – 4 Stipulation of tension member

The preselection of a tension member material currently in standard use can be made
by means of a rough assessment of the properties in application.
Tension member B EP P St
Specific strength 4 2 3 1
Additional strains 4 2 1 3
Pulley diameter 4 3 2 1
Troughing properties 3 2 2 1
Elongation 4 2 4 1
Chemical resistance 4 2 3 3
Properties under load 4 2 2 2
1 – very good, 2 – good, 3 – adequate, 4 – poor

The
nominal strength of the splice k nom V in N/mm

must be taken into account in the design of a conveyor belt. The splice*, with which
the ends of the initially open-ended belt are joined, may show a loss of strength as
compared with nominal belt strength knom; this loss is yielded purely theoretically by the
splice construction (cf. D – 4.4.3).

Even if no drop in strength in the splice is yielded theoretically, a conveyor belt must not
be strained to the nominal strength limit. Factors arising from splicing, time-dependent
fatigue symptoms and defective friction transmission lead to further losses in strength
that also depend in the case of steel cable belts, for instance, on the number of laps in
the splice and cannot yet be determined mathematically.

The design of the conveyor belt tension member, with regard to the nominal strength of
the splice, is therefore based on a safety factor S which takes into account these influ-
ences among other things.

A rough determination of the tension member needed can be made if the required or
actually available power PTr on the drive pulley is known (cf. D – 3.4).

The global determination of the conveyor belt type is based on

Safety factor S = 8

which is intended to cover not only the imprecisely determinable losses of strength in
the splice but also the increased belt tensions that may occur on starting and stopping,
together with all additional strains. This calculation is therefore reasonably reliable only
for conventional belt conveyors with standard start-up and braking properties.

* Conveyor belt splices and splicing processes are described in detail in Section E
of the ContiTech Conveyor Belt Service Manual.
59
 D – 4 Stipulation of tension member

The assumption is made that the greatest strain on the belt occurs at the entry side of
the belt on the drive pulley located at the head of the system. As mentioned in Sec-
tion D – 3.5, however, T1 can be assumed to be the maximum belt tension only when
the conveyor systems in question have a constant uphill gradient with a low conveying
height. Power Belt speed
PTr in kW v in m/s

8.38
6.70
5.42
4.19
3.35
Possible belt constructions (Selections) 2.62
1000 2.09

STAHLCORD®
2 500
2 000
1 600
1 250
1 000
800
630
500 1.68
1.31
1.05
St

500 0.84
EP 2 000/5 St
EP 2 000/4 EP 1 600/5 St
EP 1 600/4 EP 1 250/5 St
EP 1 600/3 EP 1 250/4 EP 1 000/5 St
EP 1 250/3 EP 1 000/4 EP 800/5 St
EP 1 000/3 EP 800/4 EP 630/5 St
EP 800/3 EP 630/4 EP 500/5 St

0.66

200

Multi-ply belts®
EP 630/3 EP 500/4
EP 500/3 EP 400/4

100
EP 400/3
EP 315/3

EP 200/3

50
CON-MONTEX® CON-BITEX®
1 000/2
800/2
630/2
500/2
400/2
315/2
250/2
200/2

20
16
14
12
10
500/1
400/1
315/1
250/1
200/1
160/1

8
7
6
5
Nominal strength with a safety factor of 8 4
3.5
3
2 500
2 000
1 600
1 250
1 000
800
630
500
400
315
250
200
160
125

2.5
2
Unit tension k1 in N/mm 103 1.5 2 3 4 5 6 8 104 2 5 105 2 5
300 200 100 80 60 50 40 30 25 20 16 14 12 10 8 Peripheral force FU in N
2
2.5
3
3.5
4
5
6
7
8
104

105

500
650
800 2
1000
1200
1400
1800
5
2200 1.25
2600 1.5
1.77
Tension Drive factor c1 2.0
T1 in N
Determination of belt construction
The graph applies to multiple-pulley drives too, when they are located at the head and
the transmission potential is fully exploited.
60
D – 4.1 Stipulation of tension member – Belt tensions

D – 4.1 Belt tensions

If the tension member design is based on the width-related belt tension (unit belt ten-
sion) amounting from the maximum belt tension Tmax constantly prevalent in operation
to
T max
k max = in N/mm
B
the safety factor S is to be taken into account; this covers the temporarily increased
drive traction Tmax t, that may occur in special operating states, together with addi-
tional strains that may occur at the flat-to-trough or trough-to-flat transition flights, at
transition curves or at turnovers.
k nom V = k max · S in N/mm

In general, however, the starting-up process of a belt conveyor at least will have to
be investigated besides the state of steady operation. If the unit belt tension from the
temporarily occurring maximum drive traction Tmax t is ascertained as
T max t
k max t = in N/mm
B
whereby stopping or critical section loads may need to be taken into account, a re-
duced safety factor Si can be applied for layout.
k nom V = k max t · S t in N/mm

Safety factors*
Operating conditions S St
Favourable (minimum load cycle strain and bending strain) 6.7 4.5
Normal 8.0 5.4
Unfavourable (high load cycle strains and bending strains) 9.6 6.4

Low numbers of load cycles can be assumed if the conveyor belt is being designed for
a relatively short operating period. A low bending strain results, for instance, from over
dimensioning of the drive and tail pulleys.

The conveyor system is normally constructed in such a way as to prevent extreme

additional strains. In special cases, however, a limit design may be necessary in
which the additional strains attain extremely high values or other strains of disadvan-
tage for the conveyor belt arise. In these cases, both the maximum belt tension and
the additional strains are to be taken into account (D – 4.2).

Diverging from the global considerations described in Section D – 4, the maximum
belt tension may occur at another point, for example in braked belt conveyors or with
different drive layouts. The magnitude of the belt tensions is also determined to a
considerable extent by the point and method of the belt tensioning generation re-
quired for transmission of the peripheral forces in the permanent and in the temporary
operating state. In these cases the belt tensions occurring at the individual points of
the belt conveyor must be determined. It is advisable to designate the points at which
the constant course of the belt tension changes with T1, T2, T3, T4 etc. consecutively
and to retain this designation regardless of the drive layout and the operating method.

* In some cases lower nominal belt strengths can be used if a detailed calculation is carried out and the
dynamic belt safety factor and the fatigue strength of the belt splice are checked.
61
 D – 4.1 Stipulation of tension member – Belt tensions

Although the temporary operating states are decisive in certain cases for the permanent
belt tensions too, it is the belt tension curve for operation that is first determined, since
the data required for this purpose are known in any case.

The belt tension curve is determined by a sequential calculation in which the belt ten-
sions are calculated in succession, starting at one point of the belt conveyor. In this proc-
ess it is always advisable to proceed in accordance with firm rules:
1. Starting the sequential calculation with T2. The minimum belt tension Tmin or - if a head drive is
present - the belt tension on the leaving side is used as the initial value of T2. The sequential
calculation may, however, also be started as a general rule with the assumption T2 = 0, the final
values being yielded by subsequent adjustments..

2. Addition of the motional resistances and subtraction of the peripheral forces, continuously in
belt movement direction. All variations in belt tension are taken into account with the corre-
sponding signs.

The belt tensions resulting from the motional resistances and peripheral forces at the
individual points of the top run and the return run must be adjusted if, for instance, a
certain minimum belt tension is not attained to restrict the sag.

(m LI +m GI ) ·g ·I O
T min = in N
8 ·h rel

The sag should not exceed the admissible value of hrel = 0.01 at any point of the loaded
top run, as an increased motional resistance must otherwise be anticipated. Tmin can be
selected as a smaller value by reduction of the idler spacing lo, possibly at the critical
point only.

The belt tensions may also require adjustment if the belt tension necessary for power
transmission is not present at one drive pulley. All belt tensions must be increased by the
same quantity until all demands have been fulfilled.

62
D – 4.1 Stipulation of tension member – Belt tensions

The type of belt tensioning must be known for further calculation of the temporary belt
tensions. Three systems are to be distinguished in principle:
1. Rigid tensioning (with fixed takeup pulley) by takeups, straining pulleys

2. Movable tensioning (with constant tension force) by counterweights

3. Adapted tensioning (with adjustable tension force) by controllable straining pulleys etc.

In the case of rigid tensioning, the belt elongations are constant* in their sum total for
all operating conditions. The consequence is belt tensioning forces that have to comply
with the extreme operating states on starting (or stopping) and lead in operation to the
highest belt tensions in comparison with other types of tensioning.

* For a conveyor belt the absolute elongation, approx.

T2 + T3 T5 + T1
ΔI = ·L+ ·L in m
2·B·E 2·B·E
and
T2A + T3A T5A + T1A
ΔIA = ·L+ ·L in m
2·B·E 2·B·E
It follows, with rigid tensioning and a constant takeup, that
ΔI = ΔIA
and
T2 + T3 T + T1 T2A + T3A T5A + T1A
·L+ 5 ·L= ·L+ ·L
2 2 2 2
or in simple terms
∑T = ∑TA
This condition is fulfilled by all belt tensions in operating being
increased by the difference
∑TA - ∑T
ΔT =
4
when four span end tensions are present. When calculating sections (with more than four span end
tensions) the section lengths are to be taken into account. “Span end” belt tension refers to forces
acting on the belt which occur at the beginning of a belt section of length L or of part lengths
measuring Ln .
63
 D – 4.1 Stipulation of tension member – Belt tensions

A constant tensioning force through movable counterweight gear causes belt tensions
that are constant at the takeup point in any operating state and must therefore com-
ply with the most extreme operating conditions. The consequence of this in operation
is higher belt tensions than would be required for the transmission of the peripheral
forces.

The adapted belt tensioning leads to belt tensions complying with the specific operat-
ing instance, as they are adjusted by regulating devices to the value required for trans-
mission of the peripheral forces. In operation, this more intricate type of belt tensioning
yields the lowest belt tensions as compared with other systems.

The operating instances of starting and stopping are distinguished from permanent
operation by the additional mass inertia forces and the changed peripheral forces. The
belt tension curve therefore deviates from that ascertained for operation and is to be
determined by a new sequential calculation. The belt tensions in operation are then to
be checked and adjusted where
Adjustment of drive tractions in operation
Type and location of tensioning Condition Adjustment
rigid, tensioning location ∑ T = ∑ T max ∑ T max - ∑ T
has no effect on the ΔT =
calculation 4
movable, belt tension Tv
at takeup point is T v = T v max ΔT v = T v max -T v
constant
adapted, tensioning
location has no effect – –
on the calculation

The decisive factor for the adjustment is always the largest sum of the belt tensions
∑T max or the maximum belt tension T v max at the takeup point. The operating-state
belt tensions deviating from this, that have to be adjusted, are designated as T or. T V ,
i.e. when ∑T max or T v max occurs on stopping, both the belt tensions in operation and
those on starting are to be adjusted. Apart from starting and stopping, it is also critical
section loads that may lead to an adjustment of the belt tensions.

The sequential calculation process permits the belt tensions of a belt conveyor to be
determined in accordance with the ever-constant schedule. The conclusion of each
sequential calculation is the adjustment of the belt tensions according to demands re-
lating to tension for transmission of peripheral forces and sag restriction.

A distinction is made between three stages of the sequential calculation which provide
greater precision of the results, depending on execution:

Stage 1 After conclusion of the adjustments, the belt tensions in operation (permanent
state of operation at normal rating) are at hand without starting or stopping being taken
into account. This procedure is sufficiently accurate only for horizontal or uphill belt con-
veyors with head drive, standard starting and braking properties being a prerequisite.

64
D – 4.1 Stipulation of tension member – Belt tensions

Stage 2 After conclusion of the sequential calculation for operation and adjustment, a
second sequential calculation is executed based on the peripheral forces and motional
resistances including the mass inertia forces on starting. After determination of the type
and location of the takeup, the two sequential calculations are concluded by a further
adjustment, i. e. the belt tensions in both operating states subsequently fulfil the de-
mands relating to tension, sag and the condition set by the takeup gear (e. g. a constant
sum of the span end tensions for rigid takeup). This procedure is sufficiently accurate for
all belt conveyors if the stopping can be effected in such a way that no critical operating
states occur.

Stage 3 A third sequential calculation with the stopping conditions is executed and ad-
justed. The question of which belt tensions must be adjusted in order to fulfil the result-
ant condition, again taking the takeup gear into account, is then investigated. In general
the result is sufficiently accurate for any application.

Course of belt tension determination by sequential calculation

Sequential calculation Operation

Adjustment Tensioning
Adjustment Sag

Stage 2 Stage 1

Belt tensions Operation

Sequential calculation Starting

Adjustment Tensioning
Stage 3
Adjustment Sag
Type and location of tensioning Sequential calculation Stopping
Adjustment Tensioning
Adjustment Sag
Sequential calculation Stopping

or
Adjustment of belt tensions Starting

Type and location of tensioning

Belt tension in operation Adjustment of belt tension Operation

and on starting
and / or
Adjustment of belt tensions Starting

and / or
Adjustment of belt tensions Stopping

Belt tension in operation, on

starting and on stopping

In the case of belt conveyors with varying system gradients or with critical load states, all
three stages of the sequential calculation may be executed accordingly.
65
 D – 4.1.1 Stipulation of tension member – Belt tensions – Belt tensions in operation

D – 4.1.1 Belt tensions in operation *

As the belt tensions in operation are initially determined by a sequential calculation, start-
ing with T2, a uniform schedule can be used which is equally suitable both for random
drive layouts and belt tensioning systems and for driven or braked conveying systems.
The belt tensions on starting and stopping and on section loading can also be calculated
according to the same schedule and be entered in the adjacent table. The varying fac-
tors are the respective peripheral forces to be entered at the head of the table and the
resulting belt tensions at the drive pulleys. In the case of multiple pulley drives it should
be noted that peripheral forces are transmitted at each drive pulley. In this instance the
belt tension T1/2 (or T3/4) can be entered additionally between T1 and T2 (or T3 and T4).

The belt tension Tmin required for restriction of the sag can also be determined in advance.
The peripheral forces and motional resistances
are now listed with their correct signs in Column
1 in the sequence determined by the moving
direction of the belt (cf. table D – 3.6).

The belt tension resulting after each sec-

tion can be designated and entered in Col-
umn  2. The values of the belt tensions are
determined in the sequential calculation.

Sequential calculation of drive tractions in operation

Tensioning force T2 = T min
+ motional resistance (return run) T3 = T2 + Fu
– peripheral force (if drive exists) T4 = T 3 - F U2
+ motional resistance (feeding point) T5 = T4 + FN
+ motional resistance (top run) T1 = T5 + FO
– peripheral force (control) T2 = T 1 - F U1
It must then be checked whether the belt tension required for restriction of the sag or for
transmission of the peripheral forces is being maintained at the corresponding points.

Adjustment (operation) Condition Adjustment Δ TC

Tensioning force, drive 1 T2 ≥ F U1 · c 2 F U1 · c 2 - T 2

Tensioning force, drive 2 T4 ≥ F U2 · c 2 F U2 · c 2 - T 4
Sag, feeding point T5 ≥ T min T min - T 5
Sag, discharge point T1 ≥ T min T min - T 1

The maximum value of Δ T C (sequential calculation) is decisive for the adjustment. When
each belt tension from Column 2 has been increased by the value of Δ T C, the belt ten-
sions for operation are yielded in Column 3, though regardless of starting and stopping.
Any adjustments that may arise from this can be entered in the next columns after inves-
tigation of these cases.

* Operating states in which no significant changes in belt speed occur (permanent state)
are given the abbreviated designation “Operation”. This term also covers part-load and
no-load operation.
66
D – 4.1.1 Stipulation of tension member – Belt tensions – Belt tensions in operation

Calculation of drive tractions Form 6

(example)
D – 4.1 Operating state operation
Stage 2
Tensioning manual

( m LI + m GI ) ·g ·I O T 2A 11404 N
T min = Belt tension
8 ·h rel T min 5824 N

Adjustment ΔT C 9055 N

Sequential calculation
Section 1 Motional 2 Sequential 3 after after after
resistances /  calculation adjustment adjustment* adjustment
peripheral Δ T C in N with Δ T in N with Δ T in N
forces / mass
inertia forces
T2* 5 824 14 879 38 996
2 - 9 991
T3* -4 167 4 888 29 005
– –
T4 -4 167 4 888 29 005
FN 936
T5* -3 231 5 824 29 941
1 54 673
T1* 51 442 60 497 84 614
FU1 22 808
T1/2 28 634 37 689 61 806
FU2 22 808
T2 5 826 14 881 38 998

Sum total of span end tensions 86 088 182 557

*  Span end tension

* This correction is possible only after calculation of the belt tension on starting,
and subsequent determination of the value Δ T .
67
 D – 4.1.2 Stipulation of tension member – Belt tensions – Belt tensions on starting and stopping

D – 4.1.2 Belt tensions on starting and stopping

The belt tensions on starting and stopping are also yielded by a sequential calculation,
taking into account, however, the changed peripheral forces that must be subtracted
again and the additional mass inertia forces (D – 3.5.1) that are added.
Sequential calculation of belt tensions on starting
Tensioning force T 2A = T min
+ motional resistance (return run)
+ mass inerta forces (return run) T 3A = T 2A + F U + F au
– peripheral force* T 4A = T 3A - F UA2
+ motional resistance (feeding point) T 5A = T 4A + F N
+ motional resistance (top run)
+ mass inertia forces (top run) T 1A = T 5A + F O +F ao
– peripheral force (control) T 2A = T 1A - F UA1

On stopping, the drive traction required for peripheral force transmission is yielded at the
entry side of the braking pulley.

The sequential calculation may, however, be started at the leaving side of pulley 1 in
this case too. It is then executed in accordance with the same schedule, all peripheral
forces, motional resistances and mass inertia forces being inserted with the correspond-
ing signs.
Sequential calculation of belt tensions on stopping
Tensioning force T 2B = T min
+ motional resistance (return run)
+ mass inertia forces (return run) T 3B = T 2B + F U + F bu
– peripheral force** T 4B = T 3B - F UB2
+ motional resistance (feeding point) T 5B = T 4B + F N
+ motional resistance (top run)
+ mass inertia forces (top run) T 1b = T 5B + F O +F bo
– peripheral force (control) T 2B = T 1B - F UB1
The minimum belt tensions are to be checked and adjusted if necessary by raising all
belt tensions. The sag may be ignored on starting and stopping, provided attention is
paid that no negative belt tension values occur.
Adjustment (starting) Condition Adjustment
Tensioning force, drive 1 T 2A ≥ F UA1 · c 2 ΔT C = F UA1 ·c 2 - T 2A
Tensioning force, drive 2 T 4A ≥ F UA2 · c 2 Δ T C = F UA2 ·c 2 - T 4A

Sag T > O ΔT C = - T

The minimum belt tensions are to be checked for stopping too and adjusted where nec-
essary by raising the belt tension.
Adjustment (stopping) Condition Adjustment
Tensioning force, drive 1 (braked) T 2B ≥ F UB1 · c 1 ΔT C = F UB1 ·c 1 - T 2B
Tensioning force, drive 2 (braked) T 4B ≥ F UB2 · c 1 Δ T C = F UB2 ·c 1 - T 4B

Sag T > O ΔT C = - T

* If a drive is not switched on on start-up, the inertia forces FaU of the reduced masses of
the rotating drive components are to be added at this point where applicable.
** If a drive is not combined with a brake, the inertia forces FbU of the reduced masses of
the rotating drive components are to be added at this point where applicable.
68
D – 4.1.2 Stipulation of tension member – Belt tensions – Belt tensions on starting and stopping

Calculation of belt tensions Form 5

D – 4.1 Operating state Starting
Stage 2
Tensioning manual

( m LI + m GI ) ·g ·I O T 2A 22877 N
T min = Belt tension
8 ·h rel T min – N

Adjustment ΔT C – N

Sequential calculation
Section 1 Motional 2 Sequential 3 after
resistance / calculation adjustment
peripheral with
forces / mass Δ T C in N
inertia forces
T2A* 22877
2 -696
T3A* 22181
– –
T4A 22181
Fn 936 T5A* 23117
1 91265 T1A* 114382
FuA 45753 T1/2A 68629
FuA 45753 T2A 22876
Starting:

k nom  V = k max t ·S t

114382
= · 5.4 = 772 N/mm
800

Operation:
k nom  V = k max ·S
84614
= ·8 = 846 N/mm
84614

Selected nominal belt strength:

S = 7.56
St 800 St = 5.59

Sum total of span end tensions 182557

Adjustment ΔT 24117 N

* Span end tensions

∑ T max - ∑ T 182557 - 86088

Δ T= =
4 4
69
 D – 4.1.3 Stipulation of tension member – Belt tensions – Belt tensions with regard to sections

D – 4.1.3 Belt tensions with regard to sections

Conveying systems with sections at different gradients due to topographical factors

or other constructional conditions may have increased motional resistances and thus
greater belt tensions in special loading states. Even, however, if these critical operating
instances are prevented by an appropriate control system, belt tensions may be present
at certain points of the conveying system with continuous loading, and these must be
taken into account in the design. Whereas increased belt tensions may occur at vertices
of the system layout due to the weight of belt and load, the minimum belt tension may
not be attained at saddle points.

The belt tension curve in operation, on starting, stopping and also with differently loaded
sections can be executed in accordance with the sequential calculation schedule too,
the belt tensions at the individual points of the system resulting from addition of the mo-
tional resistances or mass inertia forces of the sections and subtraction of the peripheral
forces. Following the sequential calculation, the minimum belt tensions are checked and
increased where necessary. The expanded tabular schedule attached in the appendix
can be used for this purpose.

Starting and stopping, too, are to be checked as before by a sequential calculation. It

should be observed, however, that the adjustment Δ T of the traction forces in operation
results from the equation (for starting)
T n +T n+1 T nA + T n+1A
∑ ·L n = ∑ ·L n
2 2
when tensioning is rigid, T n and T n+1 representing the span end tensions of the sections
with the length Ln. The adjustment is then
∑ ( T n + T n+1) ·L n - ∑ ( T nA + T n+1A) ·L n
Δ T=
2 · ∑ Ln

70
D – 4.2 Stipulation of tension member –  Additional strains

D – 4.2 Additional strains

Determination of the belt strength is generally founded on the calculated belt tensions,
taking as a basis the corresponding safety factors, the assumption being made that the
belt tension is distributed uniformly across the belt cross-section.
k nomV · B
Sx
Tx
These optimum conditions, however, apply to untroughed conveyor belts only. If the belt
is led through horizontal or vertical curves, undergoes transitions from flat to trough or
vice versa or, for instance, is turned, the uniform tension distribution is disturbed at these
points and also at a greater distance from them. Local additional strains overlap.

If the belt undergoes gradual transitions from flat to trough or vice versa, i. e. in the
course of a longer flight, or is led through gradual curves, i. e. those with a negligible
bend, the additional strains occurring are covered globally by standard safety factors.

Taking certain marginal conditions into account, conveying systems featuring extremely
short troughing transitions, relatively small transition radii or curves can also be equipped
with ContiTech conveyor belts. The belt strength is exploited to such an extent that val-
ues remain below the global safety factors.

Minimum safety factors for additional strains (guide values)

Belt type S min S min t (short-term)

STAHLCORD® belts with 1- or 2-lap splice 3.0 2.5
STAHLCORD belts with 3- an more lap splice
®
3.3 2.8
Fabric carcass belts 3.6 3.0

The given safety factors are to be regarded as limit values. The constructional design
must ensure that these values are always attained and that the stated minimum safety
factors are maintained even in the extremely unfavourable operating state.

The additional strains are determined essentially by the elongation properties of the ten-
sion member. This is identified by the belt parameter K G which can be read off from the
chart below for ContiTech conveyor belts.

71
 D – 4.2 Stipulation of tension member – Additional strains

Excessive traction reliefs of specific belt zones may also occur in individual cases.

Under certain conditions the additional strains are reduced by an elongation compensa-
tion outside the conveyor belt section under consideration. This can be taken into ac-
count approximately by a compensation factor C ε.
Compensation factor C ε
STAHLCORD® belts Fabric belts
Standard conditions 150 60
Adjacent transition arcs*
or troughing transitions 0 – 100 0 – 15
Turnover or inverted
trough roll in return run 100 – 150 15 – 60
High friction on tail pulley 120 – 150 30 – 60

Extreme additional strains are to be avoided in cases of unfavourable operating condi-

tions. Such a high degree of exploitation of the belt strength may reduce the service life
of a belt, so that a check must be made in the individual case, taking all affecting factors
into account, as to whether the selected belt is still suitable for the specific application.
The staff of ContiTech are available for detailed consultation on these questions.
* Adjacent, opposing transition curves can lead to more favourable relationships.
72
D – 4.2.1 Stipulation of tension member – Additional strains – Flat-to-trough and trough-to-flat transition

D – 4.2.1 Flat-to-trough and trough-to-flat transition

In order to prevent extensive additional strains in the flat-to-trough or trough-to-flat tran-

sition area, the transition lengths LY must have adequate dimensions.

The belt edges are stretched by converting the belt from the troughed form to the flat
form on the tail pulley or vice versa. This yields an uneven tension distribution that may
lead to excessive strain on the belt edges. When the belt tensions are relatively low, cer-
tain areas of the belt may also be buckled. This form of strain should also be avoided, or
a certain degree at least not exceeded.

In the rough calculation of the transition lengths Ly, it is correspondingly essential to dis-
tinguish whether the decisive criterion is the edge elongation or the buckling of the belt
centre.

In general, excessive edge elongation can occur if the mean belt tension of the conveyor
is relatively large as a result of the belt tension Tx at the place concerned being high.
Minimum transition lengths for flat-to-trough or trough-to-flat transitions (guide values)
for Transition length in m Criterion

Sx <
S min
b f /B
LY ≥ B ·λ √ S min · S x
S x – S min
·K G ·K f1
Edge
elongation

The troughing angle λ is to be inserted here in radian measure and is to be estimated for
5-part idler assemblies, possibly by means of the connecting line from the ends of the
centre idler to the belt edge. The troughing parameter K f1 can be determined from the
ratio b f/B.

bf 2 bf
K f1= ( ) - ( )3
B B
Buckling may occur when the drive traction Tx at the belt conveyor point under consid-
eration is relatively small.
Minimum transition lengths for flat-to-trough or trough-to-flat transition
for Transition length in m Criterion

Sx ≥
S min
b f/B
LY ≥ B ·λ √S x · K G · K f2 Buckling

The troughing parameter here is

bf
K f2= ( )3 Troughing angle λ and parameter K G are to be inserted as
B above.

73
 D – 4.2.1 Stipulation of tension member – Additional strains – Flat-to-trough and trough-to-flat transition

In some cases the calculation procedure described here will lead to transition lengths
that cannot be realized straight away in the case of conveyors, for example, because
of the overall construction. An improvement in the tension distribution can be attained
by raising the top edge of the tail pulley by the amount hTr above the lowest point of the
troughing. The increased height of the pulley should not exceed
1 - cos λ
h Tr = ·b f
sin λ
It should be noted that a so-called “springboard effect” may occur at the discharge pul-
ley. Increased pulley heights in which the loaded belt rises from the centre idlers should
also be avoided.

The reduced transition length results approximately with

h Tr
λred = λ - in rad
bf
Investigations have shown that a compensation of the elongations caused by the trough-
ing transition occurs outside the actual transition length too. If this is taken into account
with compensation factor cε, the necessary transition length can possibly be reduced
somewhat more.

L Y red ≈ L Y2 / √L Y
2
+ c ε · λ2 ·b f2

In those cases where an extreme dimensioning of the transition lengths is of special

importance, a verification of the effective tension distribution can be undertaken by our
Application Technique Advisory Service.

74
D – 4.2.2 Stipulation of tension member – Additional strains – Transition curves

D – 4.2.2 Transition curves

In general the belt conveyor will connect the feeding point with the discharge point of
the material handled in the straightest possible line. The course can also, however, be
adapted within certain limits to the given situation of ah optimum flight routing or the
system construction by horizontal and vertical curves.

The minimum radius of horizontal curves is normally not given by the admissible belt
strain but by the demand that the belt should maintain a steady position in the top run
and in the return run even in the least favourable operating state. This occurs when a
relatively high drive traction T X is active in the curve with an unloaded belt or with low belt
and material weight. The following formula can serve as a statement for estimating the
minimum radius R h; this formula takes into account that the idler trough or idler is raised
by the angle λR on the inside of the curve as compared with the horizontal.
Tx
Rh ≥
in m
m GI ·g [ b f /B ·tan ( λ+ λR) +I/B ·tan λR +b f /B ·tan ( - λ + λR)]

Additional measures such as tilting single idlers may enable horizontal curves to be ex-
ecuted more narrowly too. A precise investigation is indispensable in this case.

In all instances the execution of the transition curves must ensure that there is no falling
short of the minimum safety factors through the additional strains.
Minimum radii for horizontal curves (guide values)

for Minimum radius in m Criterion

S x ≥2 S min Rh ≥ B · Sx · KG Buckling

S x <2 S min R h ≥ B · S x · S min · K G Edge elongation

S x - S min

Vertical transition curves are frequently provided to attain an increased discharge for
transfer to an adjoining belt conveyor. Both concave and convex curves may arise in this
process; these have to be calculated in different ways. Transition curves are also nec-
essary with underpasses and overpasses, and occur in an extreme form on conveying
equipment with a articulated boom.

75
 D – 4.2.2 Stipulation of tension member – Additional strains – Transition curves

The radius Rk of concave conveyor belt curves must be sufficiently large to guarantee
that the belt fits into the troughing assemblies in any operating state. When the takeup
is rigid, the lifting of the belt may lead to an excessive drop in the necessary belt tension,
especially on starting in the unloaded state. In the case of tensioning with controllable
straining pulleys, too, however, the belt lengths being released may possibly not be
taken up quickly enough by the takeup loop. Any lifting of the belt should be avoided,
primarily in order to prevent discharge or scraping of material from the belt.
Tx
Rk ≥ in m
m I ·g · cos δ
G
Smaller radii are permissible if lifting in unloaded state is accepted. In this case, however,
checking brackets or idlers must be provided.

The selected radius should also be checked under all circumstances when very low belt
tensions are present or the belt in its troughed form is forced through concave curves.
Minimum radii for concave curves (guide values)
for Radius in m Criterion
S min S x ·S min bf 2
Sx ≥ Rk ≥ ·2 sin λ· · KG Buckling
( 1-b f /B ) S x -S min B
S min b f2 Edge
Sx < R k ≥ S x ·2 sin λ ( b f – ) KG elongation
( 1-b f /B ) B

The radius RV of convex conveyor belt curves is determined exclusively by the admissible
additional strains or excessive tension reliefs.
Minimum radii for convex curves (guide values)
for Radius in m Criterion
S min bf2
Sx ≥ Rv ≥ S x · 2 sin λ · · KG Buckling
b f /B B
S min S x · S min b f2 Edge
Sx < Rv ≥ ·2sin λ ( b f – )· K G elongation
b f /B S x - S min B

Taking the elongation compensation into account, the radii of convex curves can be
reduced.
R v2
R v red ≈
R v +c ε · sin λ ·b f
If extreme radii, e. g. on bends, are to be realized and if buckling of the belt is possibly
to be permitted, the ContiTech Application Technique Advisory Service should be con-
sulted.

76
D – 4.2.3 Stipulation of tension member – Additional strains – Turnover

D – 4.2.3 Turnover

Turnovers are provided to prevent the material still adhering on the belt surface after
discharge from being abraded by the idlers and leading to the conveying system being
soiled. Wear on the idlers is furthermore reduced. Turnover as a measure is of interest
primarily in the transport of bulk material where conventional belt cleaning fails to pro-
duce the required success.

There are three types of turnover to be distinguished;

these are selected in accordance with the convey-
ing system data. The turnover length LW is to be di-
mensioned in such a way that no excessive additional
strains occur.

Guide values for planning turnover lengths

Min. turnover LW for
Belt
Typ of Belt width cotton EP STAHLCORD®
speed
turnover B in mm belts belts belts
in m/s
Unguided ≤ 1200 1,6 8xB 10 x B –
Guided ≤ 1600 3.4 10 x B 12.5 x B 22 x B
Supported ≤ 2400 6,0 – 10 x B 15 x B

In order to prevent excessive strains on the belt, care should be taken that the belt wrap
round any pulley does not exceed 15° on a length corresponding to approx. half the
turnover in each instance before entry into the turnover and after leaving the turnover.

With the safety factor Sx in the turnover area, the required turnover length, in which nei-
ther buckling nor excessive edge elongation is to be expected, can be determined.
Minimum turnover lengths (guide values)
for Turnover length in m Criterion

S x ≥ 3S min L W ≥ � ·B √ Sx ·
KG
12
Buckling

S x < 3S min L W ≥ � ·B √ S x · S min

S x - S min
·
KG
6
Edge elongation

A check should be made as to whether the marginal condition below is adhered to with
the selected turnover length LW and the belt tension TX.

L W ·m GI ·g
≤ 0.015
8 ·T x

77
 D – 4.3 Stipulation of tension member – Selection criteria

D – 4.3 Selection criteria

When selecting the conveyor belt for a specific conveyor system, a number of other
aspects are to be observed that can still be taken into account by the designer or that
may lead to a reconsideration of the design already prepared. As is the case with most
technical problems, there are frequently a number of solutions in belt conveyor design-
ing. Operational reliability, expected service life and thus long-term economy can be
improved by investing more in the designing or drafting of the system. The engineers
of ContiTech’s Application Technique Department will be pleased to give advice on indi-
vidual questions.

78
D – 4.3.1 Stipulation of tension member – Selection criteria – Pulley diameter

D – 4.3.1 Pulley diameter

The minimum admissible pulley diameter is linked with the demand for an adequate
service life of the belt and in particular of its splice, the basic consideration being that the
service life of the splice equals that of the belt. In the case of belts subject to wear and
of belts with mechanical fasteners, there is therefore the possibility of using pulleys with
smaller diameters.

Type of pulley

Type of pulley

Type of pulley

A distinction is made between the following types of pulley:

A – pulleys in the region of high drive tractions with angles of wrap > 30°
(drive pulleys)
B – pulleys in the region of low drive tractions with angles of wrap > 30°
(tail pulleys)
C – pulleys with angles of wrap ≤ 30° (snub or deflection pulleys)

Stipulation of the pulley diameter depends essentially on the thickness of the tension
member in the conveyor belt selected.

The diameter of the pulley at which the highest drive traction TX = Tmax is present (pulley
type A) is determined first.
D Tr (A) ≥ S Z · C I in mm
The thickness sZ of the tension member can be drawn from the tension member data
(D – 4.4) and factor c1 is shown in the table below.
cI Tension member material in warp (longitudinal)
60 Cotton (B)
90 Polyamide (P)
105 Polyester (E)
100 CON-MONTEX®
80 CON-BITEX®
145 STAHLCORD® (St)

79
 D – 4.3.1 Stipulation of tension member – Selection criteria – Pulley diameter

The ascertained pulley diameter is to be rounded off upwards to the next standardized
size if necessary. For pulleys of types B and C, the diameters are stated in the same
stage respectively.
Standardized pulley diameters in mm
Type of pulley
Stage A B C
1 100 – –
2 125 100 –
3 160 125 100
4 200 160 125
5 250 200 160
6 315 250 200
7 400 315 250
8 500 400 315
9 630 500 400
10 800 630 500
11 1000 800 630
12 1250 1000 800
13 1400 1250 1000
14 1600 1250 1000
15 1800 1400 1250
16 2000 1600 1250

Practical experience permits the pulley diameters calculated in accordance with the glo-
bal formula to be reduced slightly.

When the belt strength is utilized to a lesser degree, pulley diameters of lower stages
can be selected.
Utilization Diameter stages Type of pulley
A B C
S
< 0.6 1 stage lower
Sx

S
< 0.6 2 stages lower 1 stage lower
Sx

In the case of conveying systems subject to extreme loads or high additional strains,
it is advisable to check the surface pressure between the conveyor belt and the pulley
circumference too (cf. paragraph D – 3.5).

80
D – 4.3.2 Stipulation of tension member – Selection criteria – Troughing properties

D – 4.3.2 Troughing properties

Impeccable belt guidance in the idler trough demands good tracking properties and
adequate troughability of the conveyor belt. ISO recommendation R 703 states that the
conveyor belt is troughable when the D/B parameter determined in a stipulated test pro-
cedure attains a certain minimum value.
Troughability in accordance with ISO R 703

Troughing angle λ 20º 25º 30º 35º 40º 45º

Min. value D / B 0.05 0.06 0.07 0.09 0.12 0.17

Practice-orientated tests by ContiTech have shown that a conveyor belt can be regarded
as troughable when more than 35 % of its width rests on the idlers in unloaded state, the
centre idler being contacted too.

The troughability is determined essentially by the transverse rigidity of the plies and the
dead weight of the belt. Troughability improves with increasing belt width. The trougha-
bility can be estimated by means of an approximation formula in the range of standard
belt widths, troughing angles and cover gauges.
B
tan λ ≤ ( SZ ) 3 ·m IIG ·c q
m IIG – conveyor belt mass in kg/m² (cf. D – 3.1.2)
B – belt width in m
S Z – tension member thickness in mm
c q – transverse rigidity factor

cq Tension member material in weft (transverse)

12 Cotton (B)
16 Viscose (Z)
18 Polyamide (P)
42 Steel cable belts (St)

Apart from the generally good troughability of ContiTech conveyor belts, it is primarily
their outstanding tracking properties that ensure reliable belt guidance even when oper-
ating conditions are unfavourable. STAHLCORD® conveyor belts with textile transverse
reinforcements differ only insignificantly from standard steel cable belts in their trougha-
bility. In special cases the troughability can be determined in our laboratory by means of
a rigidity test.

A minimum transverse rigidity is desirable in wider conveyor belts to enable the belt to
form a stable troughing form and to withstand lateral compression stresses, too. The
rigidity of fabric carcass belts is normally adequate provided that the belt is of a certain
minimum thickness.

s 1 ≥ 8 ·B in mm Belt width B in m
Belt thickness s 1 in mm
An increase in cover gauges contributes to an adequate ratio between belt rigidity and
belt width, particularly in the case of STAHLCORD® conveyor belts.
81
 D – 4.3.3 Stipulation of tension member – Selection criteria – Centre distance and takeups

D – 4.3.3 Centre distance and takeups

It is the elongation properties of the conveyor belt that determine the size of the
takeup that has to be taken into account when designing the takeup gear. If the
conveyor belt was tensioned on assembly to such an extent that the sag was largely
eliminated, it is only the further takeup for absorption of the elastic strain and per-
manent elongation that is necessary for those belt tensions required for operation.

The elastic strain and those permanent elongations that may occur in the course
of operation can be applied as guide values for the minimum takeup with a mean
safety factor of S = 10.
Average elongations with 10% belt strength utilization
Belt type reference growth total reference
elongation elongation ε
Fabric carcass belts (B) 1.5 – 2 % 0.2 – 0.4 % 1.7 – 2.4 %
Fabric carcass belts
(up to EP 200) 0.6 – 0.9 % 0.5 – 0.8 % 1.1 – 1.6 %
(from EP 250) 0.9 – 1.2 % 0.8 – 1.6 % 1.6 – 2.8 %
Steel cable belts (St) 0.1 – 0.3 % – 0.1 – 0.3 %

This produces an ever-adequate takeup guide value for tensioning at the takeup
pulley.
ε
LV = ·L
100

As the belt is generally strained with 10% of its strength on only a small part of its
length, precise values of L can be determined by means of the average belt tension.
In this instance a procedure is adopted similar to the one outlined in footnote D – 4.1.
On request our department which advises on technical applications can carry out a
calculation using the relevant characteristic values of the materials concerned.

When centre distances L are great, the use of fabric carcass belts may lead to
considerable takeups. If the belt can be subsequently shortened, the permanent
elongation component can be ignored. It is nevertheless usually advisable to use
STAHLCORD® conveyor belts when centre distances exceed 500 m, unless other
aspects are against this. Even when centre distances are below 500 m, the de-
signer should consider whether a more favourable layout of the takeup gear can be
achieved with STAHLCORD® conveyor belts.

82
D – 4.3.4 Stipulation of tension member – Selection criteria – Effects of material handled

D – 4.3.4 Effects of material handled

The tension member is protected from direct effects of the material handled by covers
of corresponding quality and gauge and possibly by solid rubber edges. It is important,
however, to use if possible a tension member material that offers sufficient resistance
even when the cover is accidentally damaged.

Significant factors include:

Moisture
Temperature
Chemical properties

The basic properties of various tension member materials towards these influences can
be seen in the tables below.
Effect of moisture
Tension Shrinkage Absorption of Strength Elongation Sustained
member % moisture % against contact with
normal state water
Cotton (B) 2-3 7.5-8 10 – 15% approx. Possible rotting
higher 10% higher

Polyester 0 0 No No No rotting
(E) change* change

Polyamide 0 4 approx. approx. No rotting

(P) 10% 10%
lower higher
Steel 0 0 No No Extensive corrosion prevention with
(St) change change galvanized cables (formation of rust
and risk of deterioration when water
is in direct contact with wires)
Viscose approx. 4 13 approx. approx. Possible rotting
(Z) 30-35% 10%
lower higher

Chemical effects
Tension Reaction Reaction Reaction to
member to acid to alkali organic solutions

Cotton (B) Destroyed by Swelling Resistant

concentrated but no destruction
and hot diluted
acids
Polyester Highly resistant to Dissolution
(E) most mineral acids in strong,
hot alkalis Generally resistant;
soluble in
Polyamide Destruction by Good certain phenolic
(P) hydrochloric resistance compounds
acid, formic acid
and acetic acid
Steel (St) Destruction Resistant
by acids

* See also footnote on page 84.

83
 D – 4.3.4 Stipulation of tension member – Selection criteria – Effects of material handled

Effect of temperature
Elongation and strength tendency
Tension member on sustained subjection to high temperatures

Cotton (B) Degradation from 120°C

Only slight degradation* up to

Polyester (E) 120°C; strong degradation from 180°C
No degradation from 80-170°C;
Polyamide (P) marked drop in strength from 170°C
No effect on steel itself but drop in pull-out
Steel cable (St) resistance of steel cable from core rubber

* If the tension member is simultaneously subjected to the effect of moisture,

strong degradation can already occur at lower temperatures - from approx. 90°C.
84
D – 4.3.5 Stipulation of tension member – Selection criteria – Feeding strain

D – 4.3.5 Feeding strain

The conveyor belt is subjected to considerable strain by the impact of the material han-
dled at the feeding point. The frequency with which this strain occurs is particularly
great in systems with a short centre distance. The covers normally provide adequate
protection against damage to the tension member. In cases of extra coarse lumps and
long falls, however, it may be necessary to select the load carrying elements not only in
accordance with the drive tractions but also to take into account the impact strain due
to the material handled. A measure of this is the drop energy that has to be absorbed
by the conveyor belt.
E F =m k ·K f ·g ·h F in Nm
with mK – mass of an approximately cubic lump with edge length k
Kf – shape factor for lumps of different shapes
hF – height of free fall
Guide values for mass mk of cubic lumps in kg
Max. lump size k in mm
Material handled
100 200 300 400 500 600 700 800
Lignite, 0.15 1.5 4.5 10 20 35 55 80
Coke, coal
Salt, slag 0.25 2.0 6.5 15 30 50 80 120
Limestone, gravel 0.3 2.5 8.5 20 40 70 105 160
Overburden, refuse 0.4 3.0 10.5 25 50 85 135 200
Ore 0.55 4.5 14.5 35 70 120 185 280

With a specific edge length k*, lumps of different shapes also have different volumes. To
determine the mass approximately, the shape factor Kf can be applied.
Shape factor Kf for different lump shapes
oblong cubic round

0.5 1 2.5

Apart from the drop energy, it is the surface texture of the lumps that is of decisive sig-
nificance.

* Contrary to geometric bodies, the edge length k is used here to denote the greatest body
diagonal of a lump.
85
 D – 4.3.5 Stipulation of tension member – Selection criteria – Feeding strain

Guide values for selection of the tension member according to height of feed strain
Surface texture
Drop energy Rounded, soft Irregular, angular Sharp-edged, hard
EF (e. g. lignite) (e. g. limestone) (e. g. granite)
in Nm
(EP) (St) (EP) (St) (EP) (St)
< 10 < 315 < 400 < 630 < 630 < 1000
10 – 100 315 to 400 400 to 630 630 to 800 630 to 800 1000 to 3150
100 – 500 400 to 630 < 630 630 to 1000 800 to 1250 800 to 2000 3150 to 4000
500 – 1000 630 to 800 630 to 800 1000 to 1600 1250 to 2000 2000 to 2500 > 4000
1000 – 2000 800 to 1250 800 to 1250 1600 to 2500 2000 to 3150
2000 – 4000 1250 to 2000 1250 to 2000 3150 to 4000
4000 – 6000 2000 to 2500 2000 to 2500 > 4000
6000 – 10 000 2500 to 3150
> 10 000 > 3150

Additional measures at the feeding point, such as yielding idlers* or a bedding layer of
material help to reduce feeding strain. In all instances, covers of adequate thickness
are to be provided on the top. STAHLCORD® conveyor belts give a better performance
than fabric carcass belts, particularly when the cable diameter and pitch are selected
correctly in relation to the nature of the material to be handled too. In cases of extreme
strain, transverse reinforcements may offer extra protection (cf. Section D – 5.3).

* Impact idlers (cf. D – 3.1) are included in ContiTech‘s production range.

86
D – 4.4 Stipulation of tension member – Tension member data

D – 4.4 Tension member data

The text below presents the essential features of the respective tension members in a
selection from the ContiTech range of conveyor belts.

Fabric carcass belts, where standardized, comply with DIN standard 22 102 and
equivalent standards. The tension members stated are primarily suitable for surface ap-
plication.

Special-purpose versions of ContiTech’s conveyor belts with textile plies, designed mainly
for surface application, are marked with the registered trade marks.
Single-ply conveyor belts with polyester/polyamide
CON-MONTEX® tension members e. g. CON-MONTEX® 200/1

or
CON-BITEX® Two-ply conveyor belts with polyester/polyamide
tension members e. g. CON-BITEX® 315/2

ContiTech supplies special-purpose conveyor belts with textile plies for underground
mining application, which have been approved by the regional mines inspectorate. These
belts meet the special demands of coal mining and are marked as special versions with
the registered trade mark
Single-ply conveyor belts for underground mining application
CON-MONTEX® with polyester / polyamide tension members
e. g. CON-MONTEX® EbPb 1250/1

or

Two-ply conveyor belts for underground mining application

CON-BITEX® with polyamide / cotton tension members
(union thread) e. g. CON-BITEX® Pb 800/2

DIN standard 22 109 (February 1988) has been edited as a standard specification for
textile-ply conveyor belts used in underground coal mining. The belts are approved
in self-extinguishing type “V”only and have rubber or PVC covers. Approval has been
granted for all strengths between 500 and 1250 N/mm and belt widths up to 1200 mm.
CON-MONTEX® conveyor belts have the LOBA approval for strengths between 630 and
1250 N/mm.

87
 D – 4.4 Stipulation of tension member – Tension member data

All ContiTech steel cable conveyor belts are marked with the registered trade mark
STAHLCORD® Steel cable conveyor belts in series R 10 strength
grades (according to standard DIN 22 131)
e. g. St 2000

and have a structure and properties

complying with standard DIN 22 131
(November 1988).

The strength grades prescribed in

standard DIN 22 131 by standard series
R 10 are supplemented by
STAHLCORD®-special versions Steel cable conveyor belts in
series R 20 strength grades
e.g. St 2800.

The tension members comply with the DIN 22 131 standard specifications in their prop-
erties and in their structure.

By using more sophisticated calculation methods and layout methods of conveyor belts,
a type can be selected from this ContiTech conveyor belt range for optimum fulfilment
of the demands. The breaking strength of the cables in these Series R 20 belts likewise
takes into account a tensile strength allowance, so that equal safety factors are guaran-
teed in the application of these belts.
Constructional features of STAHLCORD® conveyor belts in accordance
with DIN standard 22 129, 22 131 and in special versions
Type Minimum Cable Cable pitch Remarks
breaking diameter in mm
strength in mm (max.) (approx.)
in N/mm
St 500 500 3.0 12.5 Special version
St 630 630 3.0 10 Special version
St 800 800 3.8 12 Special version
St 1000 1000 4.1 12 DIN 22129, 22131
St 1120 1120 4.1 11 Special version
St 1250 1250 4.9 14 DIN 22129, 22131
St 1400 1400 4.1 9 Special version
St 1600 1600 5.6 15 DIN 22129, 22131
St 1800 1800 5.6 13.5 Special version
St 2000 2000 5.6 12 DIN 22129, 22131
St 2250 2250 5.6 11 Special version
St 2500 2500 7.2 15 DIN 22129, 22131
St 2800 2800 7.2 13.5 Special version
St 3150 3150 8.1 15 DIN 22129, 22131
St 3500 3500 8.6 15 DIN 22129, 22131
St 4000 4000 8.9 15 DIN 22129, 22131
St 4500 4500 9.7 16 DIN 22129, 22131
St 5000 5000 10.9 17 DIN 22129, 22131
St 5400 5400 11.3 18 DIN 22129, 22131
St 6300 6300 12.6 18 Special version
St 7100 7100 13.5 19 Special version

88
D – 4.4 Stipulation of tension member – Tension member data

ContiTech supplies steel cable belts in another series as

STAHLCORD® special versions Steel cord conveyor belts
e. g. St 3150 X-A

with mainly narrower cable pitches or in

strengths deviating from DIN standard
22 131. The code letters X-A refer to
the structure and the splicing system, to
which special attention must be paid.

The code letters signify:

A – interlaced splice (as DIN standard 22 131)

B – interlaced splice with deflection of cables
C – graduated splice (e. g. the so-called “organ pipe” splice)
D – other systems

These belts are made to specification and may offer additional advantages.

ContiTech steel cable belts equipped with transverse reinforcements in the covers
(cf. D – 5.3) are marked
CONTI-CROSS® Steel cable conveyor belts with textile transverse reinforcement on both sides
e. g. St 2000 T/T

Any STAHLCORD® tension member can be used for steel cable conveyor belts with
textile transverse reinforcements (STAHLCORD® tension members for steel cable trans-
verse reinforcements available on request).

For underground coal mining in the Federal Republic of Germany, approval must be ob-
tained from the regional mines inspectorate for steel cable belts too. The core of these
belts complies with the structure stipulated in DIN standard 22 129, deviating versions,
however, being permitted. All types of belt must be self-extinguishing (V). ContiTech has
obtained the relevant approval for STAHLCORD® conveyor belts for strengths of 1000
to 5400 N/mm and for belt widths of up to 1600 mm with and without textile transverse
reinforcements.

89
 D – 4.4.1 Stipulation of tension member – Tension member data – Textile tension member

D – 4.4.1 Textile tension member

Technical data (guide values)

Nominal Breaking Thickness Tension Standard Min. pulley Min. belt
strength in elongation of tension member elongation diameter width
splice (longitudinal) member mass at 10% of (drive at 30°
knom V in % (belt core) (without min. pulley) troughing
Type sZ in mm cover breaking DTr(A) B in mm
in N/mm M or N) strength in mm
mIIZ in kg/ (longitudinal)
m² in %

1-ply belts
160 2.0 2.2 200 400
200 2.0 2.4 200 400
CON- 250 12 – 16 2.5 2.5 0.6 – 1.2 250 400
MONTEX® 315 2.6 3.1 315 400
400 2.8 3.3 315 400
500 3.0 3.7 315 400
2-ply belts (with thick intermediate rubber layer)
200 3.5 3.9 250 400
250 3.7 4.1 250 400
315 3.9 4.3 250 400
CON- 400 12 – 16 4.1 4.6 0.6 – 1.2 315 400
BITEX® 500 4.7 4.8 400 500
630 5.2 6.1 500 500
800 6.3 6.4 630 650
3-ply belts
125 3.1 3.6 250 400
200 3.0 3.2 315 400
250 3.2 3.6 400 400
315 3.5 3.8 400 500
EP 12 – 16 0.6 – 1.2
400 3.8 4.3 500 500
500 4.7 4.6 500 650
630 5.1 6.3 630 800
800 6.9 7.0 800 800
4-ply belts
315 3.8 4.2 400 400
400 4.2 4.7 500 500
500 4.6 5.0 500 500
EP 630 12 – 16 5.0 5.7 0.6 – 1.2 630 650
800 6.2 6.1 800 800
1000 6.8 8.4 800 1000
1250 9.1 9.3 1000 1000
5-ply belts
400 4.7 5.3 500 500
500 5.2 5.9 630 500
630 5.7 6.2 630 650
EP 800 12 – 16 6.2 7.1 0.6 – 1.2 800 800
1000 7.7 7.6 1000 1000
1250 8.5 10.5 1000 1200
1600 11.4 11.6 1250 1200
Further belt constructions available on request

90
D – 4.4.2 Stipulation of tension member – tension member data – Steel cable tension members

D – 4.4.2 Steel cable tension members

Technical data (guide values)

Standard
Nominal Breaking Thickness Tension elongation at
strength in elonga- of tension member mass Min. pulley Min.
10% of min.
splice tion (without cover diameter cover
Type member breaking
(longitu- M or N) (drive pulley) gauge
knomV (belt core) in strength
in mm
dinal) II DTr(A) in mm
in N/mm in %
sZ in mm m in kg/m² (longitudinal)
Z in %

STAHLCORD® to DIN 22 131 specifications and in special versions (Series R 20)

St 500 500 2.9 6.3 500 3
2-3 0.1-0.3
St 630 630 2.9 6.7 500 3
St 800 800 3.6 8.2 630 3
St 1000 1000 4.0 9.6 630 3
St 1120 1120 2-3 4.3 10.1 0.1-0.3 630 3
St 1250 1250 4.8 10.6 630 3
St 1400 1400 4.0 11.2 630 3
St 1600 1600 5.5 13.0 800 4
St 1800 1800 5.5 15.2 800 4
2-3 0.1-0.3
St 2000 2000 5.5 15.8 800 4
St 2250 2250 5.5 16.5 800 4
St 2500 2500 7.1 18.6 1000 5
2-3 0.1-0.3
St 2800 2800 7.1 19.9 1000 5
St 3150 3150 7.9 22.5 1250 5.5
2-3 0.1-0.3
St 3500 3500 8.4 24.0 1250 5.5
St 4000 4000 2-3 8.9 27.0 0.1-0.3 1250 6.5
St 4500 4500 9.6 30.9 1400 7
St 5000 5000 10.7 33.6 1600 7.5
St 5600 5600 2-3 11.2 38.4 0.1-0.3 1600 8
St 6300 6300 12.3 40.9 1600 8.5
St 7100 7100 13.1 47.6 1800 9

STAHLCORD® special versions (Series X)

St 1000 X 1000 3.6 8.7 500 3
2-3 0.1-0.3
St 1250 X 1250 4.0 10.6 630 3
St 1800 X 1800 2-3 4.8 13.2 0.1-0.3 800 3.5
St 2500 X 2500 5.5 16.9 800 4
St 2800 X 2800 2-3 6.1 18.4 0.1-0.3 1000 4.5
St 3150 X 3150 6.1 20.2 1000 4.5
St 3500 X 3500 7.9 22.7 1250 5
St 4000 X 4000 8.4 25.7 1250 6
2-3 0.1-0.3
St 4500 X 4500 8.9 27.9 1400 6.5
St 5000 X 5000 9.6 31.1 1400 7
St 5400 X 5400 2-3 10.7 33.7 0.1-0.3 1600 7.5
Further belt constructions available on request

91
 D – 4.4.3 Stipulation of tension member – Tension member data – Splice dimensions

D – 4.4.3 Splice dimensions

An open-ended belt is generally spliced and part lengths joined together by means of
vulcanization; the belt tensions are then transmitted from one load carrying element to
the other by shearing stresses in the rubber. The tension member is determined with
regard to the durability of the splice (cf. D – 4). The nominal strength in the splice k nomV,
assumed in the designing process, results from the splicing system, since single plies or
cables of the tension member may be butt-jointed. The theoretical strength of any splice
construction (nominal strength k nomV in the splice) can be determined by this means.

Losses in strength, that may arise in the splice and cannot be precisely calculated, are
taken into account in the safety factors applied in the design. These include, for instance,
thermal effects dependent on operating time or fatigue of the rubber between the load
carrying elements. Special core rubber compounds have therefore been developed by
ContiTech for increased safety.

In the case of fabric carcass belts (standard version multiple ply belts) the following
correlation is yielded between the minimum breaking strength of the belt k nom and the
nominal strength k nom bof the splice, k nom being rounded off to the next standardized
strength grade upwards.
z
k nomV ≈ · k nom
z + 1
LVz
z - Number of splice laps LA LS LS

3-ply belt (Two-lap splice)

LVz
LA LS

For CON-MONTEX® and CON-BITEX®

CON-BITEX® (Single-lap splice)
k nomV = k nom

can be set in the case of overlapping or of an additional ply being inserted in the splice
area.
LVz
LA LS

CON-MONTEX® (Splice with overlap)

92
D – 4.4.3 Stipulation of tension member – Tension member data – Splice dimensions

LVz
LS LS LS LVz
LA LS LS
LA

B B

CON-BITEX® (Splice with add. fabric) CON-BITEX® (Interlaced splice)

The strain on the splice is reduced on flexing across idlers and pulleys by means of a
bias with a length of
L A = 0.3 · B
The additional belt length for the splice overlap is thus
L Vz = z · L S + L A
for fabric carcass belts with number of laps z.

The lap length L S depends on the strength of the individual fabric plies.
Splice dimensions in fabric carcass belts
Additional belt
Lap length Number length for overlap
Type
LS of laps z
L Vz in mm
CON-MONTEX® 160/1 200 200
200/1 250 250
250/1 250 250
1 + 0.3 · B
315/1 300 300
400/1 300 300
500/1 350 350
CON-BITEX® Single-lap or Two-lap or
with fabric ply interlaced
200/2 180 180 360
250/2 180 180 360
315/2 180 180 360
400/2 200 200 + 0.3 · B 400 + 0.3 · B
500/2 200 200 400
630/2 250 250 500
800/2 250 250 500
B 200/3 100 200
EP 200/3 100 200
250/3 150 300
315/3 150 300
400/3 200 400
2 + 0.3 · B
500/3 200 400
630/3 250 500
800/3 250 500
1000/3 300 600
1250/3 300 600
B 250/4 100 300
EP 400/4 150 450
500/4 200 600
630/4 200 600
3 + 0.3 · B
800/4 250 750
1000/4 250 750
1250/4 300 900
1600/4 300 900
B 315/5 100 400
EP 500/5 150 600
630/5 200 800
800/5 200 4 800 + 0.3 · B
1000/5 250 800
1250/5 250 1000
1600/5 300 1000
93
 D – 4.4.3 Stipulation of tension member – Tension member data – Splice Dimensions

Nominal strengths for mechanical fasteners, as used mainly in underground mining, are
specified for example in DIN standard 22 109.

Steel cable conveyor belts are spliced by placing the steel cables side by side alter-
nately. There is theoretically no loss of strength in standard versions of these splices as
all cables of one side are joined with cables of the other side by vulcanization of the core
rubber.

k nomV ≈ k nom Splices according to DIN 22 131

Splice with deflection of cables

The thickness of the residual core rubber between the cables is of decisive significance
for the fatigue strength of the splice. The essential minimum thicknesses of the interme-
diate rubber are guaranteed in all events with ContiTech STAHLCORD® conveyor belts
manufactured to DIN 22 131 standard specifications and in special versions.

94
D – 4.4.3 Stipulation of tension member – Tension member data – Splice dimensions

STAHLCORD® conveyor belts too are normally spliced at a bias of

L A= 0.3 · B

Butt joints are permissible too, however, provided that appropriate equipment is avail-
able. DIN standard 22 131 (Sheet 4) furthermore provides for short splicing.
Recommended splice dimensions for steel cable conveyor belts manufactured to DIN 22 131
specifications and in special version (guide values)
Additional belt Min. thickness of
Lap length Number length for overlap intermediate rubber
Type
L S in mm of laps z L Vz in mm in mm
St 500 550 1 550 3.2
+ 0.3 · B
St 630 550 1 550 2.0
St 800 300 1 600 2.3
St 1000 300 1 600 1.9
St 1120 350 1 650 + 0.3 · B 1.7
St 1250 350 1 650 2.1
St 1400 350 2 1000 1.9
St 1600 450 1 750 1.9
St 1800 400 2 1150 3.5
+ 0.3 · B
St 2000 400 2 1150 2.4
St 2250 400 2 1150 1.8
St 2500 500 2 1350 + 0.3 · B 2.5
St 2800 550 2 1450 2.0
St 3150 650 2 1650 + 0.3 · B 1.9
St 3500 650 3 2350 2.6
St 4000 750 3 2650 + 0.3 · B 2.3
St 4500 800 3 2800 2.3
St 5000 900 4 4050 + 0.3 · B 2.7
St 5400 1000 4 4450 2.3
St 6300
St 7100 Splice constructions are designed
to meet the specific circumstances

Other splicing systems are possible

Tests resulting in improved splices have been conducted by ContiTech in order to at-
tain optimum durability of the splice while at the same time minimizing both belt length
required as well as expenditure on operation and equipment. The craftsmanship of the
execution is moreover of decisive importance. Detailed information is given in Section E
of the conveyor belt service manual.

95
 D – 5 Selection of covers

D – 5 Selection of covers

 Cover material.. . . . . . . . . . . . . . . . . . . . . 5.1

 Cover gauge.. . . . . . . . . . . . . . . . . . . . . . . 5.2
Abrasion resistance.. . . . . . . . . . . . . . 5.2.1
Impact resistance.. . . . . . . . . . . . . . . . . 5.2.2
 Special cover structures.. . . . . . . . . 5.3

The main function of covers is to protect the imbedded tension member. To fulfil this re-
quirement the Cover material must offer adequate resistance to any chemical and physi-
cal corrosive action. Rubber compounds and possibly synthetics can be adapted within
broad limits to the specific demand by an appropriate composition or recipe. Cover
materials accordingly have varying principal components.
Principal components of rubber materials
Standard
international Type of rubber
symbol
NR Natural rubber
SBR Styrene butadiene rubber
CR Polychloroprene rubber
NBR Nitrile rubber
IIR Butyl rubber
BR Cis-Polybutadiene rubber
SIR Silicone rubber
EPDM Ethylene propylene terpolymer rubber

The covers of a conveyor belt must be sufficiently thick to withstand gradual wear even
for long periods and to protect the tension member from mechanical injury. Moreover,
the steel cable tension member in particular requires certain minimum cover thicknesses
in order to ensure secure imbedding of the cable ends in the splice area. The covers can
also be specially dimensioned to attain a certain transverse rigidity.

96
D – 5 Selection of covers

The conveyor belt can be adapted to special tasks, e. g. on uphill transport, by means
of patterned or cleated cover surfaces. In cases of extreme strain, transverse fabric or
steel cable reinforcements can be incorporated into the covers to increase impact resist-
ance to a certain extent. ContiTech also supplies steel cable conveyor belts permitting
an electronic slit monitoring system to be used by means of conductor loops imbedded
in the covers.
Basic properties of elastomers
Symbol
Property
NR SBR CR NBR IIR BR
Tensile strength (N/mm2) > 21 >15 > 21 > 14 > 14 >5
Hardness (Shore A) 40-90 40-90 40-95 40-95 40-95 45-80
Tear resistance good moderate good moderate moderate good
Abrasion resistance good very good good good moderate excellent
Resilience very high medium medium medium moderate very good

Resistance to
diluted acids good good good mod. to excellent good
good
concentrated acids mod. to mod. to good moderate excellent moderate
good good
aliphatic hydrocarbons poor poor moderate excellent poor very poor
aromatic hydrocarbons poor poor poor good poor very poor
ketones good good poor poor good good
lacquer solvents poor poor poor moderate poor poor
lubricating oils poor poor moderate very good poor poor
oil and petrol poor poor moderate excellent poor poor
animal and veg. oils poor poor good excellent poor poor

Resistance to
water absorption good good to good mod. to very good good
very good good
oxidation moderate good excellent good excellent moderate
ozone moderate moderate excellent moderate excellent moderate
sunlight poor poor good poor very good moderate
combustion poor poor good poor poor poor
high temperatures moderate good very good very good excellent good
low temperatures excellent good moderate good good excellent

The chemical and physical properties cannot usually be affected independently of each
other, so that any rubber material has certain features due to the components used.

97
 D – 5.1 Selection of covers – Cover material

D – 5.1 Cover material

The basic qualities or essential properties are stipulated in corresponding standard

specifications (DIN) and are accordingly identified by letters.
Code letters
Steel cable belts Fabric carcass belts
Property (DIN 22 131) (DIN 22 102)
noninflammable F
antistatic E
noninflammable an antistatic K S
self-extinguishing and antistatic V
resistant to high temperatures T
resistant to low temperatures R
resistant to oil and grease G
belts for foodstuff A
belts for chemical products C
belts with fixed mechanical parameters W, X, Y W, X, Y, Z
special qualities X

The mechanical parameters stated in the standard specifications are far exceeded in
part by corresponding ContiTech Cover materials.

Cover material K W X Y Z
Tensile strength,
≥ 20 ≥ 18 ≥ 25 ≥ 20 ≥ 15
longitudinal in N/mm2
Breaking elongation ≥ 400 ≥ 400 ≥ 450 ≥ 400 ≥ 350
longitudinal in %
Abrasion in mm3 ≤ 200 ≤ 90 ≤ 120 ≤ 150 ≤ 250

98
D – 5.1 Selection of covers – Cover material

Properties of Continental Cover materials most widely used (guide values)

Code Admissible temperature** in °C
Density Resistant
letter ContiTech quality Sustained Peak Tension
ρ in Suitability to oil and Colour Polymer
to DIN designation load load member
kg/dm3 grease
standard min max min max
X ATRB 1.09 general conveying -50 +60 -55 +70 no any type black NR
(peak requirements)
Y Conti extra 1.13 general conveying -30 +60 -35 +70 no any type black NR/SBR
Y NQ 1,1 general conveying -30 +60 -35 +70 no any type black SBR
*** ContiClean® 1.12 cases of heavy soiling -50 +60 -55 +70 no any type black BR/NR
(dirt repellent) (with high moisture
content)
Y ContiClean® Transport of desul- -40 +60 -45 +70 no any type black SBR
phurised gypsum
S, K FW (non- 1.38 underground and surface – +60 – +70 no any type black SBR
inflammable)
V V (self- 1.42 underground mining – +100 – +110 to some fabric black CR
extinguishing) 1.60 (most stringent degree only
safety regulations)
S, T VULKAN spezial 1.39 hot materials -30 +110 -30 +130 to some any type black CR
(non-inflammable) with glowing embers degree
T VULKAN T 190 1.13 hot materials -30 +130 -40 +150 no any type black SBR
T, C* VULKAN T 200 1.05 hot materials, also resis- -30 +180 -40 +200 no fabric black EPDM
tant to acid and alkali only
T TCC 1.2 hot materials -30 +180 -30 +200 no any type black CR/IIR
G OIL 1.19 oily or greasy materials -15 +100 -20 +125 yes any type black NBR
G OIL GY 1.17 oily or greasy materials -10 +70 -20 +90 yes fabric black NBR
only
G ATBX 1.13 oil sand handling -50 +60 -50 +70 yes any type black NBR
A OIL GA 1.21 foodstuffs -10 +120 -15 +140 yes fabric white NBR
(in oily, greasy or extreme only
temperature conditions)

Further Cover material and data on request.

* For application under chemical reactions we recommend detailed

consultation with our Application Technique Department.
** The temperature specifications refer to the conveyor belt. The carrying capacity also
depends on the nature of the temperature effect (see WdK guidelines, No. 339).
*** ContiClean® is a special quality with good operative properties.
99
 D – 5.2 Selection of covers – Cover gauge

D – 5.2 Cover gauge

The factor to be ascertained when determining the cover gauge is the minimum thick-
ness of the cover layers on the top and bottom of the belt. This can be taken for
STAHLCORD® conveyor belts from the relevant tables (cf. D – 4.4.2). In the case of
fabric carcass belts the minimum thickness depends on the structure of the fabric and
is between 1 and 2 mm. A rubber cover may be dispensed with completely in special
applications, e. g. in belts for sliding bed operation.

An additional amount beyond the minimum thickness is to be provided as a wearing

cover, depending on the operating conditions and the abrasive properties of the mate-
rial conveyed.

Additional (wearing) cover thicknesses on the top of conveyor belts

Properties of bulk
Loading conditions Loading frequency material conveyed
GRANULAR SIZE
fine medium coarse
frequent on short systems with
unfavourable with high relative DENSITY
low belt circulation time and
speeds, undamped drops primarily continuous operation light medium heavy
and extreme capacities or high estimated belt service life
aggressiveness
low moderate high
unfavourable frequent 3-6 6 - 10 > 10
moderate moderate 1-3 3-6 6 - 10
favourable infrequent 0-1 1-2 3-6

The cover gauges of STAHLCORD® conveyor belts can be selected asymmetrically. An

asymmetric version results when a greater cover thickness has to be provided on the top
to counteract the wear to be expected. If fabric carcass belts are to have asymmetrical
cover gauges, the top: bottom ratio s 2/s 3 should not exceed 3/1. If the differences in
the thicknesses of the covers are too great, then the natural shrinkage of the rubber after
being vulcanized can lead to harmful tensions in the belt.

100
D – 5.2.1 Selection of covers – Cover gauge – Abrasion resistance

D – 5.2.1 Abrasion resistance

The cover abrasion caused by the material handled at the feeding point can be allowed
for approximately if data on the abrasion occurring are available from first-hand knowl-
edge or if values can be assessed with adequate accuracy.

Extensive investigations, in which numerous thickness gauging were made on ContiTech

conveyor belts with highly abrasion-resistant covers, yielded empirical abrasion values
related to 100 000 revolutions of the conveyor belt and based on the following classifica-
tion of the material conveyed and the feeding conditions:
Material conveyed Feeding conditions
grain size 0-50 mm; high pro- up to 50 cm fall; low relative speed;
Grade 1: portion of fine material; low unit Favourable: cushioned bulk material feed; additional
weight; minimum abrasion abrasion-reducing measures
grain size 50-150 mm; standard 50 to 250 cm drop; medium relative
Grade 2: grain size distribution; medium unit Standard: speed; optimum bulk material control
weight
grain size 150-400 mm; sized over 250 cm fall; high relative speed;
Grade 3: material; high unit weight; sharp Unfavourable: no cushioning and steering measures
corners; aggressive

Applications are naturally conceivable in which single criteria from different groups or
grades are applicable. In such cases the influences are to be weighed up.
Guide values s w in mm abrasion, related to 100 000 belt revolutions
Material conveyed
Feeding conditions
Grade 1 Grade 2 Grade 3
favourable 0.4 0.6 1.4
standard 0.8 1.4 2.4
unfavourable 1.6 2.6 4.0

The necessary cover gauge s 2 on the top results with s w from an approximation
formula
3.6 · v ·s W ·t
s 2 ≥ min. cover gauge + in mm
200 · L

whereby
v – conveying speed in m/s
sW – abrasion in mm (related to 100 000 revolutions)
t – planned operating period in hours
L – centre distance in m

The belts of conveying systems with very short centre distances and high conveying
speeds (e. g. belts for heavy mining equipment) are subject to extra heavy wear and
therefore attain in general a relatively short operating period, resulting from the cover
gauge that is technically still feasible. ContiTech application engineers will be pleased to
give advice on such matters.

101
 D – 5.2.2 Selection of covers – Cover gauge – Impact resistance

D – 5.2.2 Impact resistance

A thicker cover makes an essential contribution to increased impact resistance in the

range of minor drop energies and shorter edge lengths up to 400 mm. This can be
confirmed by laboratory tests.
Impact energy at penetration (St-Belt) in kN

Cover gauge (s 2+ s 3) in mm

Greater cover gauges are recommended particularly for steel cable belts handling coarse-
grained or sharp-edged material of dimensions approaching that of the cable pitch. Rec-
ommendations for cover gauge selection can be provided by test results and by practical
experience.
powdery material
coal
sandy material
crushed hard stone
loose stone
unbroken hard stone
Belt width in mm
30 3200
28 3000
26 2800
24 2600
22 2400
20 2200
18 2000
16 1800
14 1600
12 1400
10 1200
8 1000
6
4
Guide values of cover gauges for steel cable conveyor belts (top cover) in mm
102
D – 5.3 Selection of covers – Special cover structures

D – 5.3 Special cover structures

Besides conveyor belts with smooth covers, ContiTech offers special-purpose versions
for specific applications. These include conveyor belts with patterned or cleated sur-
faces.

Patterned or cleated covers

Available belt Tension
Type Suitability Covers
width B in mm member
Bulk material and piece All qualities apart
Conveyor belt with Fabric, goods; improvement in
100 to 1200 from PVC top at
herringbone pattern at least 2 plies max. conveying angle by least 2 mm
approx. 5°
3-roll troughing for steep
angle transport of bulk ma-
terials and piece goods (up ATRB, Conti extra,
to approx. 30°) and grain ContiClean®, OIL GY,
Belt with chevron Fabric, sizes up to 50 mm FW, VULKAN T 150,
400 to 1200
cleats at least 2 plies 2-roll troughing for steep top at least 2 mm,
angle transport of bulk bottom at least 1
materials (up to approx. mm
30°) and grain sizes up to
150 mm
Conveyor belt with Fabric,
1 wedge guide on to 1400 at least 2 plies Short, wide belts on con-
top cover All qualities apart
veying systems with prob-
Conveyor belt with from PVC
Fabric, lematic tracking properties
1 wedge guide on 1400 to 2800 at least 4 plies
top cover

For further data and other types for steep angle conveying, elevators and piece goods conveyors,
cf. D – 6, D – 7 and D – 8.

103
 D – 5.3 Selection of covers – Special cover structures

The covers can be provided with special plies to improve loading properties. Transverse
reinforcements primarily increase impact resistance but also contribute to increased longi-
tudinal slit resistance.
↓ Start of damage

↑ Start of penetration
CONTI-CROSS T/T
CONTI-CROSS T
CONTI-CROSS S/S
without transverse reinforcement
100 120 140 Drop energy in %
780 (for St 1600-10/5) in Nm

Transverse reinforcements of covers

Type Transverse reinforcement Arrangement Tension member
Textile cord on one side STAHLCORD
CONTI-CROSS T (Polyamide) (top or bottom) (all types)
Textile cord STAHLCORD
CONTI-CROSS T/T on both sides
(Polyamide) (all types)
STAHLCORD-
CONTI-CROSS S/S Steel strands on both sides special purpose types
Fabric on one side (top)
Breaker Fabric carcass
(Polyamide) or on both

As an alternative ContiTech supplies STAHLCORD® conveyor belts with conductor loops

vulcanized into the bottom cover and forming an electronic slit warning system in con-
junction with a transmitter and a receiver. If a conductor loop is broken by any slitting,
the conveying system is stopped due to the modified signal picked up by the receiver,
so that the extent of the slit damage is restricted. Detailed information on the arrange-
ment, function and maintenance of the conductor loops is obtainable from ContiTech‘s
Application Technique Advisory Service.

104
D – 6 Steep angle conveyor belts

D – 6 Steep angle conveyor belts

 Chevron cleated belt. . . . . . . . . . . . . . 6.1

 Box section belt.. . . . . . . . . . . . . . . . . . . 6.2
Conveying capacity.. . . . . . . . . . . . . . . 6.2.1
Constructions data.. . . . . . . . . . . . . . . 6.2.2
 Fin-type belt and
belt with bonded partitions.. . . . . . 6.3

Conveying systems with steep angle belts are calculated and designed in principle in
the same way as belt conveyors equipped with conventional belts and thus suitable for
maximum gradients of approx. 20°.

Variations arise, however, in the determination of the Conveying capacity of belts fitted
with high cleats and consequently suitable for gradients of up to 70°.

Overfilling
Basis filling

The theoretical volume capacity Q Vth is influenced by the section spacing t Q and the
height h Q of the cleats. With the basic spacing
hQ
tg = in mm
tan ( δ - β)
the volume capacity results from the basic filling and the overfilling (cf. D – 6.2.1). The
Conveying capacity is increased for t Q < t g.
Conveying capacity increase in %
t Q /t g 0.5 0.75
increase by approx. 50% approx. 25%

For fine grained materials the section spacing t Q should be selected between 200 and
500 mm. For coarse bulk materials a section spacing t Q of at least 1.5 to 2 x the maxi-
mum edge length is recommended.

105
 D – 6 Steep angle conveyor belts

The belt velocities are to be stipulated with regard to feeding conditions, to the graining
of the material conveyed and to the conveying angle. The feed should be effected centri-
cally in the conveying direction and the material fall kept as low as possible.
Velocities for steep angle conveyor belts in m/s (guide values)
Grain size (edge length)
Gradient 0-50 mm 50-150 mm 150-300 mm
up to 35° up to 2.0 up to 1.6 up to 1.3
35°-50° up to 1.6 up to 1.3 up to 1.0
50°-70° up to 1.0 up to 0.8 up to 0.6

Power requirements and drive tractions can be calculated with sufficient accuracy as for
ascending conveyor systems. As the gradient is generally steeper, however, the primary
resistance is reduced in contrast to a horizontal system. The majority of the motional
resistances are usually formed by the gradient resistance F St.

One common feature of all steep angle conveyor belts is that their partitioning prevents
them from being cleaned by scrapers. When viscous or heavily caking material is being
handled, soiling of the system by the returning side has to be expected.

106
D – 6.1 Steep angle conveyor belts – Chevron cleated belt

D – 6.1 Chevron cleated belt

The ContiTech chevron cleated belt is a steep angle belt with 15 mm high chevron cleats
pressed out of the Cover material, sidewalls and 55 mm wide, plain borders permitting
chuting at the feeding point.

The theoretical volume capacity can be determined from the table for conventional belt
troughings or read off from the diagram below.

Theoretical volume flow

Q Vth in m 3/h
400

350 Example
for v = 1m/s and
15 ˚ angle of repose
300 Gradient of flight 30 ˚
250
2-part / 45 ˚ troughing
200 3-part / 30 ˚ troughing
4-part / 20 ˚ troughing
150

100

50

400 500 650 800 1000 1200

Belt width B in mm

Technical data for chevron cleated belts *

Fabric, at least 2 plies
Tension member (STAHLCORD tension members on application)
ATRB
Conti extra
Cover material ContiClean®
(cleats are of the same material) OIL GY
FW
VULKAN T 150
Top cover 2.0 mm
Minimum cover gauge Bottom cover 1.0 mm
Cleat spacing 192 mm
Cleat length 80 mm
Cleat width 8 mm
Belt mass allowance for cleats Corresponding to 1 mm additional cover thickness
400 mm
500 mm
650 mm
Widths available 800 mm
1000 mm
1200 mm
up to 2400 mm on request
250 mm
Minimum pulley diameter (minimum pulley of selected tension member to be observed)

* A significantly expanded product range with a profile height of 10 – 35 mm is in part

available ex stock. (Please ask for special documentation)
107
 D – 6.2 Steep angle conveyor belts – Box section belt

D – 6.2 Box Section Belt

This ContiTech steep angle conveyor belt is available under the designation

CONTIWELL® / MAXOFLEX®

in various dimensions and designs, thus offering optimum adaptation to any application.

The sidewall belt consists of an untroughed conveyor belt with corrugated sidwalls
mounted longitudinally and lateral profiles mounted between the sidewalls with certain
spacing.

The corrugated sidewall is distinguished by high ductility, permitting relatively small pul-
ley diameters and deflection radii. The high lateral stability of the corrugated sidewall
permits the return run to be supported on straight idlers.

108
D – 6.2 Steep angle conveyor belts – Box section belt

Dimensions of the corrugated sidewall and technical data

Type
Dimensions in mm
W 63 W 80 W 125 W 160
Corrugated sidewall height h K* 60 80 125 160
Base width b F 60 80
Corrugation depth b W 37 46 52 62
Corrugation pitch t W 60 70
Minimum pulley diameter (to suit tension member) 200 315
Sidewall mass in kg/m (approx.) 1.25 1.5 2.5 3.2

For gradients of up to approx. 20°, corrugated sidewalls can be used in conjunction with
an untroughed belt, even without transverse partitions. This provides a considerable in-
crease in conveying capacity as compared with a flat belt (cf. D – 2.5). The effective belt
width beif results in the same way as for a CONTIWELL® box-section belt.

The corrugated sidewall can be supplied in various rubber qualities adapted to the
special cover compounds and offering simultaneously optimum flexibility.

Corrugated sidewall types

Maximum Tension member
Application ContiTech cover
temperature (with transverse rigidity)
general conveying
8 60 °C Conti extra any type
(antistatic < 3 · 10 Ω )
handling of hot materials 90°C VULKAN T 150 any type
handling of hot materials (oil-resistant) 90°C VULKAN spezial any type

Belts with fabric plies (at least 3 plies) or STAHLCORD® tension members can be used,
depending on the required tensile strength.
B – cotton
EP – polyester/polyamide
St – STAHLCORD®

If the system is designed with bends in the flight routing (cf. D – 6.2.2), it should be borne
in mind that the deflection and transmission of the belt tensions are effected first and
foremost in the idler-supported or pulley supported plain edge zones, as the belt can be
supported only partially by the corrugated sidewalls.

* MAXOFLEX® sidewalls with a profile height of 40 – 400 mm are in part

available ex stock. (Please ask for special documentation)
109
 D – 6.2.1 Steep angle conveyor belts – Box section belt – Conveying capacity

D – 6.2.1 Conveying capacity

The belt gradient and the coarsest grain size of the material conveyed are to be taken
into account when selecting a CONTIWELL® box-section belt from the types available.
Guide values for the admissible grain size (max. edge length) in mm
Gradient
Type
up to 35° 35° – 50° 50° – 70°
WK 63 120 90 60
WK 80 150 120 80
WK 125 200 150 100
WK 160 300 220 120

The theoretical volume capacity Q Vth can be calculated with transverse partition interval
t Q and basic spacing t g (cf. D – 6). For t Q ≥ t g is

h Q ·b eff ·t g
Q Vth = ·v ·3600 in m3/h
2 tQ

The Conveying capacity can be estimated by reading off the volume capacity from the
diagrams below.

Theoretical volume flow for v = 1 m/s and 100 mm effective belt width
QVth in m3/h QVth in m3/h

WK 63 WK 80
Angle of repose β Angle of repose β
ca. 20 º ca. 20 º

Gradient of flight δ Gradient of flight δ

QVth in m3/h QVth in m3/h

WK 125 WK 160
Angle of repose β Angle of repose β
ca. 20 º ca. 20 º

Gradient of flight δ Gradient of flight δ

110
D – 6.2.2 Steep angle conveyor belts – Box section belt – Constructional data

D – 6.2.2 Constructional data

CONTIWELL® box-section belts can be guided through extremely narrow transition

curves and thus adapted to almost any routing.
Support in top run

Bend Drive pulley

minimum belt spacing is
R ≥ DTr diameter of pulley (a ≤ 180º)

DTr
Idlers on
separate bearings

Tail pulley
minimum belt spacing is
diameter of pulley (a ≤ 180º) Belt width B

Belt width B

Idlers on
separate bearings

Belt width B

Supporting methods Supporting methods

in the return run in the bend
Approximate values for construction data
non-profiled border dis-
Sidewall Idler diameter Idler diameter Idler width Idler width border zone zone tance
height D 1 in mm D 2 in mm B1 B 2 in mm b 1 in mm b2 b3
hk [mm] B≤650 B>650 B≤650 B>650 in mm B≤650 B>650 B≤650 B>650 in mm in mm
60 140 240 270 370 55 50 70 65 85 7,5 30
80 140 240 310 410 55 50 70 65 85 7,5 30
125 140 240 410 510 70 60 80 75 95 7,5 30
160 140 240 480 580 70 60 80 75 95 7,5 30
In this case 2 · (b 1 – 10) mm is to be deducted from the service width b eff.

The minimum admissible pulley diameters or deflection radii are normally determined
by the tension member. For belt guidance through concave curves, CONTIWELL® box-
section belts are available in special versions with plain borders.

111
 D – 6.2.2 Steep angle conveyor belts – Box section belt – Constructional Data

Belt widths and partition layouts (without plain borders)

Effective belt width
Length and mass of transverse partitions (standard quality)
Belt width* B beff in mm
Type
in mm WK 63 WK 80 WK 125 WK 160
WK 63/80 WK 125/160
(hQ = 50 mm) (hQ = 70 mm) (hQ = 110 mm) (hQ = 145 mm)
260 mm 260 mm 220 mm 220 mm
400 300 280
0.25 kg 0.35 kg 0.7 kg 0.8 kg
360 mm 360 mm 320 mm 320 mm
500 400 380
0.3 kg 0.5 kg 1.0 kg 1.2 kg
510 mm 510 mm 470 mm 470 mm
650 550 530 Single compartment 0.45 kg 0.7 kg 1.45 kg 1.75 kg

The top run and return run of CONTIWELL® box-section belts can normally be sup-
ported on straight idlers. The idler diameter and spacing can be selected for the top run
as for conventional systems.
Guide values for idler selection
Idler spacing Idler diameter
Top run in m in mm
0.8 up to 1.25 89 up to 159
Gradient
Return run*** 20° – 35° 35° – 50° 50° – 70° ≥ 89
1-part
≤ 1.0 ≤ 1.2 ≤ 1. 5

In the case of special types, it may be necessary to provide smaller idler intervals or to
take special steps to support the belt, depending on the gradient of the system, the
weight of the belt and the type of corrugated sidewalls used. Our department responsi-
ble for conveyor belt application will be pleased to advise you in this matter.

* Greater widths available on request

*** In the case of types combining a greater belt width the given sectioning (single compart-
ment) or having an extremely heavy tension member, the idler spacings are to be checked.
112
D – 6.3 Steep angle conveyor belts – Fin-type belt and belt with bonded partitions

D – 6.3 Fin-type belt and belt with bonded partitions

As an alternative to the Contiwell® box-section belt, conveying systems operating at

steep angles can also be equipped with fin-type or partitioned belts. On the one hand
their flexible dimensioning allows them to be used for wide range of applications in gen-
eral, whereas the hard wearing transverse cleats fitted to these types of belt also make
them highly suited to heavy-duty operating conditions in particular.

Fin-type belts are suitable for handling medium to coarse sized bulk materials at steep
angles. The top run can similarly be troughed using dual fins. The return run of the belt
is supported on disc idlers.

Theoretical volume flow at 1 m/s

QVth in m3/h QVth in m3/h

Fin-type belt
Fin-type belt 3-part
3-part 1000 mm wide
1000 mm wide
Fin spacing 330 mm
Fin spacing 330 mm Fin height 200 mm
Fin height 133 mm Trough angle 30 º
Trough angle 20 º

Angle of Angle of
repose β repose β

Gradient of flight δ Gradient of flight δ

Belt on return run

Design data (guide values) in mm

Belt width mm A B c d H
1000 330 225 50 60 133
1200 415 280 50 62,5 133
1400 480 350 50 60 133
1000 320 200 60 80 200
1200 405 255 60 82,5 200
1400 470 325 60 80 200

The width of the plain zones c and d can be enlarged if necessary.

Minimum pulley diameter
400 mm for a fin height of 133 mm
630 mm for a fin height of 200 mm

113
 D – 6.3 Steep angle conveyor belts – Fin-type belt and belt with bonded partitions

Partitioned belts operate in a non-troughed (flat) state and are guided on the top run
between fixed skirtings provided with sealing strips of rubber.

Theoretical volume flow at 1 m/s and 100 mm effective belt width

QVth in m3/h QVth in m3/h
Partitioned belt
Partition spacing 330 mm
Partitioned belt
Partition height 133 mm Partition spacing 330 mm
Partition height 200 mm

Angle of
Angle of
repose β
repose β

Gradient of flight δ Gradient of flight δ

Design data (guide values) in mm
Partition height 133 mm Partition height 200 mm
useful useful
B a b c d B a b c d
belt width belt width
400 280 60 – – 280 400 240 80 – – 240
1-part 500 380 60 – – 380 500 340 80 – – 340
650 240 60 50 – 530 650 215 80 60 – 490
2-part 800 315 60 50 – 680 800 290 80 60 – 640
1000 330 60 50 225 880 1000 320 80 60 200 840
3-part 1200 415 62.5 50 280 1080 1200 405 82,5 60 255 1035
1400 480 60 50 350 1280 1400 470 80 60 325 1240
The width of the plain zones b and c can be enlarged if necessary.
Technical data
Height of partitions mm 133 Height of partitions mm 200
Spacing of partitions mm 330 Spacing of partitions mm 330
Minimum pulley diameter mm 400 Minimum pulley diameter mm 630
Maximum gradient of flight 60 Maximum gradient of flight 60
Suitable for bulk materials of Suitable for bulk materials of
mixed lump sizes with a mixed lump sizes with a
diameter of up to mm 250 diameter of up to mm 350

Further details on belt applications and system design can be taken from a special
publication.

114
D – 7 Elevator belts

D – 7 Elevator belts

 Conveying capacity.. . . . . . . . . . . . . . . 7.1

 Power requirement
and drive tractions.. . . . . . . . . . . . . . . . 7.2
 Selection of bucket elevator belt. 7.3
Tension member.. . . . . . . . . . . . . . . . . . 7.3.1
Covers.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2
Buckets and attachments.. . . . . . . . 7.3.2

Belts are finding extensive application as traction elements for bucket elevators, and
here to an increasing extent elevator belts with STAHLCORD® tension members. Belt-
type bucket elevators have many advantages over chain bucket elevators, whose
significance is diminishing. One essential factor is the quiet, low-vibration operation that
permits higher conveying speeds and thus a considerably improved performance. The
development of high-strength belts with fabric or cable cord tension members means
that conveying heights of 150 m and more now present no insuperable problems.

Decisive advantages are reduced power requirements and a considerable reduction in

maintenance expenditure. The following section is intended to help the designer and the
user to ascertain the range of applications offered by ContiTech elevator belts for bucket
elevators by means of a rough layout. As most instances are single conveying systems
with special features, we recommend detailed consultation with ContiTech‘s Conveyor
Belt Application Department.

115
 D – 7.1 Elevator belts – Conveying capacity

D – 7.1 Conveying capacity

The theoretical capacity Q mth results from

3.6 · V Be · ρ ·v
Q mth = · φ in t/h
t Be

V Be bucket volume in litres

ρ bulk density of material conveyed in in t/m3
v belt velocity in m/s
t Be bucket spacing on belt in m
φ average degree of fill

Greater Conveying capacity can also be achieved by using a multiple-row arrangement

for the buckets. In this case. the theoretical capacity is taken from the sum of bucket
volumes.
Guide values
Bucket spacing
Type and Example of Shape and volume
Average Belt velocity v tBe (h1 = rear
properties material material of buckets VBe to degree of fill in m/s
conveyed conveyed height of bucket)
DIN specifications in m
fine, flour, DIN 15 231
light material semolina, DIN 15 241 0.75-0.9 0.7-1.3 (1.5-2.0) x h1
coarse meal “flat”
light granule cereals, DIN 15 232
material oil seeds, DIN 15 242 0.75-0.9 1.2-2.5 (3.0) (1.3-1.5) x h1
pulses “with flat bottom”
viscous material cane sugar, DIN 15 233
wet fine coal, DIN 15 243 1.0-1.2 1.0-1.5 2.0 x h1
damp soil “medium deep”

heavy pulverized sand, DIN 15 234

to coarse lumps cement, DIN 15 244 0.6-1.0 1.0-1.6 (1.4-2.0) x h1
raw meal, “deep”
coal
easy flowing or light ashes, DIN 15 235
rolling material potatoes DIN 15 245 0.7-0.8 1.2-1.6 (1.3-1.8) x h1
“deep, back
wall curved”

The essential data are reproduced in Section D – 7.3.4 as an example of deep buckets
complying with DIN standard 15 234 or of corresponding ContiTech rubber buckets. The
data for other bucket designs can be inspected in the relevant standard specifications or
obtained from the manufacturer.

116
D – 7.2 Elevator belts – Power requirement and drive tractions

D – 7.2 Power requirement and drive tractions

The power requirement P Tr of a bucket elevator at the drive pulley results approximately
from the lifting capacity with the capacity Q m
Qm · g · H
P St = in kW
3600

and the ratings

PS for scooping
P leer for resistances in no-load operatoin
Pz for unusual influences such as batched feeding

P Tr = P St + P S + P leer + P z

Apart from the primary component of the lifting capacity, it is the scooping capacity, par-
ticularly with lumpy material, that represents a significant component. An empiric formula
can be applied to determine this.
Qm · Ks · Es
Ps = in kW
3600
Q m in t/h

Guide values for Ks and Es are to be taken from the diagrams below.

Scoop factor Ks Specific scoop work done Es in Nm/kg

Material Bulk density Grain size
Curve
handled in t/m3 in mm
Portland
1 cement
1.2 ca 0.05
2 Cereals 0.74 2...5
3 Sand, gravel 1.5 2...10
Cement
4 clinker
1.25 5...20
Hard coal,
5 single nuts
0.75 10...30

Bucket projection
a in mm

0 0.2 0.4 0.6 0.8 1.0 0 0.5 1.0 1.5 2.0

Bucket sequence tBe/V in s Belt speed v in m/s

1 to 5 kW are to be set for no-load rating P leer depending on bucket width, whereas up
to 7 kW must be allowed for additional rating P z in unfavourable cases.

The calculation of the maximum drive traction must initially be based on an estimated
mass m GI , of the elevator belt; this may need to be adjusted later. The diagram in Sec-
tion D – 3.1.2 can serve as a basis for the estimate. The belt width can be presupposed
as approx. 1.1 x bucket width.

117
 D – 7.2 Elevator belts – Power requirement and drive tractions

Guide values for bucket masses m Be are stated in Section 7.3.4 or can be taken from
the relevant standard specifications, resulting in

(
T 1 = T v +H ·g · m GI +
m Be
t Be
) + 1000v ·P Tr
in N

In order to transmit the peripheral force to the drive pulley, which is generally located at
the top in the case of a bucket elevator, a belt tension T 2 is required; this is generated
by the dead weight of the leaving side, the weight of the tail pulley and any additional
tensioning force F v be applied.
If

(
H · g m GI +
m Be
t Be
) +
m Tr ·g
2
<
1000 ·P Tr
v
( 1
e μα -1
)
with the mass mTr of the tail pulley, a dead load or take up screw tension must be applied in addition.
Fv
2
=
1000 ·P Tr
v
( e μα -1 ) -H · g ( m
1
I
G+
m Be
t Be
) - m 2 ·g
Tr
in N

In this case the belt tension

m Tr ·g Fv
Tv = + in N
2 2
Guide values for the mass mTr of tail pulley in kg
Pulley width in mm
Pulley diameter in mm
120 250 350 450 550 650 750 850
315 16 25 38 42 48 54 60 66
400 21 33 45 61 69 77 85 93
500 29 47 69 75 83 93 103 113
630 35 57 90 115 132 148 164 180
800 46 79 124 160 190 210 230 250

Power transmission at the drive pulley of bucket elevators is effected in accordance

with the same laws as with belt conveyors. Further details are therefore omitted at this
point.
118
D – 7.3 Elevator belts – Selection of bucket elevator belt

D – 7.3 Selection of bucket elevator belt

Apart from the maximum belt tension, there are numerous other factors determining the
selection of the belt. The belt must permit the buckets to be fastened completely satisfac-
torily, so that a minimum of 4 plies is recommended in fabric carcass belts. The belt must
furthermore permit durable splicing, a factor of special significance in bucket elevators for
safety reasons. Apart from the vulcanized splice, there are reliable mechanical fasteners.

Application features for elevator belts

Belt Type of splice Operating conditions
St 1000 to St 2000 Vulcanized splice for high to Ideal for all operating conditions and
belt tensions and normal applications ranging from low capacities
operating temperatures; other- to heavy-duty bucket elevators
wise mechanical fastener
EP 500/4 to EP 1600/5 Vulcanized splice; For low to medium capacities:
mechanical fastener for very
high operating temperatures fine material: EP 500/4 (drop charging)
EP 630/4 (scooping))

coarse material: EP 630/4 (drop charging)

EP 800/4 (scooping))

119
 D – 7.3.1 Elevator belts – Selection of bucket elevator belt – Tension member

D – 7.3.1 Tension Member

The tension member of elevator belts is constructed in the same way as that of belts for
conveying systems. The essential properties and main features are thus comparable and
can be taken from the corresponding sections (D – 4.4).

The necessary nominal strength k nomV of the tension member can be ascertained with
reference to a standard safety factor S for bucket.
T1
k nomV = ·S in N/mm
B
The safety factor S also covers the starting process, the assumption being made that
a hydraulic starting clutch is installed in cases of higher power requirements. Calcula-
tions for versions with bucket-attachment perforations must be based on a higher safety
factor S due to the reduction in strength.
Safety factor S (guide values)
Operating temperature
Tension member
≤ 60°C 80°C 100°C 120°C 140°C
Fabric 8 9.5 – – –
(with vulcanized bucket attachments)
Fabric 9-10 11.5 12 13.5 14
(perforated version)
STAHLCORD® 8 8 – – –
(with vulcanized bucket attachments)
STAHLCORD®
9-10
(perforated version)

120
D – 7.3.1 Elevator belts – Selection of bucket elevator belt – Tension member

Minimum pulley diameter for customary bucket elevator belts

Drive pulley diameter
in mm with belt strength utilization of Tail pulley
Type diameter in mm
60 - 100% < 60%
EP 500/4 500 400 400
EP 630/4 630 500 500
EP 800/4 630 500 500
EP 1000/4 800 630 630
EP 1250/4 800 630 630
EP 800/5 800 630 630
EP 1000/5 800 630 630
EP 1250/5 1000 800 800
EP 1600/5 1000 800 800
St 1000 630 500 500
St 1250 800 630 630
St 1600 1000 800 800
St 2000 1000 800 800
Other types available on application

The pulley diameters for bolted attachment generally correspond to those for conveyor
belts in the respective fabric or STAHLCORD® construction. Elevator belt tracking may
be improved by cambering the drive pulley.
Cambering* h for fabric carcass belts
Pulley diameter in mm
Pulley width in mm
< 125 140/160 180/200 225/250 >280
400 1.0 1.2 1.2 1.2 1.2
500 1.0 1.5 1.5 1.5 1.5
630 1.0 1.5 2.0 2.0 2.0
800 1.0 1.5 2.0 2.5 2.5
1000 1.0 1.5 2.0 2.5 3.0

The camber should always be executed as an arc. A maximum camber of 2 mm is

admissible for STAHLCORD® elevator belts. If screw strips or flat irons let into the cover
are used for bucket attachment, these elements must be divided, owing to the camber
of the pulley.

* According to provisional figures in ISO/DIS 5286, which applies to conveyor belts in

general, the maximal crowning h should be less than h < 0.005 · DTr/2.
Also no crowning is permissible for steel cable conveyor belts.
121
 D – 7.3.2 Elevator belts – Selection of bucket elevator belt – Covers

D – 7.3.2 Covers

Elevator belts are not subjected to direct wear by the material handled, so that fabric car-
cass belts may be used without covers for subordinate purposes. In general, adherence
to certain minimum cover gauges is to be recommended, the bottom covers (pulley side)
usually being thicker than those of the top (bucket side).
Cover material selection
ContiTech Property Tension
quality designation member
Conti extra Suitable for any standard requirements, any type
antistatic < 3 ·108 Ω,
temperature resistant up to 60°C
VULKAN spezial Temperature resistant up to 110°C any type
conditionally oil-resistant and noninflammable
VULKAN T 150 Temperature resistant up to 130°C any type
VULKAN T 200 Temperature resistant up to 180°C any type
TDLX White; for handling foodstuffs; resistant to oil fabric only
and grease and to temperatures of up to 120°C
FW Noninflammable and antistatic any type
V Self-extinguishing and antistatic any type

Temperature data refer to the conveyor belt, the decisive factor being the effective
temperature to be withstood by the belt in sustained operation. Short-term peak tem-
peratures may be even higher. The material being conveyed in the buckets may possibly
have considerably higher temperatures.
Minimum cover gauges (guide values)

Operating conditions Top (bucket side) Bottom (pulley side)

Fabric Handling of cereals etc. in closed rooms Rubberized surface (without covers)
Handling of fine-grained and light materials
(cereals, sugar, sand, salt, cement, potatoes, 1 mm 1 mm
granulates)
Handling of fine-grained and powdery materials
at higher temperatures (cement, raw meal) and 2 mm 2 mm
granulated material (gravel, coal)
Handling of medium to coarse lump material
(gravel, stones, concrete) 2 mm 3-5 mm
under damp conditions
STAHL For all operating conditions
CORD® 4-5 mm 5-6 mm

The cover gauges are to be stipulated with regard to the type of bucket attachment.
The top covers can be grooved or have flat irons vulcanized in on request. Elevator belts
needing to be supported on the return side are available in transversely rigid versions on
application. The covers can also be supplied with vulcanized brackets.

122
D – 7.3.3 Elevator belts – Selection of bucket elevator belt – Buckets and bucket attachments

D – 7.3.3 Buckets and bucket attachments

The main types of buckets and attachments are described in detail in corresponding
standard specifications. Bucket elevators are normally fitted with sheet metal buckets
and - to a lesser extent - with cast iron buckets that can be attached to the belt with a
standardized bolt attachment (DIN standard 15 236).

Bucket

Belt

In addition, ContiTech‘s production range includes rubber elevator buckets with steel
frames; these weigh up to 70 % less, enabling the belt strength to be exploited more
favourably. Rubber elevator buckets display excellent properties in the handling of highly
abrasive material, e. g. coke, and their natural distortion provides outstanding discharge
properties when strongly adhesive material is being handled.
Steel frame

Rubber

Bolt attachments with standard plate bolts are adequate for standardized bucket shapes
for light and medium duty. Heavy duty service with scooping of coarse-grained material
and heavy buckets with widths exceeding 500 mm necessitates additional measures to
prevent the belt from being subjected to excessive strain. In this case it is advisable to
use screw strips or other attachments that can be obtained from specialized mechanical
engineering firms.

One measure contributing to belt protection is the bolt attachment with an additional
strip of soft rubber inserted between the rear wall of the bucket and the belt, which seals
the gap between belt and bucket even on rotation round the pulley.

Strips of soft rubber

This measure prevents the penetration of material and in some instances of moisture.
The soft rubber compound can be adapted to the Cover material.

123
 D – 7.3.3 Elevator belts – Selection of bucket elevator belt – Buckets and bucket attachments

Similar advantages are offered by bucket attachment with bonded rubber brackets.
Furthermore, perforation of the belt and the consequent reduction in strength are avoided.
Guide values for bucket attachments
Minimum pulley diameter Type of attachment

SCHWINGMETALL®
(available from Beumer machine factory only)

Rubber attachment (flexible)

Rubber attachment (hinged)

Data and dimensions for deep buckets with flat rear wall to DIN 15 236 specifications (selection)
Mass per
Buckets to DIN 15 234 specifications bucket in kg
Belt (dimensions in Belt width mm) Bucket
Number (approx.)
width capacity
of bolts
in mm Width Pro- in liters
jection h1 c d i n r Metal Rubber
b a
200 160 140 180 4.0 9.5 67 80 32 2xM 8 2.1 1.5 1.5
250 200 160 200 5.0 11.5 75 125 40 2 x M 10 3.8 2.1 2.4
300 250 180 224 5.0 11.5 85 80 40 3 x M 10 5.0 2.8 3.75
350 315 200 250 5.0 11.5 95 112 40 3 x M 10 8.6 4.1 6.0
450 400 224 280 5.0 11.5 106 100 40 4 x M 10 11.8 4.9 9.5
550 500 250 315 6.5 14.0 118 100 50 5 x M 12 19.4 5.9 15.0
680 630 280 355 6.5 14.0 132 100 50 6 x M 12 26.6 7.0 23.6
850 800 315 400 6.5 14.0 150 200 50 7 x M 12 36.9 9.4 37.5
1050 1000 355 450 6.5 14.0 170 200 50 9 x M 12 50.3 – 60.0

124
D – 8 Piece goods handling and belts for sliding bed operation

D – 8 Piece goods handling and belts for

sliding bed operation
 Conveying capacity.. . . . . . . . . . . . . . . 8.1
 Calculation of required power.. . . 8.2
 Conveyor belt design.. . . . . . . . . . . . . 8.3

Belts for handling piece goods are used essentially in the range of low to medium
capacities. Whereas belt support on conventional idlers is occasionally provided for
long conveying systems with a relatively high load, bare-bottom-ply belts for sliding bed
operation are gaining economic significance in the range of conveying lengths below
70 m and light material or single loads at greater intervals. Light bulk material too is
frequently transported on sliding-bed conveyor belts when capacities are low.
Mass flow Qm in t/h

At belt speeds below the ones

stated in each case, sliding
belts are usually preferable to
a belt support with idlers

Belt speed v in m/s

1.05

0.84
0.66

0.42
0.25

Conveying length L in m

The economic efficiency, however, is not only determined by the operating expenses
but is always closely linked with maintenance and upkeep costs, particularly in cases of
small power requirements.

ContiTech belts for sliding bed operation have proved to be wear-resistant and reliable.
Most cases of failure have been due not to surface abrasion but to poor tracking or
outside influences. No significant wear is to be ascertained on PVC-coated belts after
long-term operation either, although all parts supporting the belt are subject to greater
strain.

ContiTech conveyor belts with special-purpose slide bearings also protect the support-
ing trough surfaces.

The calculation procedures for piece goods conveyors, in particular of belts for sliding
bed operation, differ especially in the determination of the Conveying capacity and of the
motional resistances from those used for conveyor systems for bulk materials. This point
is therefore given special attention in the following pages. The basic procedure stated in
Sections D – 3 und D – 4 can be applied to determine the drive tractions.

In special instances, the design can be executed by ContiTech‘s Application Technique

Advisory Service. The questionnaire attached in the appendix can be used for this pur-
pose.

125
 D – 8.1 Piece goods handling and belts for sliding bed operation – Conveying capacity

D – 8.1 Conveying capacity

The flow of piece goods is determined by a conversion from the average loading of the
belt conveyor with single loads, the decisive factor being the largest number of lumps
that can be transported simultaneously on the flight.

With the mass m p of the single piece and the quantity z p, the capacity is

zp · mp
Q m = 3.6 · ·v in t/h
L

If charging takes place over a longer period (larger than L/v) regularly at specific intervals
t p (smaller than L/v) in seconds, the capacity results
mp
Q m =3.6 · in t/h
tp

or with the spacing between the single pieces

dp = tp · v in m
to
mp
Q m = 3.6 · · v in t/h
dp

When charging is irregular, the largest edge length (body diagonal) must not exceed the
belt width. If the piece goods are fed to the belt conveyor with absolute alignment, the
belt width can be selected in accordance with the width of the piece goods.

The tables from Section D – 2.5 are applicable to the handling of light bulk materials.

If the conveyor belt is supported on idlers for piece goods handling, an idler spacing
deviating from the longitudinal dimension of the material is recommended. In order to
prevent excessive disturbance or impacts, the piece goods should preferably rest on
more than one idler.

126
D – 8.2 Piece goods handling and belts for sliding bed operation – Calculation of required power

D – 8.2 Calculation of required power

In piece goods transport and in transport on bare-bottom-ply belts, no flexing occurs in

the material handled, which means that the calculation of the motional resistances and
the power requirement differs from that for bulk material conveyors. In general the ascer-
tainment of the power requirement from the resistive force components
F ro – friction resistance in top run
F ru – friction resistance in return run
F St – gradient resistance
FS – special resistance

is sufficiently accurate, provided that relevant values can be inserted for the friction co-
efficients µg of the belt on the sliding bed.

Guide values for friction coefficient µg

Material and temperature of supporting surfaces
Bottom of belt Steel plate (bright) Plastic Hardwood
-20°C 0°C +18°C +40°C +18°C +18°C
EP (raw) 0.3 0.3 0.3 0.25 0.28 0.25
B (raw) 0.75 0.7 0.45 0.35 0.4 0.35
B (rubberized) 0.7 0.6 0.6
Cover rubber 0.9

The total motional resistance F is then

F =C g ( F ro +F ru) +F St +F S in N

Resistive force components of piece goods conveyors and bare bottom-ply belts in N
Belt support on idlers
Designation Belt support sliding
(zR = number of idlers)
F ro µgo · ( m LI + m GI ) ·L ·g 2 ·z R +0.02 · ( m LI +m GI ) ·L ·g
F ru µgu · m GI ·L ·g 2 ·z R +0.02 ·m GI ·L ·g
F St m LI ·g ·H
The special resistance is largely dependent on the scrapers, skirt boards
FS etc. present and is to be determined if necessary from the individual
resistive forces

The material mass m L related to the length unit results from the capacity Q m to
Qm
m LI = in kg/m
3.6 · v
and the related belt mass can be determined with the guide values for the belt weight
m IIG from the equation
m GI = m IIG · B in kg/m

127
 D – 8.2 Piece goods handling and belts for sliding bed operation – Calculation of required power

Length coefficient Cg

No load

Full load

Conveying length L in m

The required power P Tr at the drive pulley is calculated from the total resistive force F.
F ·v
P Tr = in kW
1000
The efficiency of the drive is to be taken into account when determining the necessary
engine output P M.

128
D – 8.3 Piece goods handling and belts for sliding bed operation – Conveyor belt design

D – 8.3 Conveyor belt design

The conveyor belt used for handling piece goods must have not only appropriate covers
and adequate strength. Sufficient transverse rigidity must also be present, especially for
belt conveyors with idler support. The design is based on this aspect, due to the fre-
quently low drive tractions. Tension members with 2 to 3 cotton fabric plies have proved
excellent in this respect.

The power requirements determined permit the application of a single pulley drive at the
head or the tail of the conveyor in almost every instance, so that the greatest belt tension
results with sufficient accuracy from the required power as
1000 P Tr 1
T max ≈
v ( 1+ e μα
-1
) in N

The starting process can be covered globally by a safety factor. As on the one hand a
generally higher non-operating friction coefficient μg between the belt and the sliding
bed has to be observed and the starting factor on direct connection of the generally
over dimensioned drive is at K A = 2 to 2,6, and on the other hand no additional strains
occur on the belt, the safety factor to be applied must be determined approximately.

P Mnom
S ≃ 4· ·K A
PM

The necessary nominal strength k nomV of the belt at the splice thus
T max
k nomV ≥ ·S
B
The friction coefficient μ between the belt and the drive pulley surface, to be assumed for
the maximum drive traction, can be approximately equated with the value of μg.
Conveyor belts for handling piece goods and for sliding bed operation
Tension
Type Covers Suitability
member
Conveyor belts EP-Fabric on one or both sides; cleated Handling of piece goods up to
with cleated or B-Fabric or patterned on the top; cover approx. 40° belt gradient;
rubberized E-Fabric quality depending on type wood working machines;
covers bare-bottom ply belts
Sliding B2/1 Handling of piece goods;
plate B2/2 atop raw or rubberized; bottom bare-bottom-ply belts; special
B-Fabric
B3/1 with cotton sliding-bed ply purpose belts for the rubber
B3/2 industry

Other types available

129
 D – 9 Appendix

D – 9 Appendix

 Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
 Symbols.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
 Questionnaires
 Printed Forms for Calculation

130
D – 9.1 Appendix – Index

D – 9.1 Index

Abrasion resistance 5.2.1

Acceleration 3.5.1
Additional strains 4.2
Angle of repose 2.1
Angle of wrap 4.3.1
Applications of load carrying elements 4
Assessment of load carrying elements 4
Belt parameter 4.2
Belt speed 2.4.2
Belt support 2.4.3
Belt tension 4.1
Belt tensions with regard to sections 4.1.3
Belt thickness 4.4.1
Belt velocity for bucket elevators 7.1
Belt velocity for steep angle conveyor belts 6
Belt weight 4.4.1
Belt width 2.4.1/4.4.1
Bias 4.4.3
Box-section belt 6.2
Breakaway factor 3.4
Bucket elevator belts 7.3
Bucket spacing 7.1
Buckets and bucket attachments 7.3.3
Bulk density 2.1
Camber 7.3.1
Capacity 2.2/2.5/3.1
Centre distance and takeups 4.3.3
Chemical reactions on tension members 4.3.4
Chevron cleated belt 6.1
Coefficient C 3.2
Compensation factor 4.2
Concave radii 4.2.2
Constructional data 6.2.2
Cover patterning 5.3
Convex radii 4.2.2
Conveying capacity 7.1/8.1
Conveying capacity of steep angle conveyor belts 6.1/6.2.1
Conveying track 2.3
Conveyor belt design for handling piece goods 8.3
Cover gauge 5.2/5.2.2
Cover material 5.1
Covers 7.3.2
Curves 4.2.2
Deceleration 3.5.1
Deflection pulley 4.3.1
Degree of uniformity 2.5
Degree of fill 2.5/7.1
Designation of tension members 4.4
Distribution of motor powers 3.5.2
Drive clutch 3.4
Drive factor 3.5
Drive motor 3.4
Drive pulley 4.3.1
Drop energy 4.3.5/5.2.2
Economic efficiency 8
Edge length of lumps 2.4.1
Effects of material handled 4.3.4
Efficiency 3.4
131
 D – 9.1 Appendix – Index

Elongation 4.3.3/4.4.1
Elevator belts 7
Engine output 3.4
Fabric carcass belts 4.4.1/4.4.2
Fall, height of 4.3.5
Feeding resistance 3.3.1
Feeding strain 4.3.5
Filling cross-section area 2.5
Flat-to-trough transition and vice versa 4.2.1
Flow of material handled 2.2
Friction coefficients for bare-bottom-ply belts 8.2
Friction coefficient 3.5/3.5.2
Friction coefficient f 3.2
Friction transmission 3.5
Gradients of belt conveyors 2.1/2.4/2.5
Gradient resistance 3.3/3.3.1
Idler 2.4.3/3.1/3.1.1/4.3.1
Impact resistance 4.3.5/5.2.2
Leaving flight 3.5.1
Lumps of material handled 4.3.5
Masses 3.1
Masses of buckets 7.3.3
Masses of conveyor belts 3.1.2
Masses of drive elements 3.1.3
Mass inertia forces 3.5.1
Mass of lumps 4.3.5
Material handled 2.1
Minimum cover gauge 4.4.2/5.2
Minimum cover gauge for elevator belts 7.3.2
Moisture absorption by tension members 4.3.4
Motional resistance 3.3
Motional resistance of sections 3.3.2
Multiple pulley drive 3.5.2
Non-operation arc 3.5
Operating hours 2.2
Overfilling 4.4.3
Peripheral force 3.5
Piece goods handling 8
Polymers 5
Power requirement and belt tensions 3.4/7.2
Primary resistance 3.3/3.3.1
Properties of covers 5.1
Properties of elastomers 5
Properties of load carrying elements 4
Pulley diameter 4.3.1/4.4.1
Pulley diameter for corrugated sidewalls 6.2
Pulley elevation 4.2.1
Required power for sliding bed operation 8.2
Resistance coefficient f 3.2
Resistive force components 3.3.1
Safety factors for bare-bottom-ply belts 8.3
Safety factors for belt conveyors 4/4.2
Safety factors for bucket elevators 7.3.1
Sag 4.1

132
D – 9.1 Appendix – Index

Scooping capacity of bucket elevators 7.2

Secondary resistance 3.3/3.3.1
Section loading 3.3.2/4.1.3
Selection criteria 4.3
Selection of covers 5
Service arc 3.5
Service life 5.2.1
Shape factor 4.3.5
Shrinkage 4.3.4
Sliding bed operation 8
Snub pulley 4.3.1
Special cover structures 5.3
Special resistance 3.3/3.3.1
Splicing 4.4.3
Stahlcord special versions 4.4
Starting 3.1.3/3.5.1/4.1.2
Start-up factor 3-4
Steel cable tension members 4.4.2
Steep angle conveying 5.3
Steep angle conveyor belts 6
Stopping 3.1.3/3.5.1/4.1.2
Strength of splice 4.4.1
Surface pressure 3.5
Takeup systems 4.1
Tail pulley 3.5.1
Temperature influence 3.2
Temperature influence on tension members 4.3.4
Tension 4.1
Tension member of elevator belts 7.3.1
Tension member data 4.4
Textile tension members 4.4.1
Transition curves 4.2.2
Transition length 4.2.1
Transverse reinforcement 4.4/5.3
Transverse rigidity 4.3.2
Troughing design 2.4.3
Troughing properties 4.3.2
Turnover 4.2.3
Type of belt conveyor 2.4
Volume capacity 2.2/2.5
Wedge guidance 5.3

133
 D – 9.2 Appendix – Symbols

D – 9.2 Symbols

Symbol Unit Formula quantity

A m² Filling cross-section area
B m, mm Belt width
C – Length coefficient
D mm Diameter
EF Nm Drop energy
F N Force
H m Conveying height, height
J kg/m² Mass moment of inertia
K – Factor
L m, mm Conveying length, length
M Nm Torque
P kW Power
Qm t/h Material capacity
QV m³/h Material volume capacity
R m Radius
S – Safety factor
T N Drive traction
V m³ Volumes
a m/s² Acceleration
a mm Projection
b, beff mm, m Effective width, base width
bF mm Sidewall width
c – Coefficient, factor
d mm Distance, spacing
e – Natural number
f – Resistance coefficient
g m/s² Acceleration due to gravity (9.81 m/s²)
hF m Free fall
hrel – Effective height
k N/mm Belt tension (length-related force)
k mm Edge length
l mm, m Idler length, idler spacing
m kg Mass, weight
mI kg/m Length-related mass (linear load)
mII kg/m² Area-related mass (m²-weight)
n min-1 Number of revolutions
pm N/cm² Mean surface pressure
r mm Radius
s mm Thickness, cover gauge
t h, s Time
t m, mm Pitch, section spacing
v m/s Belt velocity, speed
z – Amount, number
α º, rad Angle of wrap
β º Angle of incline of material handled
δ º Angle of slope, gradient
ε – Elongation
η – Efficiency
λ º, rad Troughing angle
µ – Friction coefficient
� – Digit � (3.1416)
ρ t/m³, kg/dm³ Bulk density, density
φ – Degree of fill
134
D – 9.2 Appendix – Symbols

Indices
A Starting, bias
B Braking, stopping
Be Bucket
D Cover
E Drive element
F Fall, base
G Belt
H Principal, main
K Edge
L Load
M Motor, engine
N Secondary
Q Cross-section
R Idler
S Special, stage
St Pitch
Tr Pulley
U Circumference
V Volume, splice
W Turn, shaft
Y Troughing transition
Z Tension member (belt core)
a Mass inertia on starting
b Mass inertia on stopping
c Sequential calculation
eff Effective
f Shape
g Slide, base
h Horizontal
k Cubic, concave
l Breakaway, longitudinal
leer No-load operation
m Mass
max Maximum
min Minimum
n Number
nom Nominal
o Top run
p Piece
r Friction
red Reduction
s Scooping
sch Chute
t Short-term, temporary
th Theoretical
u Return run
v Tensioning, convex
w Abrasion
x Point, location
z Supplement, allowance

135
 ContiTech Conveyor Belt Group
Rubber and plastics technology

www.contitech.de www.contitech.de/transportbandsysteme

Market segments ContiTech Service worldwide

Mining World ContiTech ContiTech U.K.

Mining Europe Kautschuk- und Kunststoff- Chestnut Field House
Vertriebsgesellschaft m.b.H. Chestnut Field
Industry
Gewerbestraße 14 GB-Rugby,
Engineered Products Postfach 115 CV21 2PA Warwickshire
A-2351 Wiener Neudorf Phone +44 1788-57 1482
Phone +43 2236-4 91 01 Fax +44 1788-54 2245
Fax +43 2236-4 91 01 49
ContiTech Holding AG Shanghai Office
ContiTech Belgium BVBA 23F Tian An Center Building
Uitbreidingstraat 42-46 338 Nanjing Road (West)
B-2600 Berchem PRC-200003 Shanghai
Phone +32 3-206 74-20 Phone +86 21-61 41 8321
Fax +32 3-206 74-30 Fax +86 21-61 41 8326
ContiTech Continental Suisse S.A. ContiTech Scandinavia AB
Lerzenstraße 19 Finlandsgatan 14
CH-8953 Dietikon 1 Box 38
Phone +41 43-343 20 10 S-16493 Kista
Fax +41 43-343 20 11 Phone +46 8-4 44 13 30
Continental Industrias Fax +46 8-7 50 55 66
del Caucho S.A. ContiTech Continental
Cityparc-Ronda de Dalt Tyre and Rubber Singapore Pte. Ltd.
Ctra. de Hospitalet 147 298 Tiong Bahru Road
E-08940 Cornellà (Barcelona) #02-01 Tower Block
Phone +34 93-4 80 04 00 Tiong Bahru Plaza
Fax +34 93-4 80 04 01 SGP-Singapore 168730
ContiTech France SNC Phone +65 6377-1223
WT 1549 EN 06.08 Printed with CONTI AIR® offset printing blankets on bleached paper free of chlorine

3, rue Fulgence Bienvenue CE 147 Fax +65 6377-2202

F-92631 Gennevilliers ContiTech North America, Inc.
Phone +33 1-41.47.92.92 136 Summit Avenue
Fax +33 1-47.92.08.22 USA-Montvale, NJ 07645
Z.I. de la Silardière Phone +1 800-6540974
F-42500 Le Chambon-Feugerolles Fax +1 201-930-0050
Phone +33 4-77.10.19.40
Fax +33 4-77.10.19.77

Product market segment The contents of this publication are the result of many years of research and experience gamed in
Industry application technology. All Information is given in good faith; it does not represent a guarantee with
respect to characteristics and does not exempt the user from testing the suitability of products
ContiTech and from ascertaining that the industrial property rights of third parties are not violated. No liability
Transportbandsysteme GmbH whatsoever will be accepted for damage – regard-less of its nature and its legal basis – arising from
D-37154 Northeim advice given in this publication. This does not apply in the event that we or our legal representatives
Phone +49 5551 702-207 or management are found guilty of having acted with intent or gross negligence. No liability is borne
Fax +49 5551 702-504
for damage due to ordinary negligence. This exclusion of liability applies also to the personal liability
of our legal representatives and employees and other persons employed in performing our obligations.
©2008 by ContiTech Holding GmbH, Hannover. Germany. All rights reserved.