Correas Transportadoras Continental Conveyor Belt Design Manual Para Ingenieros Mecanicos

1

ContiTech Specialist in Rubber Technology

Edition

Conveyor Belting

Manual for Mechanical Engineers

Continental Aktiengesellschaft

3


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

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

Conveyor Belting Manual for Mechanical Engineers This brochure is the first time concise documentation has been compiled covering all aspects of a mechanical engineer's working environment. A thorough understanding and careful monitoring of the system are essential to ensure reliable operation of a conveyor belt line. Invaluable information is provided on the structure of a conveyor belt, preparing the site for belt installation, commissioning, operation, maintenance, repair and seasonal system shutdown.

ContiTech

Advanced technology in rubber processing and manufacture

Worldwide application

Latest technology in production and development

Responsibilities of the mechanical engineer

Planning Ordering Installation

Conti offers

Product information

Computer service

System design data

Technical advice

Project studies

Problem analysis

Research and development

Standardization

Your advantages are

Decision-making aids � the right choice of belt

Low-cost design � optimum economy

Effective standartization � less stock required

Smooth and clean operation of the conveyor system

� minimal maintenace

Conti offers

Quality

Punctual order-servicing

Comprehensive range

Your advantages are

Pre-shipment release through a neutral body of quality assurance engineers

� conformity with agreed grades of quality

Monitoring of project schedules

� smooth timing

Conti offers

Engineers who provide expert advice

Site delivery

Packaging

Your advantages are

Recommendations for optimum belt installation � time and cost-saving

Coordination of delivery � direct delivery of belt

to site; protection from damage during transportation

Splicing Comissioning Inspection

Conti offers

Optimized splicing systems

Splicing materials

Vulcanization

Fundamental research

Your advantages are

Splicing materials specially developed for each belt type � optimum strength at splice

Provision of latest vulcanizing equipment � uniform curing

Own fitters � excellent knowledge of materials and belts

Conti offers

Belt approval

Troubleshooting guidance

Expert on-site advice

Your advantages are

Localization and elemination of trouble spots � limitation of damage risk

Belt commissioning without problems � minimum delay in starting conveyor service

Conti offers

Belt inspections

Repair service

Instruction and training of vulcanizers and maintenance staff

Your advantages are

Expert opinions and reports � minimizing of overall risk

Assessment of the belt`s condition � systematic repairs

Repair materials to suit each type of belt � optimum service life

Trained maintenance staff � low-cost repairs


Quality assurance at ContiTech

CONTI® Conveyor Belting and

Conveyor Belting Accessories are state-of-the-art products in every aspect of material specification and product design. This is guaranteed by Continental's in-house quality assurance experts. All CONTI products undergo rigid, independent quality controls throughout and after manufacturing to ensure uniformity and a constant high standard of technical excellence.

Advisory service at ContiTech

CONTI's Application Engineers assist in determining the technically and economically most suitable type of CONTI product for the specific application. Backed by the R & D division of ContiTech, our consultants are able to provide not only the optimum solution but one precisely tailored to end-product service requirements.


Conveyor Belt Service

Conveyor Belting Manual for Mechanical Engineers

Edited by Dr.-Ing. R. Alles Dipl.-Ing. G. Böttcher Obering. W. Ernst

Published by Continental Aktiengesellschaft, Hannover, Germany 2nd Edition 1990

1 Structure and identification of conveyor belts _____________ 2

1.1 Tension members ____________________ 2 1.1.1 Conveyor belts with textile plies _________ 2 1.1.2 Steel cable conveyor belts _____________ 5

1.2 Covers_____________________________ 6 1.2.1 Cover thickness______________________ 6 1.2.2 Cover grade ________________________ 6 1.2.3 Cover reinforcement__________________ 8 1.2.4 Cover patterns ______________________ 8

2 Ordering and storing _________ 12 2.1 How to order conveyor belts ___________ 12

2.1.1 Example of how to order______________ 12 2.1.2 Delivery of endless belts _____________ 12

2.2 Delivery and storage _________________ 13 2.2.1 Packaging _________________________ 13

Technical data for textile tension members __________________________ 13

Diagrams showing different roll diameters ______________________ 14-17

2.2.2 Storage ___________________________ 18

3 Preparations for installation ___ 20 3.1 Preparing the structure _______________ 20

Drive pulley ________________________ 20 Take-up station_____________________ 21 Idlers and idler sets __________________ 21 Scrapers __________________________ 21 Loading and transfer chutes ___________ 22 CORREX

® abrasion resistant material ____ 22

3.2 Preparations for pulling the belt onto

the structure _______________________ 23 3.2.1 Hanging the belt roll in let-off stands ____ 23 3.2.2 Pulling in the belt ___________________ 23

4 Splicing conveyor belts ______ 26 4.1 Splicing fabric-ply conveyor belts _______ 26

4.1.1 Mechanical splices (detachable) _______ 26 4.1.2 Vulcanized splices (non detachable) ____ 26

4.2 Splicing steel cable conveyor belts ______ 29

5 Commissioning _____________ 32 5.1 Tensionieng the belt_________________ 32 5.2 Starting the belt_____________________ 32 5.3 Training the belt ____________________ 33

6 Operation and problem solving_ 40 6.1 Daily inspection of the conveyor belt;

causes of belt damage _______________ 40 6.2 Dai!y inspection of the system__________ 42

7 Maintenance and repair _______ 44 7.1 Repair materials ____________________ 44 7.2 Repairing damage with

CONREMA® repair materials___________ 46

7.2.1 Repairing damaged covers ___________ 46 7.2.2 Repairing penetrations and damage to the fabric________________________ 48

8 Seasonal shutdown and winter operation _____________ 54

Index _________________________ 56

Conveyor belt systems -

Troubleshooting guide

(Supplement)

ContiTech Specialist in Rubber Technology 1

1.1 Tension members

1.2 Covers

Aerial cableway is replaced

by a belt conveyor

Structure and identification of conveyor belts

2

1 Structure and identification of conveyor belts

Structure and identification of conveyor belts Dimensions, test values, designations, etc. of conveyor belts are specified in the following standards:

DIN 22101 Belt conveyors for bulk materials

DIN 22102 Conveyor belts with textile plies

DIN 22103 Flame resistant conveyor belts

DIN 22104 Antistatic conveyor belts

DIN 22109 Textile-ply conveyor belts for coal mining

DIN 22131 Steel cable conveyor belts

DIN 22129 Steel cable conveyor belts for underground coal mining (draft)

Ordering and delivery of conveyor belts are based on specifications given in the above standards. Any dimensions or other requirements deviating from the corresponding standard are subject to special agreement with the manufacturer.

1.1 Tension members

Conveyor belts are reinforced with one or more plies of special textile fabric or one layer of adjacent steel cables. The following code letters denote the type of material used as reinforcement.

B cotton

Z high-strength viscose staple fibre

R high-strength rayon

P polyamide (trade names such as "Nylon", "Perlon")

E polyester (trade names such as "Trevira", "Diolen")

D aramide (trade names such as "Kevlar”, "Arenka")

St steel cables

1.1.1 Conveyor belts with textile plies

In virtually all cases, square-woven fabric of various kinds of weave is used for conveyor belts. The terms "warp" (running parallel to the length of the cloth) and "weft" (running across the width of the cloth) have been taken over from the weaving process.

During the years of pioneering belt development, only cotton was used as a textile material. The advancement to fully synthetic fibres brought with it the manufacture of new high-strength types of fabric, leading to a decisive change and improvement in the structure and performance of conveyor belts.

Polyester: Fully synthetic, high strength with low elongation, high workload capacity, largely resistant to acids and alkalis, unaffected by moisture (at normal temperatures).

Polyamide: Fully synthetic, high tear resistance, high elongation, rotproof, resistant to moisture and chemicals.

Aramide; Fully synthetic, highly aromatic polyamide fibre with extra high strength and low elongation; has the advantages of all fully synthetic fibres, is flame-resistant without undergoing special treatment and is gaining significance in the manufacture of high-strength textile-ply belts.

3

Structure and identification of conveyor belts 1

Whereas earlier types of conveyor belt used to be reinforced with a "purebred" fabric, specialists in textile technology have since developed fabrics with combinations of different materials. Depending on the physical properties of the warp and weft, these mixed fabrics give the belt the right properties to meet specific in-service requirements. Textile plies are identified by two capital letters.The first letter shows the material used in warp direction and the second letter shows that used in weft direction.

e.g. EP (warp: polyester/weft: polyamide)

Good properties fort he warp are: High strength, low permanent elongation, hence short take-ups. Strength and elongation even remain unaffected by wet conditions, rotproof.

Good properties for the weft are: High elastic elongation, hence good troughability and large filling cross section, good workload capacity and therefore a good resistance to mechanical destruction.

In addition, brief reference should also be made at this point to the types of fabric commonly used for mining service:

e.g. Pb (the second letter is small)

This coding means that two different kinds of material have been twisted together to form one thread. The capital letter stands for the material giving the highest measure of strength.

Following the material code is the strength grading in figures according to DIN 22102 standard specifications. The strength of the textile fabric and that of the entire belt are stated in N/mm width (previously kg/cm width).

Strength values comply with the R10 standardized series of numbers contained in DIN 323, i.e. 160, 200, 250, 315, 400, 500, 630, 800,1000,1250, 1600, 2000, 2500, 3150, 4000, 5000, 6300.

Identification coding of a conveyor belt could for instance read as follows:

EP = type of fabric /1000 = overall strength in N/mm belt width / 4 = number of plies

i.e. the belt's tension member with a strength of 1000 N/mm belt width consists of 4 plies of polyester/polyamide textile fabric, EP 250.

The high strength and ability of fully synthetic blended fabric to withstand high dynamic stressing enabled the number of plies to be reduced. This led to the following generation of belts made by Continental:

1-ply belts (only for underground) CON-MONTEX®

2-ply belts CON-BITEX®

Multi-ply belts

4


Technical Data (guide values) Type

Nominal strength at splice

in N/mm

Elongation at break (longit.)

in %

Thickness of tension member (belt core)

in mm

Tension member mass (w/o cover M or N)

in kg/m2

Elastic elongation up to 10% of minimum breaking strength (longit.)

in%

Minimum pulley diameter (drive pulley)

in mm

Minimum belt width at 30° troughing angle

in mm

2-ply belts (with thick intermediate rubber layer) 200/2 200 12-16 3.5 3.9 0.6 - 1.2 250 400

250/2 250 3.7 4.1 315 400 315/2 315 3.9 4.3 315 400 400/2 400 4.1 4.6 400 400 500/2 500 4.7 4.8 400 500 630/2 630 5.2 6.1 500 500 800/2 800 6.3 6.4 500 650 1000/2 1000 7.1 7.9 630 800

CON- BITEX

®

1250/2 1250 7.7 8.8 800 1000 2-ply belts

200/2 100 12-16 1.8 1.9 0.6 - 1.2 200 400 250/2 125 2.0 2.3 250 400 315/2 160 2.2 2.4 250 400 400/2 200 2.6 2.8 315 400 500/2 250 3.2 3.2 400 500 630/2 315 3.8 4.2 500 500 800/2 400 4.8 4.8 630 650 1000/2 500 5.8 5.9 630 800

CON- MULTEX

1250/2 630 6.2 6.5 800 800 3-ply belts

315/3 200 12-16 2.7 2.8 0.6 - 1.2 315 400 400/3 250 3.0 3.4 315 400 500/3 315 3.3 3.7 400 500 630/3 400 3.9 4.2 500 500 800/3 500 4.8 4.8 500 650 1000/3 630 5.7 6.4 630 800

CON- MULTEX

1250/3 800 7.2 7.2 800 800 4-ply belts

400/4 315 12-16 3.2 3.8 0.6 - 1.2 400 400 500/4 400 4.0 4.5 500 500 630/4 500 4.4 4.9 500 500 800/4 630 5.2 5.6 630 650 1000/4 800 6.4 6.4 800 800 1250/4 1000 7.6 8.5 800 1000

CON- MULTEX

1600/4 1250 9.6 9.6 1000 1000 5-ply belts

500/5 400 12-16 4.0 4.7 0.6 - 1.2 500 500 630/5 500 5.0 5.7 630 500 800/5 630 5.5 6.1 630 650 1000/5 800 6.5 7.0 800 800 1250/5 1000 8.0 8.0 1000 1000 1600/5 1250 9.5 10.6 1000 1200

CON- MULTEX

2000/5 1600 12.0 12.0 1250 1200

Other types of belt available on request

5

Aufbau und Kennzeichnung der Fördergurte 1

1.1.2 Steel cable conveyor belts

All ContiTech Steel Cable Conveyor Belts bear the registered trade name of STAHLCORD

®.

Reinforcement for steel cable conveyor belts is in the form of one ply of high-tensile steel cables embedded in rubber and arranged in one plane running parallel to each other longitudinally. STAHLCORD

® Conveyor Belts

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

®

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

® Conveyor Belts also have a good

troughability.

Identification and dimensions are specified in DIN 22131 (Standard DIN 22129 "Steel cable belts for underground coal mining" is available in draft version). Coding for the tension member is made up as follows:

St = steel cables / 2000 = overall strength in N/mm belt width

Since only one layer of steel cables is embedded in the rubber according to DIN 22131, the figure after the oblique which appears in the coding reference for textile-ply belts does not apply in this case. Strengths of steel cable conveyor belts currently range from 500 N/mm to 7300 N/mm. The strength of the belt is determined by the strength of the steel cables and their spacing (pitch).

Grades of strength specified in DIN 22 131 are supplemented by special versions according to the R 20 series.

Technical Data (guide values)

Tension member mass (belt core) without covers

Type Nominal strength

at splice

Pitch Thickness of tension member (belt core) (M or N) (V)

Minimum pulley diameter (drive pulley)

Minimum cover thickness

in N/mm in mm in mm in kg/m2 in kg/m

2 in mm in mm

St 500 500 12.5 2.8 5.3 6.4 500 3 St 630 630 10 2.8 5.8 6.8 500 3 St 800 800 12 3.6 7.4 8.8 630 3 St 1000 1000 12 4.0 8.9 10.4 630 3 St 1250 1250 14 4.7 10.6 12.3 630 3 St 1400 1400 9 4.0 10.3 11.6 630 3 St 1600 1600 15 5.5 12.8 14.7 800 4 St 1800 1800 13.5 5.5 13.5 15.4 800 4 St 2000 2000 12 5.5 14.3 16.2 800 4 St 2250 2250 11 5.5 15.0 16.8 800 4 St 2500 2500 15 7.0 18.0 20.3 1000 5 St 2800 2800 13.5 7.0 19.0 21.3 1000 5 St 3150 3150 15 7.8 22.0 24.5 1250 5.5 St 3500 3500

1) 15 8.2 23.6 26.3 1250 5.5

St 4000 40001) 15 8.8 26.6 29.4 1250 6.5

St 4500 45001) 16 9.6 29.0 32.1 1400 7

St 5000 50001) 17 10.7 33.0 36.3 1600 7.5

St 5400 56001) 17 11.7 36.2 39.9 1600 8

St 6300 63001) 18 12.2 40.4 44.0 1600 8.5

St 7300 73001) 19 13.1 43.9 47.7 1800 9

1) without allowances according to DIN 22101

6


1.2 Covers

If the reinforcement of a conveyor belt is to retain its strength, it must be given ample protection from mechanical damage and rotting. The tension member is therefore provided with a cover on the top or conveying side of the belt and also on the bottom side.

1.2.1 Cover thickness

Cover thicknesses are generally determined by the anticipated amount of wear caused by the conveyed material and measure between 0.5 and 20.0 mm. A somewhat thinner bottom cover can be selected in most cases but the ratio of top to bottom cover thickness should not exceed about 3:1 (cf. DIN 22101). Great differences between the two cover thicknesses can lead to undesired tensions within the belt and bulging of its edges due to shrinkage of the rubber following vulcanization.

Minimum cover thicknesses are prescribed for steel cable conveyor belts (DIN 22101). Special attention when selecting the cover thicknesses can also optimize the lateral rigidity required for some applications.

1.2.2 Cover grade

It is easy to realize the different types of stressing a conveyor belt is subjected to when we consider the vast range of materials to be conveyed - literally anything from coal to foodstuffs. Similarly, the number of different cover grades to choose from is high.

Basic qualities and main properties of a cover are specified in correspond-ing DIN standards and are distinguished by the letters shown below:

Code letters

Property Steel cable belts (DIN 22 131)

Fabric-ply belts (DIN 22 102)

flame resistant F

antistatic E

flame resistant und antistatic* K S

self-extinguishing and antistatic* (DIN 22 131) V (DIN 22 109)

resistant to elevated temperatures T

resistant to low temperatures R

resistant to oil and grease G

belts for foofstuffs A

belts for chemical products C

belts with fixed mechanical parameters

M, N M, N, P, Q

special grades X

* (Belt cover grades for coal mining service are subject to special conditions of approval issued by the German mines authorities.)

It is quite possible that several of these properties have to be fulfilled by one belt, e.g. in the handling of freshly baked bread or confectionary, the cover may have to be white and resistant to oil and grease as well as higher temperatures.

When ordering it is therefore extremely important to give a precise definition of the material to be conveyed and its characteristics.

7


Properties of the most popular ContiTech cover grades (guide values)

Permissible temperature** in °C

DIN Code

Continental equivalent

Density p

kg/dm3

Suitable for

constant

min. max.

peak

min. max.

Resistant to oil and grease

Tension member

Colour Polymer

M ATRB 1.09 general conveying (maximum requirements)

-50 +60 -55 +70 no any type

black NR

N CONTINENTAL EXTRA

1.13 general conveying -30 +60 -35 +70 no any type

black NR/ SBR

X CONTI-CLEAN®

(dirt repelled)

1.12 heavy soiling (with high moisture content)

-50 +60 -55 +70 no any type

black BR/NR

N, K FH (flame retardant)

1.24 machine belts in open cast mines

-30 +60 -35 +70 no any type

black NR/BR

S, K FW (flame resistant)

1.38 underground and surface

-30 +60 -35 +70 no any type

black SBR

V V (self-extinguishing)

1.42 1.60

underground mining (maximum safety requirements)

- +100 - +110 within limits

fabric steel

black CR

S, T VULKAN®

spezial (flame resistant)

1.39 hot materials with glowing embers

-30 +110 -30 +130 within limits

any type

black CR

T VULKAN®-

T 130 1.13 hot materials -30 +110 -40 +130 no any

type black SBR

T VULKAN®

extra-T150

1.13 hot materials -30 +130 -40 +150 no any type

black SBR

T, C* VULKAN®

super - T 180 1.13 hot materials,

also resistant to acids and alkalis

-30 +160 -40 +180 no fabric only

black IIR

G TDAX

1.17 oily, greasy materials

-10 +70 -20 +90 yes fabric only

black NBR

G TBBX 1.13 oil sand -50 +60 -50 +70 yes any type

black NBR

A TDLX 1.21 foodstuffs (oily, greasy and hot)

-10 +120 -15 +140 yes fabric only

white NBR

X, C* TOWN 1.0 materials with acid content

-40 +60 -45 +70 no fabric only

grey NR

E TBBN (electrically conductive)

1.25 potentially explosive materials

-30 +60 -35 +70 no any type

black NR

V PVC (self-extinguishing)

1.35 underground -5 +50 -5 +60 yes fabric only

brown PVC

* For applications involving potential chemical attack, we recommend prior consultation with our Application Engineers.

** These temperature specifications refer to the conveyor belt; maximum temperature loads are However also subject to the nature of exposure to these temperatures (see also German Rubber Manufacturers` Association guidelines No. 339).

Details of other cover grades and specifications given on request.

8


1.2.3 Cover reinforcement

To protect the tension member and give added resistance to impacts, the cover can be provided with additional transverse reinforcement made of textile cord or steel strands. This increases the belt's resistance to penetra-tion and reduces the danger of longitudinal slitting.

Transverse reinforcement of the covers

Type Transverse reinforcement

Arrangement Tension member

CONTI-CROSS T

textile cord (polyamide)

one side

(top or bottom)

STAHLCORD®

(all types)

CONTI-CROSS T/T

textile cord (polyamide)

both sides STAHLCORD®

(all types)

CONTI-CROSS S/S

Steel strands both sides STAHLCORD®

special-purpose types

Breaker fabric (polyamide)

one side (top) or both sides

fabric-ply belts

1.2.4 Cover patterns

To ensure optimum transport of special materials, e.g. on luggage and parcel conveyors, industrial assembly and sorting conveyors, or when conveying at a certain gradient, it may be necessary to provide the belt cover with a pattern. The most popular patterns to improve holding or eliminate rollback of materials can be seen below.

Coarse cloth impression Transverse ribbing

Coarse duck impression Transverse multi-cleats

Herringbone pattern Longitudinal multi-cleats

9


The Steep-Angle Conveyor Belt with 15 mm high chevron cleats on the top cover is designed to carry bulk materials such as coal, sand, gravel, ore minerals, etc. This belt can be troughed at 45° and is capable of transporting its load at a gradient of up to about 30° depending on the type of material handled.

In addition to cover patterns, there are belts with high bonded sections. Section designs are varied and are vulcanized-on using the cold bonding process. These belts are named as follows:

Partitioned Belts

Fin-Type Belts

CONTIWELL®

Box-Section Belts

CONTIWELL®

Corrugated-Sidewall Belts

Gradients of up to approx. 60° can be achieved using these belts, depending on the type of belt and the material being conveyed.

Conveyor belts cannot be used for gradients exceeding 60°. This is where it becomes necessary to make use of vertical conveyors or elevator belts.

CONTIWELL® Box-Section Belts can also be used for vertical conveying

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

Steep-Angle Conveyor Belt with Partitioned Conveyor Belt chevron cleats

Fin- Type Conveyor Belt, 2-section Fin- Type Conveyor Belt, 3-section

CONTIWELL® Box-Section Belt

10


2.1 How to order conveyor belts

2.2 Delivery and storage

Ordering and storing

Site delivery

12

2 Ordering and storage

Ordering and storage

2.1 How to order conveyor belts

Ordering is done on the basis of standards already named on the previous pages. In most cases reference can be made to specifications of systems already in operation when ordering replacement belts.

Based on the DIN standard 22102, an enquiry or purchase order should include the following information:

a) Extended or unwound length of the belt in m, specifying an "additional overlap length for splicing", or if the belt is to be delivered in one continuous length "endless...m". The client is responsible for specifying the correct length.

b) Type of belt (e.g. steep-angle conveyor belt).

c) Belt width in mm. Standard widths are 300, 400, 500, 650, 800, 1000, 1200 and so on at an increase of 200 mm.

Non-standard widths may be supplied in agreement with the manufacturer. Continental manufactures belts up to a width of 3200 mm without a longitudinal joint.

d) Type of reinforcement.

e) Nominal strength of the belt in N/mm.

f) Number of plies.

g) Cover thicknesses (top and bottom) in mm.

h) Cover material (rubber, PVC or the manufacturer's designation).

i) Cover grade, DIN 22102 code, basic properties, resistance requirements or the trade name if known.

j) Additional information, e.g. type of splice.

2.1.1 Example of how to order

Conveyor belt 40 m inner circumference, 500 mm width, 2 plies polyester/ polyamide, nominal strength 500 N/mm, rubber cover, cover thicknesses -top cover 3 mm, bottom cover 2 mm, belt to be supplied unspliced, additional overlap length for splicing required.

This order is summarized as follows:

40 m CON-BITEX® Conveyor Belt + overlap

500 mm wide EP 500/2 3+2 mm CONTINENTAL EXTRA (N)

If you are ordering for the first time or planning to erect a new conveyor, you are strongly advised to complete the manufacturer's data sheet giving full system specifications or ask for one of ContiTech's engineers to pay you a visit. This is the only way to ensure that you select the right type of belt with optimum conveying capacity and economy.

2.1.2 Delivery of endless belts

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

13

Ordering and storage 2

The process of dismantling and refitting parts of the structure usually involves a great deal more work than on-site belt splicing and installation. ContiTech's specialist engineers can be of help when deciding whether to select an endless belt or an unspliced one.

A detailed summary of all ContiTech Conveyor Belt types, with descriptions and information on available sizes can be taken from the CONTI Conveyor Belt Service Manual, Part C "Conveyor Belting, Product Range".

2.2 Delivery and storage

For long-distance conveyors it is often necessary to divide the total conveyor belt length into a certain number of part lengths agreed upon between the client and the manufacturer. The number of part lengths is always kept as low as possible in order to keep the number of splices at the installation location to a minimum. Each splicing operation means a loss of time and money.

Part lengths are usually selected in accordance with the transportation and installation facilities at the site. Outer dimensions of the conveyor belt roll and its gross weight must be calculated beforehand when determining the mode of shipment.

2.2.1 Packaging

Conveyor belts are wound onto wooden cores for shipment. Light belts are wound onto wooden cores with 400 mm outside diameter and a square centre hole of 90x90 mm to hold the roll axle; long and heavy belts are wound on wooden cores with 600 mm outside diameter and a square centre hole measuring 200x200 mm to hold the axle.

Extra large belt rolls can also be shipped on wooden or steel drums. When shipping endless belts the inner and outer loops are lined with rollers to prevent damage to the tension member through sharp kinking.

The thickness of the conveyor belt can be determined by means of the tables on pages 4 and 5.

Conveyor belt thickness = thickness of tension member + thicknesses of the two covers

The roll diameter can be taken from the graphs on pages 14 to 17 using the factors belt thickness and belt length.

The belt weight is determined with the aid of the following tables: - textile tension member (page 4) - steel cable belts (page 6) - cover materials (page 7).

Net Belt weight [kg] = (cover weight [kg/m

2] + tension member weight [kg/m

2])

.

belt width [m] . belt length [m]

Cover weight [kg/m2] =

density of cover material [kg/dm3]

. thicknesses of the two covers [mm]

Formlua:

14


Conveyor belt roll diameter with 400 mm core diameter

30 28 26 24 22 20 19 18

Roll

dia

mete

r in

mm

3000

2000

1000

100 200 300 400 500 Belt length in m

Belt th

ickness in m

m

15



30 28 26 24 22 20 19 18 17 16 15 14 13

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

12

11

10

9

8

7

6

5

50 100 150 200 Belt length in m

Belt th

ickness in m

m

Roll

dia

mete

r in

mm

16



30 28 26 24 22

Roll

dia

mete

r in

mm

3000

2000

1000

100 200 300 400 500 Belt length in mm

Belt th

ickness in m

m

17



30 28 26 24 22 20 19 18 17 16 15 14 13

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

12

11

10

9

8

7

6

5

50 100 150 200 Belt length in m

Belt th

ickness in m

m

Roll

dia

mete

r in

mm

18


Extra special care must be taken during loading and unloading. On no account should the belt be tipped from the truck or freight car as damage to the edges and covers would be inevitable. Lateral slipping of the roll (telescoping) too would complicate belt installation. If fork-lift trucks are used for unloading, the sharp-edged forks must be padded (corrugated cardboard, wood, conveyor belt waste, etc.). A suitable axle and a spreader must be used for loading and unloading by crane or hoist. If wire cables that touch the roll edges are being used, boards must be inserted, or better still, an additional strong wooden board of a length equalling the belt length can be wedged as a spacer bar between the two cable ends.

If the belt roll has to be rolled, it is essential not to roll it counter to the winding direction. The roll is otherwise telescoped laterally into a funnel shape. Wooden boards should be placed underneath for rolling too, so that the belt is not damaged by stones or building materials.

2.2.2 Storage

If prolonged intermediate storage is necessary, it is advisable to suspend the rolled belt with one axle in two mobile stands. If this is not feasible, the roll should be turned at intervals to change the contact surface. Storage location should be selected so as to avoid heat and direct sunlight. The belt should also be protected from contact with chemicals, grease or oil. Premature ageing, cracking, hardening or swelling would affect the service life of the conveyor belt (cf. DIN standard 7716, May 1982 - Rubber products: directions for storage, cleaning and maintenance).

In the event of prolonged storage in the open air, the cut edges at the start and end of the belt have to be protected from moisture. It may be advisable to coat the edges with ContiTech's CONREMA

® Solution.


3.1 Preparing the structure

3.2 Preparations for pulling the belt onto the structure

Pulling in a STAHLCORD

®

Steel Cable Conveyor Belt

Preparations for installation

20

3 Preparations for installation

Preparations for installation

Installing and splicing a conveyor belt is a job for experts. To give a proper description of these operations at this point would involve far too much detail (cf. Conveyor Belt Edition, "Installing and Splicing Conveyor Belts").

3.1 Preparing the structure

11 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-trought transition

4 Snub or deflector pulley 12 Trough-to-flat transition

5 Tail or bend pulley

(take-up pulley)

13 Feed chute

14 Belt cleaner (transverve scrapter)

6 Top run (tight side) 15 Belt cleaner (plough-type scraper)

7 Return run (slack side) 16 Drive unit

8 Top run idlers 17 Counterweight

A thorough inspection of the entire structure for any defects or damage should be made before installing a new belt on an existing conveyor system. It is extremely difficult to check dimensions, take corrective action, replace damaged parts or do any welding jobs once the belt has been installed.

The structure must be carefully cleaned and feed/discharge points cleared of any leftover materials. The whole length of the conveyor should be optimally aligned, i.e. straight-tracked without any twisting.

The drive pulley, tail, snub and take-up pulleys should be set square to the centre line of the conveyor and be horizontal. If the pulleys are lagged, this is the best opportunity to inspect the lagging with optimum access to the pulleys. Various types of rubber lagging can be supplied for various applica-tions.The elasticity of rubber lagging and its grooves serve to effectively dissipate any moisture, prevent sticky materials from caking, as well as to cushion and accommodate stones depending on their size thereby keeping the belt in good working order. Friction grip of the rubber lagging is maintained.

ContiTech supplies CORREX® Rubber Sheeting in different grades and surface patterns to cater for different needs. Lagging can also be applied to the pulleys after the system has been in operation.*

* Further details of available types and instructions for lagging pulleys can be found in ContiTech's brochure, CORREX® Rubber Sheeting, Drum Lagging Materials and Abrasion Resistant Lining Materials.

21

Preparations for installation 3

The take-up station with the take-up pulley is positioned for textile fabric belts at the point of the shortest belt length. After splicing of the belt, sufficient take-up must be available to offset the belt sag during installation and its elongation.

Steel cable conveyor belts are low in elongation; the design engineer there-fore has to consider a shorter take-up than that for systems fitted with textile fabric belts. Nevertheless, belt sag during installation must also be taken into account for steel cable belts. Once the belt has been adequately tensioned, it is recommended that the take-up pulley or take-up carriage is adjusted so as to leave enough belt material for a join in the take-up length. The advantage of this is that it facilitates dismantling of the pulleys during structure repairs, and in the event of heavy damage to the belt, the belt can be tightened and a join made. Spindles, guides, rollers and hoists are to be cleaned and kept operational.

Idlers and idler sets in top and return runs are centered square to the belt line. Idlers have to be checked that they are rotating properly and that any material build-up is removed. Idlers with dented or worn covering, as well as those with bearing defects are to be replaced. Idlers have to be lubricated from time to time depending on the type. Self-aligning idlers on the top and return runs must be cleaned, re-aligned and kept rotating freely. Return idlers are exposed to heavy soiling and material build-up.

ContiTech Support Rings protect the idlers from wear and material accumulation; they contribute to the true running of the belt and help to keep the conveyor clean due to the low belt bearing area.

Scrapers and chuting are always those elements which, together with the conveyed materials, contribute the greatest amount of wear to the conveyor belt. Careful thought should be given during the initial phase of designing a conveyor system to ensure that the belt is subjected to the least amount of punishment. Deep troughing at the feeding point, restriction of the material flow and suitable configuration of the belt charging point can nowadays frequently eliminate the need for chuting or at least enable its positioning so that it has a protective instead of an abrasive effect on the belt.

Scrapers are made from rubber or plastic according to their intended application. The scraper material must be compatible with the materials being conveyed in order to achieve optimum cleanliness and protection against wear. Scrapers made from old conveyor belt waste, wood, steel or other materials lead to accelerated and premature wear of the belt.

Weighted or even self-adjusting scrapers are to be checked that they can move freely. Attachments are to be inspected for signs of damage, loose bolts or bent parts which could damage the belt.

Rubber scrapers can only be set and adjusted once the belt has already been installed and tensioned because this is the only way to achieve the correct contact pressure on the belt cover.

ContiTech supplies Scraper Blades made from different materials suited to individual requirements of the material conveyed and the conveyor.*

* See details of ContiTech's product range.

22


Loading and transfer chutes, tip chutes as well as hoppers should be inspected and relined with abrasion resistant material if required. Metal wearing plates and braces should be firmly seated. Loose plates are frequently the cause of belt slitting. Excellent results are achieved with ContiTech's CORREX

® Rubber Abrasion Resistant Sheeting which can be

subsequently applied using the cold bonding process.*

ContiTech offers a versatile range of materials with different technical properties to suit various in-service requirements.

CORREX® Abrasion Resistant Material with adhesive layer

(guide values)

Thickness Specific gravity

Hardness Abrasion

(to DIN)

Type

in mm in kg/dm3 Shore A in mm

3

6 8 10 15

CORREX®

CYCLOP L L 1.2 70 300

CORREX®

extra L L 1.1 60 110

CORREX®

super L L L L 1.1 55 55

CORREX®

red L L L L 1.1 45 200

CORREX®

beige L L L L 1.0 40 901)

CORREX®

red with herringbone pattern

L 1.1 45 200

L=stock line rolls of 50m, approx. 1200 mm wide. Also spezial-purpose grades, e.g. „V“=self-extinguishing, „FW“=flame resistant, oil resistant within limits, etc., available on request. 1) Measured at half load.

Standard sizes:

Thickness Width Length

4-15 mm 1200 mm 50 m ≥ 16 mm 1400 mm 5 m

All safety devices must be carefully inspected! This not only includes guards around the belt motor drive and the erected awnings, but also all electrical monitoring systems, visual and acoustic warning signals, emergency switches, safety lines, belt mistracking and slip monitoring devices, incorrect loading/spillage control, slit detection systems, etc. This work should be carried out prior to actual belt installation.

* See also ContiTech's brochure on CORREX® Rubber Sheeting, Drum Lagging Materials,

Abrasion Resistant Lining Materials.

23

Preparations for installation 3

3.2 Preparations for pulling the belt onto the structure

It is particularly important when setting up a new conveyor system that, prior to installation, a site inspection plus preliminary discussions on the procedure take place between engineers in charge from both the conveyor construction company and the belt manufacturers, as well as competent maintenance and electrical engineers from the client. During these discus-sions an installation programme should be established, the provision of auxiliary equipment and assisting engineers/staff planned, and the different areas of responsibility determined.

The site for hanging the new belt in let-off stands, the optimum method of pulling the belt onto the structure and the site for intermediate and final splicing should also be jointly agreed upon.

3.2.1 Hanging the belt roll in let-off stands

The winding method is governed by local conditions. The belt roll is suspended in mobile let-off stands, the simplest type of which is fitted with open U-shaped bearings to support the axle ends. Bearings should be secured by bolts or stirrups. For small conveying systems, mobile cable reel jacks are also adequate for hanging in the roll.

For conveying systems over substantially different levels of ground, the belt must be pulled in upwards using an appropriate hoist or downwards onto the system by means of suitable braking and intercepting devices capable of effectively moderating the maximum slope fall.

To ensure the belt is pulled straight onto the system, the roll should as far as possible be positioned at right angles to the centre line of the system and centered in front of, behind, below or above the structure. If it is only possible to pull the belt in from the side, it should be done at an acute angle to the system. This requires a number of deflection idlers and fender rollers between the unwinding point and entry onto the structure or groups of laterally extended troughing idlers to form a lead-in guide onto the centre of the system. All short twists and bends must be avoided when pulling the belt onto the structure and particular care should be taken to avoid any tendency to tear the belt edges.

3.2.2 Pulling in the belt

Before belt installation, all parts of the structure that come into direct con-tact with it must be cleaned of oils and lubricants. The belt may not be dragged across sharp-edged steel sections or wall edges. Fender rollers must be fitted at such points. The process itself of pulling in the belt is also determined by local conditions. Although small belts can be lifted manually or with pulling cables or a hoist, long belts require motor-driven cable winches or cables with corresponding traction vehicles such as trucks, Unimogs, bulldozers, etc.

Prior to lifting the belt onto the system, a control must be made to ensure that the top cover of the belt will come to rest upwards in the top run and downwards in the return run. If the top cover of the belt is not marked with a stamp, it can be recognized by the cut edge at the beginning of the belt as the thicker of the two covers.

24


The top cover of a rolled belt usually faces outwards. If the suspended roll is unwound from above, the outer cover is also on top when the belt enters the conveyor system.

If the roll is turned so that unwinding is done from below, the outer cover faces downwards.

If the worn belt of a conveyor system is to be replaced by a new one, the easiest method is often to attach the new belt to the old cut belt so that when winding up the old belt the new one is automatically drawn onto the system.

The method chosen is best left to the discretion of the supervising engineer. There are a number of different possibilities depending on site conditions, but it would involve too much detail to explain them all in this brochure.


4.1Splicing fabric-ply conveyor belts

4.2 Splicing steel cable conveyor belts

Splicing conveyor belts

Hot vulcanizing press

26

4 Splicing conveyor belts

Splicing conveyor belts Depending on the length of a conveyor system, the belt is made endless either by splicing its two ends after it has been drawn onto the structure, or by suitably splicing the individual part-lengths to form one continuous length.

4.1 Splicing fabric-ply conveyor belts

There are two methods of splicing fabric-ply belts.

4.1.1 Mechanical splices (detachable)

Hook fasteners

Detachable splices using mechanical fasteners are recommended for conveyor belts which have to be frequently replaced, shortened or lengthened, as in underground mining service.

The mechanical splice is quick to carry out and allows the conveyor to resume operation after just a short time. Another advantage is the low loss of belt material - splicing is done with straight, rectangular belt ends and the fasteners do not extend far into the belt, which means little waste when making a new splice or replacing a defective one.

Utilization of the belt strength varies to a great degree when using mechanical fasteners. It depends largely on the type of belt, the type of fabric in particular as well as on the type of fastener, and ranges between 50% and 90%. If a thin, flexible belt is to be joined with mechanical fasteners, care should be taken that the pulley diameters are suited to the fastener holding ability.

4.1.2 Vulcanized splices (non-detachable)

The commonest and most successful type of splice for fixed conveyors and heavy-duty belts is still the hot vulcanized or cold vulcanized splice. If made properly by an expert, this splicing technique guarantees maximum utiliza-tion of the belt strength, longest service life and the best tracking properties of the belt. These splices also display optimum properties when chuting is used at loading points or when scrapers are fitted to eliminate material build-up or clean the belt.

Fabric-ply conveyor belts are normally spliced with staggered steps and butting of the corresponding fabric plies of the two belt ends.

27

Splicing conveyor belts 4

The splice is the weakest point in the entire belt. Due to this method of stepping the plies, one fabric ply has to be omitted reducing the tensile strength of the joint by a percentage which is related to the overall number

of plies in the belt. The lower the number of plies, the greater the loss of strength as a percentage of the overall belt strength.

The high tensile strength of today's fully synthetic fabrics enables conveyor belts to be manufactured in all strengths up to 1250 N/mm belt width with just two fabric plies. The special feature of the CON-BITEX

® Belt is its thicker

rubber interlayer which permits various types of splices to be made.

Whereas the one-step splice only transmits approx. 50% of the belt strength, up to 100% of the belt strength can be attained using additional fabric or the interlaced splice.

The strain on the splice when bending over idlers and pulleys is reduced by taking a bias length of

LA = 0.3 . B

The additional belt length for the splice overlap is therefore

LVZ = z . LS + LA

for fabric-ply belts with z number of steps.

Step length LS is determined by the strength of the individual fabric plies.

Two-step splice

One-step splice

Splice with additional fabric (CON-BITEX

®)

Interlaced splice (CON-BITEX

®)

28


Splice dimensions for fabric-ply belts

Additional belt length for overlap Belt type Step length LS in mm

Number of steps z LVZ in mm

160/1 200 200

200/1 250 250

250/1 250 250

315/1 300 300

400/1 300 300

CON-MONTEX®

500/1 350

1

350

+ 0.3 . B

CON-BITEX

®

one-step or with additional fabric

two-step or interlaced

200/2 180 180 360 + 0.3

250/2 180 180 360

315/2 180 280 360

400/2 200 200 400

500/2 200 200 400

630/2 250 250 500

800/2 250

250

+ 0.3 . B

500

B 200/3 100 200

200/3 100 200

250/3 150 300

315/3 150 300

400/3 200 400

500/3 200 400

630/3 250 500

800/3 250 500

1000/3 300 600

EP

1250/3 300

2

600

+ 0.3 . B

B 250/4 100 300

400/4 150 450

500/4 200 600

630/4 200 600

800/4 250 750

1000/4 250 750

1250/4 300 900

EP

1600/4 300

3

900

+ 0.3 . B

B 315/5 100 400

500/5 150 600

630/5 200 800

800/5 200 800

1000/5 250 800

1250/5 250 1000

EP

1660/5 300

4

1000

+ 0.3 . B

29

Splicing conveyor belts 4

4.2 Splicing steel cable conveyor belts

In a steel cable conveyor belt splice the individual corresponding cables of the two belt ends are placed side by side alternately and embedded in a special rubber compound. The type of splice used is predetermined for each belt strength rating by the diameter and spacing of the cables.

Splicing configurations to DIN 22131 (provisional standard)

one-step splice

three-step splice Steel cable belts too are normally spliced at a bias of

LA = 0.3 . belt width B

Right-angle joints are possible if suitable equipment is available.

two-step splice

30


Recommended splice dimensions for steel cable belts to DIN 22131 and special types (guide values)

Belt type Step length Number of steps Additional belt length for overlap

LS in mm z LVZ in mm + LA

St 500 250 1 550

St 630 250 1 550

St 800 300 1 600

St 1000 300 1 600

St 1250 350 1 650

St 1400 350 2 1000

St 1600 450 1 750

St 1800 400 2 1150

St 2000 400 2 1150

St 2250 400 2 1150

S1 2500 500 2 1350

St 2800 600 2 1550

St 3150 650 2 1650

St 3500 650 3 2350

St 4000 750 3 2650

St 4500 800 3 2800

St 5000

St 5400

St 6300

St 7300

Splicing system is chosen in accordance with design conditions

Other splicing systems are possible

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


5.1 Tensioning the belt

5.2 Starting the belt

5.3 Training the belt

Commissioning

Long-distance conveyor in operation

32

5 Commissioning

Commissioning

After splicing the conveyor belt, the press, worktop and all auxiliary splicinig facilities are dismantled and removed. Idler sets are returned to their positions in the top and return runs, properly aligned and secured.

5.1 Tensioning the belt

It is assumed that the structure will have been erected correctly before belt tensioning takes place. If using the screw take-up method, the take-up gear on either side of the take-up pulley is to be adjusted so that the pulley with- draws square to the centre line of the system, thus tensioning the belt. With a gravity take-up, the supported counterweight is returned to its hanging position, or alternatively the winch tightened accordingly in the case of winch tensioning.

The belt must be tensioned so as to ensure that

a) the required tension is available at the drive to effectively transmit the peripheral force of the drive to the belt. Insufficient tension leads to belt slip on the pulley, premature wear of both belt and lagging, causing interference during operation.

b) there is no belt sag between the individual idler sets and that troughing

does not flatten to allow material spillage.

c) the belt shows a good flat-to-trough transition even when running with no load, thereby gaining enough friction contact with the lateral idlers to keep it running true. For small conveyor systems, the expert installation engineer will be able to adjust the correct tension on the basis of experience. For large conveyor systems, the required tension is predetermined during the design phase, or calculated from the required tension of the pulley and permissible sag of the belt between idlers.

5.2 Starting the belt

All is now prepared for the initial run, however it is recommended that the entire system is inspected again before starting the commissioning operation. Any tools left lying around or parts of the structure, screws, etc. placed on the return run are to be removed. If necessary, the return run should be swept clean again. Check that work has been satisfactorily completed on all parts of the system.

A locking device over the electric switch has proved to be an effective precautionary measure in this connection. It is secured by each group of workers with a marked padlock and the conveyor is not released for commissioning until all padlocks have been removed.

33

Commissioning 5

If the system has a large centre distance, it is advised that a team of capable observers be posted at intervals along the conveyor in such a manner as to enable visual and audible signalling. First of all the belt is switched on briefly to move it forward about 10 to 15 m depending on the system length. This makes sure that the belt initially rests properly on the idlers. Then a second short burst of power is given, after which the supervising engineer awaits the reaction of his observers. If no problems are reported, the belt can be run under steady power. Constant monitoring is important to see if there is a tendency to run out of line, so that corrective action can be taken.

Fabric-ply belts in particular require a certain amount of time before running with load to allow them to adapt to the system configuration and troughing. If a belt shows a tendency to run off-centre at the beginning, there is no reason to interrupt the trial run and expect to find the cause in the work of the vulcanizers or even a faulty belt. Every start-up operation needs corrective action. Belt and system must adapt to one other. This is best done with the belt running, if possible under full load conditions.

5.3 Training the belt

Training a belt, especially on a long conveyor system, requires a great deal of patience, clear logical thinking and action. If at the beginning the belt comes into contact with some points of the fixed structure, the conveyor does not have to be stopped immediately - belt edges do not suffer the damage that easily. Alignment is only possible when the belt is running, because it is only during operation that the effect of any adjustment can be observed. If the belt runs off-centre, correction begins before the point of misalignment seen in the direction of belt travel.

How can misalignment be corrected?

The drive pulley has been thoroughly checked during preparations for commissioning: it is horizontal and set square to the belt axle. It has been cleaned of all caked material. Therefore, this pulley should as far as possible be left untouched. If the belt does not centralize, the final troughing idlers before the drive pulley are to be adjusted.

The tail pulley, often designed as a take-up pulley on small conveyors is usually screw-adjusted. Though it would be preferable to leave the pulley in the position it was during control of the belt tension, belt tracking can be corrected at this point if absolutely necessary.

The general rule is:

Conveyor belts enter downwards

34

5 Commissioning

Conveyor belts enter downwards

A belt always follows the path of reduced tension, i.e. it runs towards the pulley edge which has retracted as a result of slackening the screw take-up.

The troughing idler transoms on the top run are attached to the structure by means of slots or clamps in such a manner that lateral adjustment is possible. By tilting the idler sets forwards or backwards, a position is attained where the friction between idler and belt acts as a steering force on the belt.

The following rule generally applies in practice: To bring the belt closer - hammer the group of troughing idlers away from the direction of belt travel. To push the belt further away - hammer the group of troughing idlers towards the direction of belt travel.

Direction of belt travel

Axle position

Direction of belt travel

To bring the belt closer

To push the belt further away

35

Commissioning 5

The following characteristic behaviour should be noted:

The belt always runs towards the point of initial contact with the idler!

Idler adjustment likewise requires a lot of patience and initiative. Three to four idlers at a time are slightly adjusted and the results are observed during operation before further alignment is made. Idler adjustment on the return run is done in the same way as that for the top run.

Centralization of the belt on the return run is substantially more difficult to control than on the top run. Return idlers in particular and the tendency to arching of a belt with largely varying cover thicknesses frequently cause trouble due to the small area of contact between the belt edges and the idlers, resulting in low forces to steer the belt. It is therefore advisable to install two-part return idlers at a slight troughing angle on large conveyor systems.

Return run idlers are in permanent contact with the carrying side of the belt and are highly vulnerable to soiling and material build-up resulting in misalignment. ContiTech Support Rings are Rubber-Covered Rollers can be installed to prevent the material from accumulating on idlers.

It should be remembered though that support rings do not have a cleaning effect due to the rolling line contact with the belt surface, i.e. care must be taken to ensure that the structure beneath the conveyor belt is kept as clean as possible. Rubber sleeves drawn over standard carrying idlers make better contact with the belt surface due to their flexibility. This in turn considerably enhances the steering properties needed to minimize belt training problems. On the other hand, flexing of these sleeves cleans the belt surface which means that a greater amount of material accumulation beneath the structure is to be expected.

True running of the return strand just before the tail pulley is of prime importance. Material feed onto the belt centre is only possible if the belt is straight when it enters the tail pulley on the return run and this is essential for straight tracking on the top run. Off-centre feeding can escalate belt misalignment to such a degree that it may run to one side and curl upwards. This always leads to heavy damage to the edges and partial destruction of the fabric plies. Under these circumstances, the tension member of a steel cable belt can be completely destroyed after curling up and winding around a pulley.

Effective adjustment can be made at the snub pulley as the area of contact is particularly high at this point. For this reason the use of conventional carrying idlers for narrowing down is not recommended, but instead pulleys with an appropriately large diameter and rubber covering. No support rings are to be fitted to the snub pulley.

If a long conveyor system has a very unstable return run, belt tracking may be improved by installing a group of reversed troughing idlers on the return run. The last set of this idler type should be positioned approx. 4 to 5 m before bend point so that the steering forces can be fully effective right up to where the belt enters the pulley.

36

5 Commissioning

Section A - A

Vertical idlers to restrict the degree of float are only to be considered in an emergency. They are to be spaced as wide apart as the system allows to ensure that they are not in constant operation, thereby exerting unnecessary pressure or causing excessive flexing of the belt edges.

Centre feeding of materials is important to ensure true running of the belt. A decisive factor is the design of the material loading point. If two conveyors are erected at an angle to each other, devices should be installed to redirect material flow so that it enters the belt in the direction of belt travel, i.e. chutes, troughs, spiral chute feed hoppers, etc. This guarantees proper loading of materials onto the belt centre and takes care of the conveyor belt. If connecting structure is not possible for reasons of space, baffles are to be hung in the trajectory to ensure that the materials bounce off and fall onto the belt centre.

37

Commissioning 5

Effects of weathering when exposed to wind, rain, snow and frost can lead to considerable mistracking if the conveyor is unprotected. Pulleys, idlers and the return strand are susceptible to moisture on one side, particularly at the onset of heavy rain when it is slanted by strong winds. This results in different friction values between the two sides of the belt and the structure parts and eventually to belt misalignment. Here too, a substantial improve-ment is achieved by using pulleys with grooved rubber lagging which squeezes off the film of moisture.

If a conveyor is elevated, e.g. across a valley, the belt may be forced off the structure by strong gusts of wind. Particularly vulnerable conveyor systems are therefore fitted with gale shackles.

Long conveyors with a tendency to unstable running due to various influential factors can be provided with groups of self-aligning idlers for automatic belt alignment. These are sets of troughing idlers or flat idlers which are supported in the centre and swivel around a pivot. Various types are available on the market but they all work according to the same principle. Two lateral rollers set at right angles to the outer troughing rollers are connected to the pivoting set of rollers via a lever attachment. If the belt wanders, its edge is pressed against the lateral roller, which is in turn pushed forward in the direction of travel together with the set of rollers on the same side via the lever attachment. The group of rollers turns the opposite flank against the direction of travel, which brings the belt closer. The belt realigns automatically. Special care should be taken that self- aligning idlers are positioned somewhat higher than the other groups of idlers, so that the belt weighs more heavily on them.

Direction of conveying

38


6.1 Daily inspection of the conveyor belt; causes of belt damage

6.2 Daily inspection of the system

Operation and problem solving

Belt entering a turnover

40

6 Operation and problem solving

Operation and problem solving

If commissioning a new conveyor or installing a new belt on an already existing conveyor, much of this work can be regarded as normal maintenance procedure.

The life of a belt is determined by two factors:

a) Aggressiveness of the materials conveyed

b) Maintenance of the structure

A belt takes the greatest amount of punishment from its burden at the loading point. Once the materials have come to rest properly on the belt and are accelerated, they cause hardly any wear (except in the case of hot or chemically aggressive materials). All other damage is caused mechanically by the structure, i.e. damage to the structure is reflected in the belt. A regular inspection program by maintenance staff increases belt life.

6.1 Daily inspection of the conveyor belt

If a replacement belt has been installed, the take-up point is to be closely monitored. Initial belt stretch requires an increase in the tension. Belt splices are to be checked for any signs of separation. Covers of the belt are to be inspected for damage to the carrying and the bottom side. The cause of longitudinal grooving, excessive localized wear and chatter marks can generally be found at the following points:

a) Scrapers:

adjust rubber where needed

b) Structure:

check where the belt is chafing against the structure; the cause of damage may be protruding bolts, bent bracing or jammed stones

c) Idlers:

missing idlers, belt is rubbing against attachment or structure bracing; stalled idlers, belt is dragging across idler or material accumulation; idler shell worn away, open edges cause slitting; defective bearing, idler out of line, belt chafing and mistracking

d) Feeding and transfer points:

foreign matter and stones lodged in the hopper, over-filling due to faulty operation or clogging; materials accumulating beside the structure and falling onto the return run; stones jamming between the bend pulley and the baseplate

e) Drive pulleys:

damaged pulley shell, material build-up, damaged lagging f) Inspect coupling, brake adjustment and take-up point; belt slips on

starting and stopping

g) Chuting may be exerting too much pressure; adjust rubber, remove lodged materials.

Note: Please also see the troubleshooting guide in the back sleeve of this brochure.

41

Operation and problem solving 6

The cause of penetrations or holes in the cover should initially be sought at the feeding point. The source of both these types of damage can usually be found here.

a) High forces of impact caused by material with a large lump size or falling from a great drop height. This can be remedied by installing chutes, a grid, vibration ducts, etc. Whenever possible, load fines first. Reduce spacing between troughing idlers and equip with ContiTech Impact Rings. The use of garland idlers which give way has also proved successful.

b) Material between the belt and pulley. Remedy: Side lining at the loading point and lateral chuting are to be designed to prevent the material from spilling or bouncing out. The return strand is to be covered beneath the feeding point. The plough scraper on the return run must be beyond the feeding point and fitted closely before the tail pulley. The tail pulley is to be provided with a cleaner and dirt repellent to ensure that scraped off material does not drop back onto the return run and is caught up in circulation.

If cracking on the top side should occur around the area of impact, then the belt has been exposed to too much heat.

Should swelling show on the cover, this is caused by oil, grease or chemical attack (excessive lubrication of structure parts should be avoided).

42

6 Operation and problem solving

Damage to belt edges

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

6.2 Daily inspection of the system

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


7.1Repair materials

7.2 Repairing damage with CONREMA

® Repair Materials

CONTI STAHLCORD

® Steel Cable

Conveyor Belt carrying broken limestone

Maintenance and repair

44

7 Maintenance and repair

Maintenance and repair Large companies usually have their own team of maintenance personnel, including specially trained vuicanizers, who are capable of conducting all maintenance work.

Maintenance work is often contracted out to vulcanizing specialists who undertake to procure replacement belts, install them, perform all splicing jobs, inspect the conveyor system at regular intervals and do repairs when the conveyor is not in operation. Depending on the size of the company, a general overhaul on dismantled belts is frequently carried out on the specialist's own premises.

It is still advisable to repair damaged points as quickly as possible and avoid damage spreading, even with today's fully synthetic fabrics which are insensitive to moisture. ContiTech's CONREMA

® Cold Bonding Repair

Materials were specially developed for the time-saving and reliable repair.

7.1 Repair materials

CONREMA® Cold Bonding Repair Materials are designed for conveyor

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

CONREMA® Cold Vulcanizing Cement

(approved for use in underground mines in Germany)

CONREMA® Cement is mixed with 5% CONREMA

® Activator Solution

(approved for use in underground mines in Germany). 1 kg and 3 kg packs are held on stock. CONREMA

® Activator is portioned in accordance with the

pack sizes of CONREMA® Cold Vulcanizing Cement. Larger packs, with or

without activator, are available on request.

CONREMA® may only be applied as a mixture (cement + 5% activator). Only

the exact amount required is mixed immediately before use.

Cold Vulcanizing Cement and Activator are easy to mix and are workable for approximately 2 hours.

CONREMA® Patches and Tapes

Type N for the normal cover grade Type V for coal mining service (approved for use in underground mines in Germany)

These patches and tapes are packed in protective film to avoid damage to the cover and adhesive layers. They are tapered off at the edges.

The following sizes are available:

CONREMA® Round Patches (contents:10 pcs.)

Patch diameter: 50 mm

80 mm

100 mm

120 mm

45

Maintenance and repair 7

CONREMA® Diamond Patches (contents: 10pcs.)

Diamond sizes: 110 x 135

190 x 245

270 x 345

CONREMA®-Repair Tapes (contents: 10pcs.)

Tape sizes 50 x 4000 mm

100 x 4000 mm

150 x 4000 mm

220 x 4000 mm

400 x 4000 mm

CONREMA® Repair Sheeting

Types N and V (approved for use in underground mines in Germany) CONREMA

® Repair Sheetings is supplied in rolls.

The adhesive layer is covered with protective film

Repair Sheeting is available as follows:

With adhesive layer on one side

Sheeting thickness 1.5 mm

2.0 mm

3.0 mm

5.0 mm

Length of roll: 10 m

Width of roll: 1200 mm*

* also available in other cut-width

With adhesive layer on both sides

Sheeting thickness: 1.5 mm

3.0 mm


Width of roll: 1200 mm*

* also available in other cut-width

CONREMA® Repair Fabric

This is an EP 200 fabric with adhesive layer on both sides, both covered with protective film.


Width of roll: 1000 mm

CONREMA®

Adhesive Layer

The adhesive layer is covered with protective film.

Sheet thickness: 0.5 mm

Length of roll: 5 m

Width of roll: 1200 mm

46


7.2 Repairing damage to conveyor belts with CONREMA® Repair Materials

Preparing the damaged area

- thoroughly remove any residues of conveyed material

- cover and fabric must be clean and dry

- use hot-air blower or infrared dryer

Treating the damaged area

- slightly roughen the cover and cut edges

- use rotating wire brush, emery cloth or other roughening device

- do not damage the fabric surface

- thoroughly remove buffing dust using a dry process

- first coat of CONREMA® Cold Vulcanizing Cement and Activator mixture

must be allowed to dry completely

- allow second coat of CONREMA® Cold Vulcanizing Cement and Activator

mixture to dry until tacky

Applying the repair materials

- CONREMA® Patches, Sheeting and Tapes must be recessed into the cover

to avoid damage by the belt scraper

- peel off protective film, coat the adhesive surface once with CONREMA®

Cold Vulcanizing Cement and Activator mixture

- place the surfaces together, apply firm pressure using a roller and working from the centre outwards

- moisture and dust on the surfaces impair the level of adhesion obtained

7.2.1 Repairing damaged covers

Repairs with CONREMA® Round or Diamond Patches

- clean the damaged area of any residues of conveyed material

- select suitable shape and size of patch

- place patch over damaged area

- mark patch outline on damaged area

- strip cover rubber from damaged area or cut into it using an inclined knife (approx. 30° to the belt surface)

- pull off cover rubber

- dry the damaged area if necessary

- slightly roughen the cover edge and cut area using a rotating wire brush

Caution! Avoid damaging the fabric or smoothing off the rubber

- remove buffing dust by a dry process - mix CONREMA

® Cement with 5% CONREMA

® Activator

47


- coat cover edge and damaged area with CONREMA® mixture

use a short-bristled brush work well into fabric structure

- allow first coat to dry thoroughly

- apply second coat to damaged area

- peel protective layer from adhesive layer of the patch

- coat adhesive layer once

- check degree of dryness of the second coat

Caution! Back to the hand test, i.e. the coat does not dry completely but feels tacky to touch

- once the stage of feeling tacky has been reached, apply patch with its adhesive layer on the damaged area and by turning the patch edges

upwards, apply the centre part first

Caution! Do not try to remove the atch again after it has made contact with thesurface as this destroys the adhesive layer

- press down using a wide hand roller, working from the centre outwards

- roll again firmly with a narrow roller

- avoid or roll out trapped air

- finally roll firmly around the edge of the patch

Repairs with CONREMA® RepairTapes

The same procedure is followed to prepare the damaged spots when repairing cover cracks or chafed areas. CONREMA

® Repair Tapes are used

to fill out the damaged areas.

When joining a number of repair tapes, the beveled start of the second tape is overlapped over the beveled end of the first tape.

48


Caution! When tapes are joined, the direction of taper should be opposite to that of belt movement, so as to avoid any tendency for the scraper to "lift" the tape

When repairing long tears the belt can be advanced to reposition the working area once the first repair tapes have been firmly applied.

Repairs with CONREMA® Repair Sheeting

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

® Repair Sheeting in various thicknesses.

Methods are the same as those described on the previous pages, except that the patches are cut to size from CONREMA

® Repair Sheeting in

accordance with the damaged area. As these self-made patches have no tapered edge, the patch edge is firmly rolled onto the slanted cut edge of the damaged area and the excess patch edge is trimmed using a inclined knife.

Steel cable conveyor belts are also repaired with CONREMA® Repair

Sheeting following the same procedure. Since it is not possible to remove the cover from one fabric ply, the cover is sliced or chamfered down to just above the steel cable layer using a knife held at a slant and then buffed. The prepared damaged area is then mended using CONREMA

® Repair Sheeting

as already described.

Where covers are thick or damage is deep, the damaged area is initially filled in using repair sheeting with adhesive layers on both sides, which is sandwiched and then covered with ordinary repair sheeting.

7.2.2 Repairing penetrations and damage to the fabric

It is essential to repair a penetration immediately to avoid the fabric tear extending. CONREMA

® Repair Sheeting and CONREMA

® Repair Fabric are

designed for this repair work. The fabric tear may not exceed 25% of the belt width (danger of the belt ripping apart and risk of belt tracking problems). If the damaged area is too large, cut the whole section out and replace it with a new piece of belt.

When repairing fabric damage, the cover and the individual layers are stepped in length and width at about 30 mm.

Shape of the area to be repaired

Diamond-shaped with the point towards the direction of travel and longitudinal edge parallel to the belt edge.

- clean the damaged area of any residues of conveyed material

- outline the dimensions of the repair area with rule and chalk on the belt surface

- cut into the cover as shown with the knife inclined at approx. 30°

- cut rounded corners

49


- raise the cover from the fabric around the cut area using a loosening tool

- pull off the cover with saddler's pliers or blunt nipper pliers

- where large areas are involved, cut the cover in strips beforehand using a ripping knife

- mark the first 30 mm wide step on the exposed layer of fabric

- cut into the fabric layer with a layer knife

- force up the cut edge of the fabric layer with a loosening tool

- cut the fabric into longitudinal strips

- pull off the fabric strips with saddler's pliers

- repeat fabric stepping until all fabric layers have been stepped; only the bottom fabric layer with the tear remains intact

- slightly roughen the slanted cover cut and a 15 mm wide border strip of the cover using a rotating wire brush

- remove residual rubber on the fabric plies with a rotating wire brush without impairing the fabric

- remove buffing dust using a dry process

- either turn the belt over, twist or advance it, or continue work on the bottom side underneath the belt

50


- continue work on the bottom side following the methods already described by cutting a rhombic shape into the cover and pulling it out. The fabric layer remains intact.

- slightly roughen the slanted cut area of the cover and an approx. 15 mm wide cover border strip with a rotating raising brush

- remove buffing dust using a dry process

Check the damaged area for moisture; if necessary, dry the fabric thoroughly using an infrared dryer or hot-air blower.

- if the fabric tear is badly frayed, trim the torn edge with scissors

- coat the prepared area of the bottom side, including the slanted cut in the cover and the cover border strip with CONREMA

® mixture

- measure the thickness of the extracted piece of cover

- choose CONREMA® Repair Sheeting approx. 0.5 mm thinner

- cut a patch from the repair sheeting, about 10-15 mm wider and longer than the prepared repair area

- peel the protective film from the adhesive layer

- apply a second coat of CONREMA® mixture to the prepared repair area

- the adhesive layer of the patch is also given a coat of CONREMA®

mixture

- check how dry the second coat is

- once it has reached the tacky stage, apply patch with adhesive layer to the repair area

- press down patch well with a roller, working from the centre outwards

- trim patch excess at the cover border strip using an inclined knife

- turn belt over again to repair the top cover

- coat repair area and cover border strip with CONREMA® mixture

- fill the gap in the bottom fabric ply resulting from trimming the fabric tear with tie gum

51


- press down the tie gum firmly using a narrow roller

- cut a suitable piece of the CONREMA® Repair Fabric for each stepped

area

- coat the bottom fabric ply with CONREMA® mixture

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

® mixture

- once it has reached the stage of feeling tacky, place the piece of repair fabric on the bottom fabric ply of the repair area

- press the repair fabric down well using a hand roller

- after rolling, pull the protective film from the upper side of the repair fabric

- coat the next fabric step and the surface of the inserted piece of fabric with CONREMA

® mixture

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

® mixture

- once the repair fabric has reached the tacky stage, position the repair fabric and roll down firmly

- repeat this procedure until all fabric steps have been filled in

- measure thickness of the extracted piece of cover

- choose repair sheeting approx. 0.5 mm thinner

- cut a patch from the repair sheeting, about 10-15 mm wider and longer than the prepared repair area

- coat the last step of the repair area, fabric surface and adhesive layer with CONREMA

® mixture

- once the tacky stage has been reached, apply the patch to the repair area, unrolling it from one side

52


- press down the repair sheeting firmly with a roller, working from the centre outwards

- trim patch excess using an inclined knife

- roll the edge of the patch again firmly along the slanted cut

- coat the patch outline with CONREMA® mixture and allow to dry

With steel cable conveyor belts, penetration damage is repaired from the top and bottom sides in the same way as that done for covers. If more than one cable has been destroyed, damage assessment should always be obtained from an expert to see whether the remaining belt strength is sufficient or whether the belt will have to be cut open and respliced using the hot vulcanizing process in order to re-establish the full belt strength.

Detailed instructions on repair procedures with CONREMA® Repair

Materials are given in ContiTech's brochure: CONREMA® "The Repair of

Conveyor Belts using the Cold Bonding Process".

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


Seasonal shutdown and winter operation

View of a downhill

conveyor

54

8 Seasonal shutdown and winter operation

Seasonal shutdown and winter operation

Conveyor operators who shut down the system at certain intervals are advised to use these periods of standstill for a thorough overhaul of both the belt and the system structure.

The belt should be emptied of all materials and properly cleaned. Cleaning should be done as far as possible using clear water, with perhaps a small amount of washing agent added. Do not use solvents, diesel oil or petrol. A final wipe with a mixture of glycerine and spirit likewise does no harm.

The belt must be slackened and all scrapers or cleaners disengaged. No special treatment of the belt is necessary because an anti-oxidant has already been applied to the covers.

All structure parts should also be cleaned and inspected as described in section 3.1 - Preparing the structure.

Where circumstances allow, the conveyor system should be run empty from time to time in winter during periods of heavy frost. If the belt should slip due to ice on the pulley, this can be remedied by throwing a few handfuls of sawdust between the pulley and the belt. Never use sand or grit for this purpose!

A concise manual such as this cannot possibly cover all likely occurrences, but we do hope to have provided some useful tips to help enhance performance and cut costs in the operation of your belt conveyor.

55

56

Index

B Belt conveyor, layout _____________3.1 Belt damage ____________________6 Belt designation _________________1.1.1/1.1.2 Belt splice ______________________4.1 Belt tension _____________________5.1 Box-section belts ________________1.2.4

C Changing a belt__________________3.2.2 Chuting ________________________3.1 CON-BITEX

® (2-ply)

conveyor belts _________________1.1.1/4.1.2 CON-MONTEX

® (1-ply)

conveyor belts _________________1.1.1 CONREMA

® repair materials _______7.1

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

® abrasion resistant

material ______________________3.1 Corrugated sidewall belts __________1.2.4 Covers_________________________1.2.2/6.1 Cover thickness _________________1.2.1 - patterns _____________________1.2.4 - reinforcement_________________1.2.3 - repairs ______________________7.2.1

D Damage to belt edges_____________6.1

E Elongation______________________3.1

F Fabric-ply belts __________________1.1.1/4.1 Feeding chutes __________________3.1 - hoppers _____________________3.1 - points _______________________3.1/5.3/6.1 Fin-type belt ____________________1.2.4

G Garland idlers ___________________6.1 Guide idlers_____________________5.3

I Idlers __________________________3.1 - impact rings __________________3.1/6.1 - positioning ___________________5.3 - rubber sleeves ________________5.3 - support rings _________________3.1 Impact rings ____________________3.1/6.1 Inspection ______________________6.1 Inspection of belt splices___________6.1 Installation______________________3.1/3.2

M Material feeding point _____________3.1/5.3/6.1 Mechanical fasteners _____________4.1.1 Misalignment____________________5.3/6.1 Multi-ply conveyor belts ___________1.1.1/4.1.2

O Order data______________________2.1

P Partitioned belt _________________ 1.2.4 Penetrations ___________________ 6.1 Plough-type scrapers ____________ 6.1 Pulley lagging __________________ 3.1 - positioning __________________ 5.3

R Repair ________________________ 7 Repairing penetrations ___________ 7.2.2 Repair materials ________________ 7.1 Repair procedures ______________ 7.2 Roll axle ______________________ 2.2 Roll sizes______________________ 2.2 Rubber sleeves _________________ 5.3 Running behaviour ______________ 5.3/6.1

S Safety devices__________________ 6.2 Scrapers ______________________ 3.1/6.1 Self-aligning idlers_______________ 6.1 Service life_____________________ 6 Slip __________________________ 6.1/8 Splice, detachable (mechanical fasteners)__________ 4.1.1 Splice, non-detachable (vulcanized) __________________ 4.1.2 Splicing fabric-ply belts ___________ 4.1 Splicing steel cable belts__________ 4.2 STAHLCORD

® steel cable belts ____ 1.1.2/4.2

Steep-angle conveyor belts _______ 1.2.4 Storage _______________________ 2.2 Strength ratings_________________ 1.1.1 Support rings___________________ 3.1

T Take-up pulley__________________ 3.1/5.1 Tension member repairs __________ 7.2.2 Tension members _______________ 1.1.1 Training _______________________ 5.3 Transportation__________________ 2.2 Troughing idlers ________________ 5.3

W Wear _________________________ 6 Weight________________________ 2.2 Winter operation ________________ 8

57

ContiTech Spezialist in rubber technology Conveyor Belting

Conveyor belt systems - Troubleshooting guide

Continental Aktiengesellschaft

ContiTech has compiled this problem location table especially with the conveyor system operator in mind. It serves as an effective aid in quickly tracing any problem to its source.

The conveyor belt must be optimally matched to the conveyor system to ensure reliable, problem-free operation and maximum service life. Early "problem analysis" can help to avoid errors and eliminate con-sequential damage.

If you have any difficulty in locating the cause of disturbances even after consulting our table, or if you have any further technical questions, do not hesitate to contact ContiTech's Application Engineers.

Research and Development Conveyor Belting Application Engineering (Dept. 63311) Continental Aktiengesellschaft P.O. Box 1 69 3000 Hannover 1 Germany Phone: (511) 21 41-1 Fax: (511) 21 41-5 83 Telex: 9 2 170 con d

ContiTech Specialist in rubber technology

Range ContiTech Continental Offices

Conveyor Belts:

Fabric Ply Belts

Steep Angel and Vertical Conveyor Belts

Special Purpose Belts

Special belt types

STAHLCORD® (steel cable)

Conveyor Belts

Conveyor Belting Accessories:

CORREX® Pulley Lagging with

patterned surface and adhesive layer

CORREX® Pulley Lagging and

Abrasion Resistant Materials with smooth surface and adhesive layer

Scrapers

CONREMA® Cold Bonding Cement

CONTI PLUS® Adhesion Promoter

CONREPA® Repair Paste

Cleansing Agent

CONREMA® Cold Repair Materials

with adhesive layer

Hot repair and splicing materials for fabric belts

Hot repair and splicing materials for STAHLCORD

® (steel cable) belts

Support and Impact Rings

Corrugated Sidewalls and Extrusions

Advanced technology in rubber processing and manufacture

Worldwide application

Latest technology in production and development

Conveyor Belting

Coated Fabrics and Engineered Products

Industrial and Automotive Hose

Power Transmission Products

Air Springs

Anti-Vibration and Sealing Mouled Products

Extrusions

Footwear Products

Cushioning Products

Austria C.U.P. Gummi Gesellschaft m.b.H. Continental Eisgrubengasse 4 Postfach 13 A-2334 Vösendorf-Süd � (02 22) 69 25 01 Fax (02 22) 69 25 01 37

Belgium P.U.E. S.A. Continental Noorderlaan 121 Postfach 38 B-2030 Antwerpen � (3) 5413720-27 Fax (3) 5416929

France Continental Caoutchouc Industriel 68, Rue de Paris F-93804 Epinay- sur-Seine Cedex � (1) 48.23.46.16 Fax (1) 48.22.28.44

Great Britain C.U.P. Ltd. Continental Technical Products Division Cottage Leap Clifton Road Rugby Warwickshire CV21 3RQ � (0788) 71482-87 Fax (07 88) 53 66 08 Italy Continental S.p.A. Divisione Prodotti Tecnici Via Marcantonio Colonna, 42 I-20149 Milano � (02) 33 00 06 27-29 Fax (02)33000632

Republic of South Africa Continental Gummi (Pty) Ltd. P.O.Box 76.212 Wendywood Sandton 2144 � (011)8 02-10 44/45/46 Fax (011) 802-4604

Singapore Continental Aktiengesellschaft Singapore Office 10 Collyer Quay 07-07 Ocean Building Singapore 0104 � 5 33 86 90/5 33 82 90 Fax 5 33 87 70

Spain Continental Industrias del Caucho S.A. Bruc, 21 E-08010 Barcelona � (93) 41211 20 Fax (93) 4123414

Sweden C&S Rubber AB Continental Box 12 94 S-17125 Solna � (08) 29 04 80 Fax (08) 29 57 58

Switzerland Continental Caoutchouc (Suisse) S.A. Vogelsangstrasse 28 CH-8307 Effretikon � (0 52) 32 70 21 Fax (0 52) 32 2819

USA Continental Products Corporation 1200 Wall Street West Lyndhurst, N.J. 07071 � (2 01) 4 60 02 00 Fax (201) 4608372

Continental Aktiengesellschaft Geschäftsbereich Transportband Postfach 169 Continental-Haus D-3000 Hannover 1 Phone (0511) 2141-1 Telex 9 217-0 con d Telefax (0511) 2141-5 83

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

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


Continental Aktiengesellschaft Geschäftsbereich Transportband Postfach 169 Continental-Haus D-3000 Hannover 1 Phone (0511) 2141-1 Telex 9217-0 con d Telefax (0511) 2141-5 83

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

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

Documents

Correas Transportadoras Continental Conveyor Belt Design Manual Para Ingenieros Mecanicos