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E MANUAL –

H336073-PM

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04 Edificio Stud

– MINA MINIS

M031/A 45011

JECT B6042

dio Las Condes

STRO HALES

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  Fono: 56‐2‐22

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2320825 

                            

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X1 X 2 X 3

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Technical ManualTechnical Manual

Design, Installation,Operation andMaintenance

Design, Installation,Operation andMaintenance

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11/10 1

Table of ConTenTs DESIGN ...........................................................................3 Introduction ................................................................4 Beltwall Products .......................................................5 Corrugated Sidewalls .........................................5 Beltwall Cleats ...................................................6 Beltwall Cross-Rigid Belting ...............................9 Initial Considerations ..............................................12 The Choice for Beltwall ....................................12 Material Characteristic Considerations ............12 ConveyorConfigurations .................................13 Design Considerations ............................................16 Belt Speed .......................................................16 BeltProfiles ......................................................18 Belt Horsepower ..............................................21 Belt Tension Ratings ........................................21 Belt End Preparation ........................................22 Conveyor Components and Design .......................24 Pulleys and Bend Sections ..............................24 DeflectionWheels ............................................28 Idlers ................................................................29 Slider Beds.......................................................35 Guide/Training Idlers ........................................35 Take-Up Arrangements ....................................36 Inspection/Access Panels ................................36 Belt Cleaning....................................................37 Cleat Spillage Plates ........................................43 Assistance and Drawing Review ............................44 CorrugatedSidewallSampleSpecifications .........45 Design Information Data Sheet ..............................47 INSTALLATION ...................................................................49 Belt Storage ..............................................................50 Belt Installation ........................................................51 Belt Splicing .............................................................56 Beltwall Packaging Options ....................................61 OPERATIONS & MAINTENANCE ......................................63 Troubleshooting .......................................................69 Preventive Maintenance Checklist .........................73 GLOSSARY ........................................................................75

This publication is intended to provide general guidelines pertaining to the design, installation, operation, and maintenance of Beltwall belting manufactured by Beltwall Division, Beltservice Corporation. All information is given in good faith and is offered as a guide only. The user of this information must determine the suitability of this information for his/her own purposes. Beltservice Corporation and its Beltwall Division shall have no liability whatsoever for any error or omission in the contents of this publication, or for any loss or damage which may result from reliance by any person on such contents. All products are subject to Beltwall’s term of sale.

11/102

11/10 3

Design

11/104

INTRODUCTION

Beltwall® belting offers the most advanced conveying concept available in the industry today.

The ability to change planes of travel in an extremely short distance and elevate at any angle up

to and including 90 degrees allows the conveyor designer a nearly unlimited range of engineering

options.

The design and selection of Beltwall belting and conveyors present unique requirements

thatmustbecarefullyfollowedinordertorealizethefullpotentialoftheBeltwallconcept.While

most standard and conventional conveyor design techniques are applicable, there are additional

considerations which are necessary to ensure the successful operation of any Beltwall system.

However, while unique, these considerations are quite simple in both their design and

application. The basic selection and design techniques outlined in this manual, when followed

closely, will provide the foundation for a solid application of Beltwall technology and will allow

successful and continuing service from Beltwall belting with minimal maintenance.

The standards depicted here are based upon the results of years of design, testing, evaluation,

and the experience gained from thousands of successful installations in virtually every industry

throughout the world. These techniques are, however, intended exclusively for use with Beltwall

belting. The design and manufacturing standards inherent only in Beltwall belts may not be

appropriate for the products of other manufacturers, and therefore should only be used for

belting designed and manufactured by Beltwall Division, Beltservice Corporation.

11/10 5

BELTWALL PRODUCTS

BELTWALL CORRUGATED SIDEWALLS

Beltwall offers a full line of corrugated sidewalls in a complete line-up of small sizes and

compounds. Heights range from 1 inch (25mm) to 16 inches (400mm) including all standard

metric sizes with compounds in Black Standard, Black Oil Resistant, Black High Heat Resistant,

BlackFlameRetardant(FR),BlackHighOilResistant,andWhiteOilandFatResistant(FDA),

to handle a full range of capacities and material characteristics

BELTWALL CORRUGATED SIDEWALLS

Eachcompoundisspeciallyformulatedforextremelyhighflexlifeandabrasionresistance.

Microscopicstrengtheningfibersarecompoundedintotherubberforhighcutandtearresistance

under even the most severe operating conditions. All Beltwall sidewalls 6” and taller also have a

fabric ply embedded in the vertical sections for unsurpassed strength and durability.

Pulley Diameter In Inches

Height In

Inches

WallWidth (in.)

Pitch(in.)

Black Std/ High Heat

Oil Resistant/ FR/ White

4 1 8

4 2/1-1 8

2

1-1/2 1

6 88 2/1-2 12

01 3 12

01 4 145

2 1-1/2

12 16

61 6 20

02 8 2410

3-1/8 2-1/2

24 30

63 21 48

164-1/8 3-1/2

42 54

Pulley Diameter In millimeters

HeightIn

mm

WallWidth (mm.)

Pitch(mm)

Black Std/ High Heat

Oil Resistant/ FR/ White

201 52 152

201 83 152

51

38 25

152 203 302 46 305

452 67 305

452 201 355127

51 38

305 406

604 251 508

805 302 610254

79 64

610 762

419 503 1,219

406105 89

1,066 1,371

Height 1"25 mm

1 1/2"38 mm

2"51 mm

2 1/2"64 mm

3"76 mm

4"102 mm

5"127 mm

6"152 mm

8"203 mm

10"254 mm

12"305 mm

16"406 mm

11/106

BELTWALL CLEATS

A complete array of cleat styles and sizes complements the Beltwall sidewalls for conveying

any capacity at any angle. The cleats are also available in Black Standard, Black Oil Resistant,

BlackHighHeatResistant,BlackFlameRetardant(FR),BlackHighOilResistant,andWhiteOil

and Fat Resistant (FDA) compounds.

All Beltwall cleats are hot-molded to the belt covers by a unique, patented process that

greatly reduces the possibility of cleat separation during operation.

Straight “I” cleats are available in heights from 1/2” (13mm) through 15-1/4” (387mm). “I”

cleats are generally used on inclines up to 40 degrees. Standard heights through 5” (127mm) are

a one-piece rubber hot-molded construction. Those 5-1/2” (140mm) and taller are an unequalled

two-piece design with a “U” shaped hot-molded rubber foot into which a replaceable urethane

cleat blade is bolted. Under even the most abrasive conditions, the urethane blade construction

proves far superior to other materials. In the unlikely event of cleat damage, however, the blades

arereadilyrenewablebyremovingthebaseboltsandrefittingreplacementblades.

Beltwall “I” Cleats

Height 1"25 mm

1/2"13 mm

1-1/2"38 mm

2"51 mm

2-1/2"64 mm

3-1/2"89 mm

4-1/2"114 mm

5-1/2"140 mm

7-1/2"191 mm

9-1/2"241 mm11-1/4"286 mm

15-1/4"387 mm

I or I(B)I I or I(B) IB

( ) Indicates optional two-bolt attachment of cleats to sidewalls. B Denotes two-bolt attachment of cleats to sidewalls.

11/10 7

“I” cleats can be fastened to the sidewalls by means of bolt and bolt support arrangements for

additional belt stability where effective widths are 24” (610mm) or more with rubber cleats.

Sidewall Attachment to “I” Cleats

Scoop “C” cleats are available in heights from 1/2” (13mm) through 5” (127mm). “C” cleats

are used when additional capacity is required in steep angle applications up to and including 90

degrees. All “C” cleats are a one-piece rubber hot-molded construction.

It is not practical to attach “C” cleats to the sidewalls. Attachments to the sidewalls require the

alignment of a straight cleat section perpendicular to the belt surface and aligned with the inner

vertical section of the sidewall to prevent the radial misalignment of the cleat and sidewall as the

belt negotiates bends and pulleys.

Beltwall “C” Cleats

Height 1"25 mm

1-1/2"38 mm

2"51 mm

2-1/2"64 mm

3-1/2"89 mm

4-1/2"114 mm

C5"

127 mm

11/108

Combination “S” cleats are available in heights from 4 1/2” (114mm) through 15-1/4” (387mm).

“S”cleatsarespecifiedforhighercapacityapplicationsatanglesusuallygreaterthan40degrees.

A one-piece rubber hot-molded construction is available for heights through 5-1/2” (140mm),

and the two-piece design with a “U” shaped rubber hot-molded foot into which an angled cleat

blade is bolted is utilized for heights 5-1/2” (140mm) and taller. Either the one-piece or two-piece

construction is available for 5-1/2” (140mm) cleats.

Whiletheangledsectionofthe“S”shapeprovidesadditional“percleat”volumecapacity,

the vertical base section allows attachment to the sidewall by means of bolt and bolt support

arrangement for additional belt stability on designs with 24” (610mm) and more effective widths

between the walls with rubber cleats and on all inclined applications 75 degrees or steeper.

Forfine, free-flowingmaterials,specialsidecleatpartitionsareavailable incombinationwith

theattachmentof thesidewall toeliminateanyfluidizingormaterial leakageonsteep-angle

applications.

Beltwall “S” Cleats

Height 4-1/2"114 mm

5-1/2"140 mm

7- 1/2"191 mm

9-1/2"241 mm

11-1/4"286 mm

15-1/4"387 mm

SB

SS S or S(B)

( ) I ndicates optional two-bolt attachment of cleats to sidewalls. B D enotes two-bolt attachment of cleats to sidewalls.

Sidewall Attachment to “S” Cleats

( ) Indicates optional two-bolt attachment of cleats to sidewalls.B Denotes two-bolt attachment of cleats to sidewalls.

11/10 9

BELTWALL CROSS-RIGID BELTING

Beltwall has developed an industry standard cross-rigid or cross-stabilized belting design

that provides lateral rigidity or stiffness for side-to-side support while still allowing the longitudinal

flexibilitynecessarytooperatearoundthesameminimumpulleydiametersthatarerecommended

for conventional plied belting of comparable tension ratings. The cross-rigid design is absolutely

essential toprovide for long life throughdeflectionwheelbendsand forstandard idler return

on the sidewall tops or with stub idler return idlers on the belt recesses without the potentially

disastrous bowing or sagging that would exist with conventional belt designs. A cross rigid belt

is developed by utilizing two plies, with the strength yarns running across the belt, one in the

top cover and one in the bottom cover. If the cross rigid demand is relatively low, which is the

case for belts with tension demands of 150 or 220 pounds per inch of width, the cross rigid plies

canbepolyestermonofilament.Ifthecrossrigiddemandishigh,asisthecaseforbeltswith

tension demands of 330, 440, and 550 pounds per inch of width, the cross rigid plies should be

fiberglasswhichisamuchstifferfabricprovidinggreatercrossrigidity.

BELTWALL CROSS-RIGID BELTING CONVENTIONAL BELTING

11/1010

Beltwall cross-rigid belting is available in a full range of tension ratings in Black Standard,

Black Oil Resistant, Black High Oil Resistant, Black High Heat Resistant, Black Flame Retardant

(FR),andWhiteOilandFatResistant(FDA)compounds.Listedbelowisabriefdescriptionof

each compound:

1. Black standard is the most common rubber belt compound used in over 75% of all belting

applications. It provides excellent abrasion resistance and good cut and gouge resistance.

2. Black oil resistant is compounded to resist the effect of wood chips, moderately oily grain,

and waste water treatment applications.

3. Black high oil resistant is compounded for maximum resistance to mineral, animal, and

vegetableoils,oilysteelparts,crushedsoybeans,andtrashrecycling.Itisalsofireretardant.

4. Black high heat resistant is compounded to withstand temperatures between 180°F

(80°C) and 350°F (175°C). The base belt is compounded from EPDM rubber. Cleats up to 5-1/2”

(140mm) are also EPDM. Cleats over 5-1/2” (140mm) are high heat urethane bolted into an

EPDM cleat base. Sidewalls are butyl. Due to the concentration of material at the cleat base,

creating greater pressure on the belt than on conventional conveyor belts, it is necessary to use

high heat resistant belts at lower temperature 180°F (80°C) than for conventional belts. EPDM

and butyl compounds are also quite often used for chemical resistance. Please contact Beltwall

forspecificationassistance.

5.BlackflameRetardantFR-SBRiscompoundedtoselfextinguishwithin60secondsafter

aflameisremovedfromthebelt.

6. Stacker is Goodyear’s compound for superior abrasion resistance.

7. RMA-1 is recommended for severe cut and gouge resistance.

Each Beltwall cross rigid belt contains high modules longitudinal tension plies for a belt

carcass construction that withstands the most rigorous design applications.

Standard cover thicknesses are listed below. Because conveyed material is held static on the

Beltwall belt, cover thickness is typically less than that found on a conventional belt conveying

the same material. On a conventional belt, there is constant abrasion due to material movement

each time the belt climbs over an idler. Heavier covers, Stacker and RMA-1, are available if the

belt will be exposed to extremely abrasive materials such as copper or nickel ore or if the belt

willbeexposedtoheavyimpact.ConsultBeltwallforspecifics.

11/10 11

Note:

1.800PIWCrossrigidbeltsareavailableforhightensionL-shapedsystems.

2. Steel cable cross rigid belts with steel cross rigid plies are available for high tension

S-shaped systems.

3. Consult Beltwall for belt selection.

For horizontal systems without cleats, cross rigid belting is not necessary with center distances

less than 50 feet (15.25m) and sidewall heights below 4” (102mm). If the center distance between

pulleys is greater than 50 feet (15.25m) or the sidewalls are 4” (102mm) in height or more cross

rigid belting is necessary to prevent the sidewalls from dishing in on the return and abrading

against the return structure.

BELTWALL CROSS-RIGID BELTS SEILP LLAWTLEB

Belts Covers

Tensile

X-Rigid

Nominal Thickness

WorkingTensionPIW

051 mm 7.8 ”23/11 2 2 eraB x ”61/1 etihW 2251 XWBBWX1522BlkStandard5/64”x1/16” 2 2 7/16” 11.1 mm 150 BWX1522BlkOilResistant5/64”x1/16” 2 2 7/16” 11.1 mm 150 BWX2222BlkStandard1/8”x1/16” 2 2 15/32” 11.8 mm 220 BWX2222BlkOilResistant1/8”x1/16” 2 2 15/32” 11.8 mm 220 BWX2222BlkFlameRetardant(FR)1/8”x1/16”2 2 15/32” 11.8 mm 220 BWX2222BlkHighOilResistant1/8”x1/16” 2 2 15/32” 11.8 mm 220 BWX2222BlkHeatResistant3/16”x1/16” 2 2 9/16” 14.2 mm 220 BWX3332BlkStandard1/8”x1/16” 3 2 9/16” 14.2 mm 330 BWX3332BlkOilResistant1/8”x1/16” 3 2 9/16” 14.2 mm 330 BWX3332BlkFlameRetardant(FR)1/8”x1/16”3 2 9/16” 14.2 mm 330 BWX3332BlkHighOilResistant1/8”x1/16” 3 2 9/16” 14.2 mm 330 BWX3332BlkHeatResistant3/16”x1/16” 3 2 5/8” 15.9 mm 330 BWX4442BlkStandard1/8”x1/16” 4 2 5/8” 15.9 mm 440 BWX4442BlkOilResistant1/8”x1/16” 4 2 5/8” 15.9 mm 440 BWX4442BlkFlameRetardant(FR)1/8”x1/16”4 2 5/8” 15.9 mm 440 BWX4442BlkHighOilResistant1/8”x1/16” 4 2 5/8” 15.9 mm 440 BWX4442BlkHeatResistant3/16”x1/16” 4 2 23/32” 18.2 mm 440 BWX5552BlkStandard1/8”x1/16” 5 2 3/4” 19.0 mm 550 BWX5552OilResistant1/8”x1/16” 5 2 3/4” 19.0 mm 550 BWX5552FlameRetardant(FR)1/8”x1/16”5 2 3/4” 19.0 mm 550 BWX5552HighOilResistant1/8”x1/16” 5 2 3/4” 19.0 mm 550 BWX5552HeatResistant3/16”x1/16” 5 2 13/16" 20.6 mm 550

Cross Rigid Plies Tension Plies

Belt End View

11/1012

INITIAL CONSIDERATIONS

THE CHOICE FOR BELTWALL

Beltwall belting can be used in almost any application for transporting bulk materials. In every

instance, the Beltwall design virtually eliminates side spillage and can carry the capacities of

conventional troughed belts within a much narrower width.

However, the most valuable and cost-effective use of Beltwall is as an elevating device.

Whenevermaterialshavetobeliftedorelevated,Beltwallshouldbealogicalfirstconsideration.

Theoverallsavingsinstructure,conveyorcomponents,andfloororgroundspacecanusually

provide a very cost-effective alternative to conventional elevating means. Replacing up to three

separate systems (infeed, elevator, outfeed) with one eliminates transfer points, reduces material

degradation, increases versatility, and provides discharge capabilities at the very point of desired

delivery. Beltwall also provides long-term cost savings from a maintenance and replacement

standpoint as well.

MATERIAL CHARACTERISTIC CONSIDERATIONS

Beltwall belting is used in virtually every industry to convey almost any bulk material from

fine,dry,fluidicpowderstolarge-lumpminedminerals-fromfoodproductstowetcoal.When

considering Beltwall, of course all possible states of the material - wet or dry - must be taken into

account.

Saved Ground Space, Hardware,

and Structure

BELTWALL CONVEYOR SYSTEM VERSUS CONVENTIONAL BELT CONVEYOR

11/10 13

Loadinganddischargeoftheproductmustbeevaluatedwithregardtoeaseofmaterialflow,

maximum lump size, angle of repose and surcharge angle, oil or chemical content, moisture,

and temperature. It is critical in the consideration of Beltwall belting that the material can both be

loaded within the pockets and discharged acceptably.

CONVEYOR CONFIGURATIONS

The primary advantage of Beltwall belting is the design flexibility offered by its ability to

change planes quickly through a very small vertical curve and negotiate up to an including 90

degreeinclines.ThemostcommonBeltwallconveyorconfigurationsare:1.horizontal,2.straight

incline,3.reverseL-shaped,4.L-shaped,5.S-shaped,6.90degreeS-shaped,7.S-shaped

with angled infeed and/or discharge, 8. S-shaped with additional bends.

In addition to the elevating capabilities, the designer should also consider the ability of Beltwall

belts to reverse, as indicated by the directional arrows in both directions, and in some cases

become an excellent declining, even power-generative conveyor.

1. 2. 3. 4.

5. 6. 7. 8.

11/1014

The following design guidelines should be considered when determining the conveyor

configuration:

LOADING

A.Themostefficient loadingofaBeltwallbeltoccurs inahorizontalplane.By loading in

a horizontal plane, the product can shift upon turning into the incline to fully load each cleat.

If loaded on the incline, only the wedge-shaped cross-section created by the cleat and base

belt is loaded, thus limiting the overall potential of the carrying capacity per cleat. Therefore,

while loading on the incline is perfectly acceptable, the resultant reduction in capacity must be

considered. Another advantage of loading on a horizontal section and upturning is the availability

of a lower return bend pulley which is the primary tracking mechanism for a corrugated sidewall

system.

B.Thelengthofanyloadingsectionshouldprovidesufficienttimefromtheloadingpointto

the inclined section to allow the material to settle and rest on the belt prior to the plane change to

prevent turbulence at the bend. A minimum of 1 second of elapsed time is necessary for material

to settle in the pocket before upturning if the material weighs 40 lbs/ft3 or more. A minimum of 2

seconds is necessary if the material weighs less than 40 lbs/ft3.

C. The load area should allow at least a full pocket length between the center of the shaft of

the tail pulley and the beginning of the load point.

D. Loading in line is themost preferredmethod of feeding a corrugated sidewall belt. If

loading at 90° is necessary, a rock box is recommended to turn the material in the direction of

belt travel.

E. Metered loading is the recommended procedure. Material should never be force fed into a

corrugated sidewall belt from a live bottom hopper. Depending on the material conveyed, either

a slide gate; or belt, vibrating, screw or chain feeder should be used.

Horizontal loading produces optimal cleat loading on incline Incline loading produces less than optimal cleat loading

11/10 15

F.Loadingchutesshouldbedesignedtoeliminatespillage,butatthesametime,provide

enough clearance between the sidewalls and cleats so the chuting does not damage the

belt. The loading chute generally extends inside the sidewalls 1” (25mm) for belts up to 24”

(610mm) in width and 2” (51mm) for belts over 24” (610mm) wide. A minimum of 1/2” (19mm)

vertical clearance from the top of the belt to the structure is required. Additionally, a minimum

of12”(305mm)verticalclearancefromthebottomofthebelttothefloororstructureshouldbe

allowed.

If the system needs to be dust tight, an additional piece of steel can be used off the chuting

with rubber skirting down to the recessed portion of the belt.

DISCHARGE

Themaximumrecommendedangleforefficientdischargeis50°fromnormalbeltspeeds.

Beyond this limit, “back-legging”, or the reintroduction of material back down the return side

of theconveyor ispossible.Angles50 to75degreesrequireabeltspeedof≤100fpmora

horizontal“noseover”isrequiredtoaccomplishefficientdischarge.ConsultBeltwallforthemost

practical speeds for various angles.

OPTIMUMANGLEOFINCLINE

The optimum angle of incline will vary from application to application. Typically, steeper angles

are more cost effective for the entire conveyor system. However, this is not always the case.

Capacity, material density, and space constraints will all play a varying role from installation

to installation. If a particular angle of incline is not dictated by other design constraints, it is

recommended to do an array of preliminary system “take-off” cost studies at various angles to

arrive at the most economically-advantageous combination.

11/1016

DESIGN CONSIDERATIONS

BELT SPEED

Generally, the speed of a corrugated sidewall conveyor belt will be the same as the speed

of a conventional conveyor. However, Beltwall should always be consulted at speeds over 500

FPM (2.5m/sec). In addition, a dust collection expert should be consulted for conveying any

aerated or powdery material at speeds over 300 FPM (1.5m/sec.) to ensure the dust collection

system is capable of accepting any extra dusting caused by the cleats during loading. There are

several criteria beyond normal standards for belt speed determination that must be considered:

1.LOADING-Themostobviouscriteriaforbeltspeedconsiderationistheabilitytoloadthe

belt.OnBeltwallbeltsusingcleats,therequiredvolumeofmaterialmustbecapableoffilling

one cleat space or pocket before the next cleat passes the loading zone, thus eliminating the

“window” through which the material must pass.

The direction of loading - whether in line or angled to the center line of the Beltwall conveyor

- and the horizontal velocity of the material relative to the speed of the Beltwall belt - whether

falling straight down or trajected in line with the direction of travel of the Beltwall belt, have a

major effect on the ability to load the belt. As with all conveyors, the preferred method of loading

a Beltwall belt is in a direction in line with, and at a horizontal velocity equal to or slightly grater

than, the receiving belt.

One must also remember that material in general and lumps in particular are accelerated

instantaneously on a cleated Beltwall belt, and any resultant turbulence must be considered

Taking into account the length and width of the infeed area or opening, a gravimetric calculation

basedonthetotalverticaldropshouldbeperformedpriortofinalspeedselection.

2. TRAJECTORY - The two major areas of awareness that much be considered from a

trajectory standpoint are the discharge point and the noseover section.

11/10 17

The discharge point obviously is ultimately affected by the material trajectory in the design of

discharge chutes and clearances. The actual trajectory must take into consideration: 1. maximum

possible material depth (equal to the sidewall height), 2. belt speed, and 3. angle of discharge.

The discharge trajectory calculation is extremely important with Beltwall belting to prevent

the inadvertentplacementofbafflesorchutework thatwouldcausematerialor lumps tobe

deflectedbackagainstthebelt.Inthecaseofcleatedbelts,thereintroductionofmaterialinto

the cleated area can result in the “batting” of material out of the desired discharge area resulting

in both material carry-back and spillage as well as possible belt damage.

NOTE: Further discussion on discharge trajectories and calculations can be found in CEMA’s

Belt Conveyors for Bulk Materials.

11/1018

BELT PROFILES

Thethreemostcommonbeltprofileconstructionsare1.sidewallsmountedflushontheside

of thebasebeltwithoutcleatsforuse inhorizontalorslightly inclinedstraightconfigurations,

2.sidewallsmountedflushonthesideofthebeltwithcleatsbetweenthewallsforadditional

capacityonsteeperstraightinclines,and3.themostcommonprofile,sidewallsrecessedfrom

thebeltedge toallow forverticalbendsbymeansofdeflectioncomponentsandwithcleats

mounted between the walls for additional capacity.

In some cases, types 1 and 2 may be used with the sidewalls recessed to allow the use of

stub return idlers on wider belts or on heavier belts to prevent premature sidewall wear.

SIDEWALLRECESS

The sidewall recess should always be an absolute minimum of 10 percent of the sum of the

belt width plus the sidewall height.

In most cases, a larger than minimum recess is provided to allow for additional design comfort

andtoabsorbthetensionatthedownturndeflectionwheeloveragreaterarea;therebyallowing

the use of a lower tension belt.

Recess(R)≥.1 [ BeltWidth(BW)+SidewallHeight(H) ]

11/10 19

BELTWIDTH

The belt width is generally selected to be greater than four times the sidewall height to

prevent the possibility of “top-heavy” loading that may hamper training.

BeltWidth(BW)≥4xSidewallHeight(H)

EFFECTIVEWIDTH

The effective width, or the lateral distance between the sidewalls, is recommended to be at

least two times the largest lump size to prevent possible product bridging or entrapment.

EffectiveWidth(EW)≥2xMaximumLumpSize

CLEATSPACING

The cleat spacing, or the longitudinal distance between the cleat centers, is recommended to

be at least two times the largest lump size to prevent possible product bridging or entrapment.

CleatSpacing(CS)≥2xMaximumLumpSize

BW BW

H H

EW EW

CSCS CS

11/1020

Cleat spacing is always recommended to coincide with the pitch of the sidewall convolutions

in order to align the cleat with the vertical sidewall section and prevent material from spilling

around the cleat end through the convolution spaces.

CLEATHEIGHT

All cleat heights are recommended by Beltwall to be minimum of 1/2” (12mm) less than the

sidewall height to reduce the possibility of interference from conveyor chute work and structure or

from debris that might accidentally enter the system. This clearance also prevents the “clipping”

offlatreturnidlersbythecleattopsonthereturnrunonbelts24”wideorless.

Cleat heights must be a minimum 75% of the maximum lump size on any Beltwall belt with

an inclined section to reduce the chance of material roll-back. If the inclined section is 75° or

steeper, the cleat height should be a minimum of 150% of the maximum lump size.

If angle of incline is less than 75°

Cleatheight(C)≥.75xMaximumLumpSize

If angle of incline is 75° or greater

Cleatheight(C)≥1.50xMaximumLumpSize

11/10 21

BELT HORSEPOWER

Belt horsepower calculations are based on standard CEMA formulas with slight differences

due to a lower friction factor since two bearings support the carrying idlers on a Beltwall belt

versus six bearings on the can idlers of a trough conveyor. Beltwall calculates only the running

horsepower, or the horsepower that must be delivered to the drive shaft during operation at the

full selected belt speed.

For motor horsepower selection, factors which also should be considered include start-up

acceleration time, possible start-up under full load, moisture, drive component losses, electric

motor logic circuitry, coupling design, possible power loss over lengthy electric motor cables,

operation temperature (Beltwall calculations assume temperature [Kt] factor of 1.0), loading the

belt to 100%, and any other external condition that might affect the operating conditions of the

system.

BELT TENSION RATINGS

TherearetwoareasofconsiderationforfinalBeltwallbasebelttensionratingselections:

1. The actual operating tensions at each point on the conveyor.

2. The cross-rigid limitations of each tension rating construction versus the selected belt width.

Under area 1 the actual operating tensions at each point along both the carrying and return

sides are checked to ensure the selected belt rating construction is adequate for all points under

all conditions. One of the most dramatic differences in tension rating selection occurs at the

concavebendsorupturnanddownturndeflectionpoints.Unlikeconventionalbelts,thedesigner

must remember that while total tensions in these areas are usually less than at the drive pulley,

thetensionstheremustbetotallysupportedbythedeflectionwheels,andthereforeonly the

recessed areas of the belt can be considered as the width of belt that must withstand the total

belt tension at that point. In other words, while the belt tensions at those points are generally

lower than at the drive or head pulley, the belt width used for the “tension per unit of width”

calculation is only a fraction of the total belt width. As a result, in the majority of cases, it is

thereforethedeflectionareas,ratherthanthedrivesections,thatbecomethedeterminingfactor

in the tension rating selection of the base belt.

11/1022

FINAL BELT SELECTION

There are a number of criteria which absolutely must be considered when selecting a

Beltwallbelt:capacity,materialcharacteristics,loading,conveyorconfiguration,manufacturing

constraints, and cost, just to name a few.

Thefirst-handapplicationexperienceandfamiliaritynecessaryforanaccurateanddependable

selection go beyond simple formulas and charts to assure a professional and cost-effective

selection. Beltwall provides this selection service by means of a computerized quotation process

that employs state-of-the-art technical information based upon years of both laboratory-tested

andfield-proventechniques.Thelargest,mostexperiencedtechnicalstaffintheindustrystands

ready to instantly provide the calculations and results necessary for the complete design of a

successful Beltwall system.

The Design Information Data Sheet provides a guide for the information necessary to

accurately select the optimal Beltwall design.

BELT END PREPARATIONS

The ends of a Beltwall belt can be joined in any conventional manner — either with mechanical

fastenersorvulcanizedsplices.Mechanicalfastenersareverycommonforfinallengthsofless

than 100 feet (30.5m). For longer belts, vulcanized splicing should be considered.

If mechanical fasteners are used, hinged-type constructions are preferred in order to allow the

belt to more evenly navigate the pulleys and bends sections. The additional strength inherent in

Beltwall cross-rigid belting provides outstanding fastener retention, and allows for the installation

or repair ease associated with mechanical fasteners.

Vulcanizedspliceareascanbepreparedatthefactoryforfieldcompletion,orspliceareas

canbesimplymarkedforfieldreferencewithanadditionalpulling“tab”onthebeltleadingedge

for installation assistance. The latter option is always recommended for belts over 100 feet

(30.5m) to prevent damage to the prepared lap areas during installation. Refer to page 56 thru

60 for splice preparation and vulcanizing instructions.

11/10 23

VULCANIZED SPLICE

1.Extrabasebeltmarkedforfieldinstallofvulcanizedsplice

a. Sidewalls will be left loose over the splice and will be cold bonded once the

splice is installed.

b.Cleatssuppliedlooseforfieldinstallationoverthesplice.Thesecleatsare

typicallycoldbondedbythefieldvulcanizer.Asanoptionforabusiveorsteel

cableapplications,Beltwallcansupplyamoldtothefieldvulcanizingcompany

for hot vulcanizing to the base belt loose two piece cleat bases between 5-1/2”

and 9” heights.

2. Vulcanized endless at the factory.

3.Beltendspreparedforfieldvulcanizing.Beltwalldoesnotrecommendthisoptiondue

to the possibility of contamination during shipping and damage during install.

MECHANICAL SPLICE

1. Fasteners factory installed. Various fasteners are available and selection is based

uponthebeltandapplication.Thesidewallsaretypicallybuttedforfieldbolting.

2. It is common on a conventional belt to trim belt edges in the mechanical fastener area.

This should never be done on a corrugated sidewall belt. On a system with bends, all

of the tension must be absorbed by the recess portion of the belt across the face width

ofthedeflectionwheel.Ifthebeltedgeistrimmedatthefastener,holdingabilityislost

causing fasteners to pull out.

SQUARE ENDS

1. Belts are cut with square ends. As an option, mechanical fasteners can be provided

looseforfieldinstallationortheendscanbepre-punchedforaparticularstyleoffastener.

11/1024

CONVEYOR COMPONENTS AND DESIGN

PULLEYS AND BEND SECTIONS

Beltwall cross rigid base belts are a very high-modulus/low-stretch construction. Straight

faced, curved crown, or trapezoidal crown pulleys are recommended for high tension systems

using Beltwall belts. Standard center crown pulleys, although commonly used on small systems,

will create more training problems than they prevent due to the lateral stiffness of the Beltwall

belt.

Standard wing-type pulleys may put unwanted stress on the cleats and sidewalls by means

of the small wing ends that may cause accentuated small radius bend patterns through the base

belt. In addition, corrugated sidewall belts are trained by adjusting the bend pulleys. If wing

pulleysareused,mostofthecontactbetweenthepulleyandbeltislost,makingitdifficulttotrain

the belt. Therefore, Beltwall recommends against the use of standard wing pulleys.

If the characteristics of a standard wing pulley are required, Beltwall recommends the use of

a standard “spiral-wing” design pulley.

11/10 25

It is common practice to use pulleys at the drive or head and at the tail. Pulleys are also used

atthelowerreturnbendonL-andS-shapedsystemsandatthenoseoveronS-shapedsystems

if the system is operating slow enough to prevent fountaining of the product. Standard pulley

laggings are acceptable as used on conventional conveyors.

Pulley Locations

The primary tracking mechanism for a corrugated sidewall belt is the lower return bend pulley.

Thebearingssupportingallpulleys(anddeflectionwheels)shouldbeadjustableinthesame

direction as the belt coming into the pulley. Jack bolts should be incorporated for adjustment and

the bearings should be mounted on slotted holes.

Noseover Rollercurve Location

Onlargersystems,themostpracticalconfigurationoftencombinestheuseofarollercurve

at the noseover section with standard pulleys at the other convex bend sections.

11/1026

The vertical curve radius of any convex bend, i.e., the noseover section, will be dictated by

the belt speed to prevent any material from becoming airborne and in effect “fountaining” in

those areas.

Minimum Noseover (Vertical Convex) Radius

Under Sized (Vertical Convex) Radius

NOTE:Theseformulasrequireiterationtofindthefinalnosecoverradius.

The maximum spacings for any rollercurve construction should be a maximum of 1-1/2 times

the individual roller diameter, or a maximum arc angle of 10 degrees, whichever is less.

V

V

s2

r ≥ g

Refer to page 27 for Rollercurve details.

s2

r ≥ g cos

11/10 27

Beltwall recommends a minimum 5 inch roll diameter for use in any rollercurve construction.

Rollercurveidlersmustbeselectedbaseduponshaftdeflectioninadditiontototalsupported

belt/productload.Live-shaftrollsarethemostcommonly-useddesignsinordertoadequately

support the high resultant loads due to belt tensions around the arc as well as the weight of the

material and belt.

Rollercurve Construction

ResultantLoad(peridler)=TotalResultantLoadatRollercurve

(# of idlers)

Never use a pulley to bend or snub a Beltwall belt across the sidewalls. The excessive

compression force on any sidewall top can cause premature wear and possible failure.

NOTE: Both the maximum angle and the maximum spacing must be considered.

11/1028

DEFLECTION WHEELS

Beltwallrecommendstheuseofdeflectionwheelassembliesatupturnanddownturnbend

sections.

DeflectionWheelLocations

Thedeflectionwheelsshouldbedesignedwithaclearancebetweentheinsideofthe

wheels and sidewalls of 15% of the recessed area of the belt or a minimum of 3/4” (19mm),

whichever is greater. Maximum clearance should be 2” (50mm).

Therecommendeddeflectionwheelconstructionincludestheaffixingofthewheelstothe

shaft, with the shaft mounted using outboard bearings or pillow blocks.

DeflectionWheelConstruction

Thediameterofthedeflectionwheelshouldbeatleastfourtimesthesidewallheight,noless

than 12” (305mm), to prevent the sidewall convolutions from rubbing together. The face width of

thedeflectionwheelshouldbeequaltoorgreaterthantherecess.

11/10 29

IDLERS

Standard flat idlersmay generally be used on both the carrying and the return sides of

Beltwall conveyors if the belt width is 24” (610mm) or less. Minimum 4-inch (102mm) diameter

rolls are recommended. Stub idlers should be used on the return run to support belts that are 30”

(762mm) or wider. See page 33 for details.

Idler Spacing

3’ 6” ( 1 m ) Maximum Spacing

3’ 6” ( 1 m ) ÷ COS ø [ Maximum 6’ 0” ( 1.75 m )]

11/1030

IDLER BACKING HEIGHT

wolla ot thgieh gnikcab reldI :ETON acol ot edis nruter te 1/4 x sidewall

,enil tnegnat woleb thgieh not to .) mm 46 ( ”2/1-2 deecxe

NOTE: Idler backing height to maintain return side level with tangent line in any section leading to a downturn deflection point.

TANGENT LINESTANGENT LINES

TANGENT LINES

11/10 31

IDLER BACKING HEIGHT (Continued)

t

NOTE: Idler backing height to allow return side to locate 1/4 x sidewall height below tangent line, not to exceed 2-1/2” ( 64 mm ).

NOTE: Idler backing height to allow return side to locate 1/4 x sidewall height below tangent line, not to exceed 2-1/2” ( 64 mm ).

TANGENT L

INES

TANGENT LINES

11/1032

RETURN IDLER LOCATION ADJACENT TO DRIVE OR RETURN BEND PULLEY

Neverlocatedaflatreturnidlercloserthan3feet(1m)“downstream”fromadrivepulleyor

a return bend pulley to prevent possible “whipsawing” or “buckling” against the idler.

3’ 0” Minimum(1 m)

3’ 0”

Minimum

(1 m)

3’ 0” Minimum(1 m)

3’ 0” Minimum(1 m)

11/10 33

Stub idlers are recommended for use on the return side for belts 30” (762mm) and wider. It

is preferred that the cans be compounded from urethane, or at least urethane lagged, to offer

greater protection to the belt should the idler bearing become frozen.

Stub Idler Section on Return Side

Notethestubidlersaregenerallyangleddowntowardthebeltcentertofacilitatethemodified

catenary shape of the suspended cross-rigid belt.

Stub idlers should not be angled down in any section immediately prior to a downturn

deflectionwheel,suchasthereturnsideofthedischargesectionofanS-shapedsystem.Stub

idlers are level from side to side to prevent any inadvertent outward canting of the sidewall that

mayresultininterferencewiththedeflectionwheel.

Consideration must be given to total idler load when sizing; include not only belt load but also

dynamic loads due to product loading, impact due to product accumulation on idler rolls, etc.

Idler design considerations include:

Bearing Design - Overhung double bearing type idlers may be used for most applications.

Double bearing (inboard/outboard) type idlers should be used for extremely heavy loadings.

Overhung Bearings Inboard / Outboard Bearings

11/1034

Shaft Sizes / Mounting - Appropriate shaft sizes for stub idlers will typically be approximately

1/2” larger than carrying idlers. Idlers should be mounted as close as possible to the belt to

minimize overhung shaft loads and twisting moment applied to conveyor structure. Twisting

momentsduetoidlersmustbeconsideredinstructuraldesigntopreventidlerdeflection.

Product Accumulation - In applications where sticky products are being conveyed, the

product may accumulate on the idler rolls. Consideration should be given to lagging the rolls with

urethane to minimize buildup.

StubIdlerSelectiononReturnSidePriortoDeflectionWheel

Stubidlerspacingsandbackingheightsarethesameasthoseforflatreturnidlers.

If a Beltwall belt with no cleats is used on a horizontal or straight incline conveyor with no

bends,flatidlersordiscidlersmountedtocontactonlytheflatbeltbetweenthewallsmaybe

used.

Cross rigid belting is not necessary for horizontal conveyors with center distances of 50 feet

(15.25m) or less. Conventional belting may also be used on horizontal if the sidewalls are less

than 4” (102mm) in height. If the center distance is more than 50 feet (15.25m) and the sidewalls

are 4” (102mm) in height or more, cross rigid belting is necessary to prevent the sidewalls from

dishing on the return and abrading against the return structure.

11/10 35

SLIDER BEDS

SliderbedreturnsarepermissibleonlywithUHMWcleats.TheUHMWcleatshouldbebolted

into a rubber cleat base vulcanized to the base belt. The cleat should extend 1/2” (13mm) higher

thanthesidewalltopreventanycontactofthesidewallandthereturnpan.AUHMWlinershould

beusedonthereturnpantoreduceabrasionoftheUHMWcleat.TheUHMWcleatmustbe

replaced when it abrades to the same height as the sidewall. If the cleats are not replaced at this

point, sidewall abrasion will cause premature sidewall failure.

GUIDE/TRAINING IDLERS

If a conveyor is level and true, the belt will track satisfactorily with no external guiding devices.

However, it is of course recognized there are those operating conditions that do indeed dictate

theuseofsomeformoftrainingdevice.Wheneverguiderollsortrainingdevicesareused,itis

absolutely necessary to understand that these units must be considered only as a secondary

and never as a primary means of training - there is no substitute for a level and true conveyor.

Operating personnel must be made aware that immediately upon the observance of the guide

or training devices becoming active, there is another condition occurring elsewhere to make the

beltmistrackatthatpoint.Thaterrantconditionmustimmediatelybeidentifiedandcorrected

to prevent the training device from exerting force on the belt for an extended period of time and

possibly causing belt damage. The guide idlers should have 1/8” (3mm) less clearance from the

beltedgesthantherecommendedclearancesforthesidewallsfromthedeflectionwheelsand

stub idlers.

If guide or training rolls are necessary, the optimum placement should be just prior to any bend

section, no nearer to the bend than two times the belt width, or 8 feet (2.4m), whichever is less,

wherever possible. Guide idlers should be either pneumatic tires or a minimum of 6” (152mm)

diameter cans compounded from rubber or urethane to protect the belt edge. Additionally, using

a pair of guide idlers on each side will minimize the point stress to the belt edge should it make

contact with the guide idlers.

11/1036

Optimum Guide Roll Placement

TAKE-UP ARRANGEMENTS

Beltwall recommends locating the take-up arrangement at the tail of the system. Screw-type

take-ups are the most common, but gravity and hydraulic units are employed with carriage-

mounted tail pulleys on systems of 200 feet or more in pulley center distance.

Although Beltwall cross-rigid belts have a very low stretch factor, it is still advisable to allow 2

to 3 percent of the total conveyor centers for take-up travel to facilitate the ease of installation and

splicing,aswellasprovidinganadditionalmarginofsafetyinspecifyingthefinalbeltlength.

INSPECTION/ACCESS PANELS

In order to allow inspection and/or service of all moving parts, inspection doors or some form

of easy access should be located at all pulleys, idlers and bend sections. Failure of mechanical

parts may cause immediate and severe belt damage. Inspection doors allow regular preventative

maintenance to avoid this situation.

11/10 37

BELT CLEANING

There are two locations on an S-shaped corrugated sidewall belt conveyor that may need

regular cleaning, (A) the head or drive section and (B) the lower return bend area and space

between it and the pulley.

CLEANING AT THE HEAD SECTION

A small quantity of moist material may stick to the belt after discharge at the head pulley. If

the material is not cleaned off the belt, it may build up in the lower area impending the belt travel

causing damage to the sidewalls and belt tracking problems.

Currently, the following methods of clean-up for the head end are available.

Standard Rotating Belt Cleaner

One effective method for cleaning a Beltwall belt is the use of a rotating belt cleaning device.

Commonly called “belt beaters” or “belt thumpers”, the units are used to impact the belt as little

as possible and still affect carry-over material discharge. The most common error in placement

and operations involves excessive impact that may cause belt damage or unwanted system

noiseandvibration.Generally,1/4”to3/8”deflectionissufficienttosatisfactorilydischargethe

material.(Seefig.1)

The rotating belt beater should be placed as close to the discharge pulley as possible and

run at a recommended speed of 500 RPM. Adjustments in both the vertical and horizontal planes

isdesired tooptimize thedischargeand toallow forminormodification in casesympathetic

harmonic frequency vibrations occur.

Figure 1. Rotating “Belt Beater” is a common method of cleaning beltwall belts at the head section of the conveyor.

11/1038

It is important to dampen the vibration created by the cleaner using damping idlers as

outlinedinfig.1.Thiseliminatesexcessivevibrationwhichcandamagebearingsthroughoutthe

conveyor.

The key to successful belt cleaning device design is the “over design” of the entire unit. The

designer must appreciate the impact forces involved due to the shock load experienced by

the rolls impacting on the belt. A minimum of 2-7/16” diameter shaft with double row spherical

roller bearing should be used. The rolls thumping the belt must rotate independently to prevent

scuffingthebeltuponcontact.

If thematerial is relativelydryand freeflowing, thebeltbeatermaybe theonlycleaning

system necessary.

AIR SYSTEM

This consists of a set of nozzles connected to an air knife that are directed at the belt as it

goes around the discharge pulley after the material has been discharged. One nozzle should be

aimed at the middle of the belt and one at the edge of the pocket on each side. The system is

preferable on small systems such as sludge conveyors in waste water treatment plants and for

conveyors with sidewalls not exceeding 5” in height. Experience has shown that the air system

alone is inadequate for clean-up on systems with sidewalls over 5”. The air system can operate

directly from plant air or with a dedicated air compressor. Extra caution may have to be used with

dust collecting if the air system is used with aerated materials.

11/10 39

WATER SPRAYS

These systems are not as popular as the systems described above due to the cost of the

releaseagent.Waterspraysmaybeusedonthereturnsideofthebeltaftertheheadpulley;

however, provisions must be made to recycle the water.

The most practical method of cleaning on a large system (50 foot elevation or more) is by

enclosing the return side with a drip pan and allowing the material to slide down the pan. The

material collects at the junction of the decline section of the belt and the horizontal loading

section. From here it can be removed or recycled by any of the following methods. Please call

Beltwall for phone numbers of an agent for these systems.

Dumpster System

If the material conveyed is relatively dry and

only a small amount of carryback is anticipated,

a chute can be attached to the drip pan to collect

the material at the lower return bend and empty

into a dumpster. The dumpster can periodically be

emptied and material can be placed back on the

carrying side of the belt either manually or with a

portable industrial vacuum system. The dumpster

is the least expensive method of collecting carried

back material; however, it demands the most man-

hours to remove it. If the dumpster isn’t emptied, there is a possibility of material backing up

through the chute and trapping in the lower return area resulting in potential belt damage.

Figure 2. Air or water sprays

Figure 3. Dumpster cleanup is for use with systems enclosed on the return and anticipated to have minimal carryback.

11/1040

Stationary Industrial Vacuum

If more carryback is anticipated than practical for a dumpster, a stationary recirculating

vacuum system can be used. The system can be connected to a chute for pulling the material out

of the lower bend area with the same unit

returning the material back onto the belt.

This type of system has the advantage of

being very low in maintenance and is less

costly than a portable industrial vacuum

system. A derivative of this system is

using the same dust collector as used on

the system for dust control. However, if

the carryback is great enough, it may take

an unacceptable amount of man hours

emptying bag houses. This type of system

is not practical with heavy materials (over 75 lbs/ft3), wet/sticky materials, or with materials

containing lumps.

Screw reclaim system

Another method of cleaning at the lower return is a combination of two screw conveyors;

one removes material from the lower return

area through a chute in the same position as

the chute in the same position as the chute

for the industrial vacuum described above,

another screw conveys back to the carrying

side of the belt. If the lower horizontal section

is longer than normal, a third screw can be

added along the length of this section. (See

Figure 5 above)

Figure 4. Vacuum cleanup systems handle more carryback than most dumpster systems and require little maintenance.

Figure 5. Screw reclaim system.

11/10 41

Recirculating Drag Conveyor

Another alternate clean-up method is a drag conveyor extending beyond the tail pulley,

elevating the material en masse, and discharging back on the belt. This system has the

disadvantage of being more expensive

than either the screw or stationary industrial

vacuum and normally experiences greater

maintenance cost. (See Figure 6)

Note: Some customers have tried a belt

conveyor slave driven from the lower return

bend around the tail pulley discharging the

material back on the carrying side of the

belt. Beltwall does not recommend this type of cleanup system since the tension to slave drive

the belt is different around the tail than it is at the lower return. Therefore, the greater pressure

around the tail causes the slave driven belt to crush the sidewalls resulting in premature sidewall

failure.

Circular Chain System

One more example of clean-up involves

cutting a section out of a lower return pan

and chuting the material into a circular chain

conveyorwithflightsthatrotatethematerial

to a discharge point above the conveyor, into

a chute, which places the material back onto

the carrying side of the belt. A small screw

conveyor can be used to feed the material

from the lower return bend pulley to the

circular chain.

Figure 6. A recirculating drag conveyor starting beyond the lower return.

Figure 7. Two views of a circular chain system.

Side View

End View

11/1042

Figure 8. View of a Pulley Shield

A

SECTION A-A

A

Enlarged View

Return Bend Pulley Shield

V-plows are mounted on the return side

of the belt prior to the lower return bend.

They remove destructive material from the

underside of the belt and discharge it to

both sides of the conveyor. This prevents

material from becoming trapped between

the pulley and belt, protects the belt from

puncture damage, and reduces build-up

on the pulley thereby reducing alignment

problems.

Recess Area Scraper

The scrapers are mounted in the

recessareapriortotheUpturndeflection

wheels. Positioned to lightly contact the

top cover and divert material off of the

belt, the scraper prevents material from

becoming “pinched” between the belt

anddeflectionwheel,thusprotectingthe

belt from damage. The inside edge of the

scraper should have the same offset from

thesidewallasthedeflectionwheel.The

scraper should be constructed of rubber

or urethane.

Figure 9. V iew of R ecess Area Scraper at Upturn DeflectionWheel

11/10 43

Cleat Spillage Plates

BeltwallCleatSpillagePlatesaredesignedtocontainsmall,granular,orfree-flowingmaterials

conveyed at incline angles greater than 75 degrees. Spillage plates are installed on each end

of the cleats, effectively blocking theadjacent sidewall convolutionandpreventing flowpast

the cleat into the following cleat pocket. Spillage plates are also occasionally used to prevent

product entrapment in the sidewall convolutions and subsequent carryback.

Shown above is a typical “C” cleat plate. Spillage plates also block extended

convolutions at the noseover, reducing product entrapment.

11/1044

Assistance and Drawing Review

Beltwall offers technical assistance and drawing review for mechanical components as a

standard service to all customers. Designers are strongly encouraged to utilize this resource

for the rapid return of information based on experience gained from thousands of successful

installations. Beltwall technical personnel are available for comments and review on all mechanical

aspects of the design, installation, and operation of any Beltwall.

System application recommendations, along with any other written or verbal information from Beltwall Division, Beltservice Corporation, is accurate and reliable. However, it is offered as a service only. No warranty is either expressed or implied, and Beltwall cannot assume any liability whatsoever regarding its use. The user of Beltwall products must determine for himself the suitability of such products and recommendations for his own purposes, or the specific purposes to which those products and recommendations may be applied.

11/10 45

CORRUGATED SIDEWALL SAMPLE SPECIFICATIONS

The following information can be used as a basic reference for specifying corrugated sidewall

belting:

1. Belt Construction

A. Base belt to be cross rigid construction, with two cross rigid plies preferred.

B. Maximum belt stretch should be 1 1/2% at 100% rated tension.

C. Minimum covers for fabric construction should be 1/8” top by 1/16” bottom.

2. Corrugated Sidewalls

A. All belts with rubber cleats and an effective carrying width (distance between

sidewalls) greater than 24” (610mm) must have sidewalls bolted or otherwise

attached to cleat ends. This is not necessary for urethane cleats up to 75 degrees

incline.

B.Sidewallstobemoldedfromfiberloadedcompound.

C. All sidewalls 6” (152mm) and taller must be fabric reinforced.

D. On belts with recessed sidewalls, the recess shall be a minimum of [0.1 x (belt

width+sidewallheight)].

3. Cleats

A. Cleats are to be hot molded to the base belt with the cleat rubber being cured

as it is vulcanized into the base belt.

B.Cleatendsmustbeflushwiththeinsideofthesidewallconvolutions.

C. All cleats must be a minimum of 1/2” (13mm) less in height than sidewalls.

D. Two-part cleats should be used over 5-1/2” (140mm) in height with rubber base

hot vulcanized to the base belt and urethane cleats bolted into the cleat base.

4.DeflectionWheels

A.Deflectionwheels(hold-downwheels)shallhaveaminimumdiameterof12”

(305mm) or four (4) times the sidewall height, whichever is greater.

11/1046

B.Innerdeflectionwheelsarenotrecommended.

C.Deflectionwheelsshallhaveafacewidthnolessthanthesidewallrecess.

D.Wheelsshallbespacedtoprovidesidewallclearanceoneachsideequalto3/4”

or .15 x sidewall recess; whichever is greater; with maximum of 2”.

E.Inneredgeofthedeflectionwheelshouldcontaina3/8”(10mm)radius.

5. Idlers

A. Idler spacings on both carrying and return sides shall be a maximum of 3’6”

(1m) on horizontal sections, and a maximum of [3’6” (1m) divided by COS (angle

of incline)] or 6’ (1.35m), whichever is less, on all inclined sections.

B. Stub idlers must be used on the return run on all systems with a belt width of

30” (762mm) and greater.

C. Idler diameter shall be 4” (102mm) minimum.

6. If self-cleaning pulleys are required on the tail, spiral wing pulleys may be used, but

never standard wing pulleys.

7. Standard snub pulleys should never be used. If snubbing is necessary, deflection

wheels should be used. Consult Beltwall.

8.Allpulleysshouldbeflatfaced,trapezoidal,orcurvedcrown.Centercrownpulleysare

never recommended with cross rigid belts.

9. If rollers are used for the noseover, there should be a minimum of 1 for every 10

degrees of incline plus 1 additional roller. Spacing of the rollers should be a maximum of

1.5 x roller diameter. Shaft sizing is to be based upon the resultant load.

11/10 47

Design Information Data Sheet

A C

BE

F°

D

DESIGN INFORMATION -- ALL BELTSMax. Temperature:

Oily Condition? Yes N o

Moisture? %

Belt Width Preference?

Belt Speed Preference?

CONFIGURATION

A

BE

C

F°

D

BE

A

F°

C

B

CF°

E

EXISTING BELTBelt Length

Belt Width (BW)

Sidewall Height (H)

Sidewall Recess (R)

Sidewall Width (SW)

Effective Width (EW)

Belt Speed

Belt Type

Covers

Cleat Height

Cleat Type

Cleat Spacing

Pulley Dia.

End Prep.

FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5

FIGURE NO.AB

CD

EF °

Material:

Required Capacity: (STPH)

Density: (lbs./cu. ft.)

Angle of Surcharge: °

Lump Size: Min. Max.

EW

C

BW

SWRR

H

Cleat Types

"I "S"" "C"

A C

BE

F°

D

DESIGN INFORMATION -- ALL BELTSMax. Temperature:

Oily Condition? Yes N o

Moisture? %

Belt Width Preference?

Belt Speed Preference?

CONFIGURATION

A

BE

C

F°

D

BE

A

F°

C

B

CF°

E

EXISTING BELTBelt Length

Belt Width (BW)

Sidewall Height (H)

Sidewall Recess (R)

Sidewall Width (SW)

Effective Width (EW)

Belt Speed

Belt Type

Covers

Cleat Height

Cleat Type

Cleat Spacing

Pulley Dia.

End Prep.

FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5

FIGURE NO.AB

CD

EF °

Material:

Required Capacity: (STPH)

Density: (lbs./cu. ft.)

Angle of Surcharge: °

Lump Size: Min. Max.

EW

C

BW

SWRR

H

Cleat Types

"I "S"" "C"

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Installation

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INTRODUCTION

The installation of a Beltwall belt must be carefully planned. Conventional methods of handling

andstringingmaybeinsufficientforallbutshort,narrowconveyorswithlessthantwovertical

bends.

Due to the unique shape, weight, and value of Beltwall belting, it is extremely important that

proper methods and equipment be utilized. Beltwall has prepared these suggestions to assist in

the successful installation for your application.

BELT STORAGE

For proper protection, Beltwall belting should be stored in its original shipping crate or

container until ready for installation.

Normally, the belts will be festooned back and forth along the length of the crating or container

inanaccordionfashion(Figure1).Thebeltwillbepackagedatthefactorywithsufficientsupports

to prevent settling or shifting during normal shipping and handling.

Packaging for Shipment and Storage

Figure 1

Please notify Beltwall if storage for longer than 1 year is anticipated.

Belts should be stored in dry, heated environments away from direct sunlight. Extreme

temperature variations can have an adverse effect on a belt over long periods of time. The ideal

storage range is between 50°F (10°C) and 70°F (21°C).

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Long exposure at temperatures lower than 40°F (5°C) can harden or stiffen the belts. If

installed on a conveyor in this stiffened condition, the belt may not train well until it adjusts or

“warms up” to the system.

Sunlight and ozone can also deteriorate any exposed rubber over time. Store your belt out

of the direct sunlight whenever possible. Electrical generators or arc welders can sometimes

generate ozone. It is best to store your belt some distance away from this type of equipment.

If adequate storage facilities are not available, or if extended storage may be necessary,

advance notice should be given to Beltwall and special provisions arranged to ensure optimal

lifeofthebeltupontheeventualinstallation.Priortofinalbeltfabrication,notifyBeltwallofthe

intended direction of installation onto the conveyor so that the belt can be packaged to allow for

the easiest installation.

BELT INSTALLATION

TIMINGOFINSTALLATION

Beltwall belting should be installed only when ready for use. Stresses involved with high angled

conveyors may be detrimental to the belt construction during extended periods of inactivity. The

minimum recommended usage for any inclined Beltwall belt, loaded or unloaded, is one hour at

full speed every other day.

POSITIONINGOFTHEBELT

Whenpreparingforthestringingofthebelt,thecrateorcontainershouldbealignedtomake

a straight-line pull from the crate or container directly to the loading zone. Offset staging of the

beltmakesstringingunnecessarilydifficultandrisksdamagetothebelt.

The relative elevation of the crate or container should be as close to the elevation of the

loading zone as possible. Small differences of 5-8 feet (1.5-2.5m) in elevation either upward or

downward are not critical as long as the potential does not exist for interference that may result

in damage to the belt.

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The recommended, and certainly most common loading zones are at the tail or along the

lower horizontal section. Any plans for the erection of surrounding structural members, installation

of machinery, or assembly of conveyor components and covers should be scheduled to allow

for the location of the belting in this manner. In the event this preferred method is not practical,

the location of the belting for installation should allow for the adherence to these guidelines as

closely as possible, while remembering that the safest, fastest, and most economical location

for the splicing of the belt will be at the section with the lowest belt tensions - usually the loading

zone as described above.

CONVEYORALIGNMENT

The following items must be checked to ensure optimum belt performance:

A. The conveyor must be true relative to the center line.

B. The conveyor must be level from side to side.

C.Allcarryingandreturnidlers,deflectionwheelsandpulleysmustbesquarewiththe

frame. In addition, they must be perpendicular to the belt center line and parallel to one another.

D.Sufficientclearancemustbeprovidedonbothsides,underandbelowthehead,tail,

and bend sections.

E. Belt ends need to be examined to make sure they are squared.

F. To assure alignment of items A, B, and C, a survey instrument may be used to sight

a straight line parallel to direction of belt travel. Having completed this, make sure the

axesofpulleys,deflectionwheels,andcarryingandreturnidlersareperpendiculartothatline.

HANDLINGANDSECURINGBELTDURINGINSTALLATION

Remove any banding and packaging necessary to allow free access to the belt. Extreme care

should be given to prevent the binding or interference of the belt, sidewalls, or cleats with any of the

supports or braces used for packaging. Be aware there may be bracing hidden inside the walls that

cannot be seen from outside the crate or container. Determine the location of all packing materials prior

to any belt transfer to allow for the simultaneous removal of the packaging as each layer is lifted. Do

not remove the lower levels of bracing until necessary in order to continue providing support as long as

possible.

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To avoid inadvertent damage, protect the belt from any sharp bends or folds at all times

during handling. Never place excessive weight on unsupported sections of belt or sidewall.

Supporttheloopsattheendofeachlayerwithsufficientlylargebendstopreventkinkingasyou

advance the belt.

There are a number of ways to pull/place the Beltwall belting onto the conveyor:

A. Thread a rope or cable opposite the direction of belt travel around the idlers and pulleys,

then link the rope or cable to the new belt by means of a lead plate or belt clamp to evenly

distributethetensionoverthewidthofthebeltfordrawingthebeltintoitsfinalposition.

B. Attach the new belt to the end of the old belt which has been cut for replacement and

use the old belt to pull the new belt into place.

C. Pull the belt in place by hand.

* Method A is the most preferred of all those available.

Only the smallest of Beltwall belts can be managed by hand onto the conveyor. Due to the

weight and length involved, most belts require the use of a hoisting source such as a crane, hoist,

puller, or vehicle with a winch. Additional lifting equipment is advised to aid in the simultaneous

lifting and pulling as the belt is gradually drawn from the crate or container to the loading zone

andfeed-inpointontotheconveyoraroundtoitsfinalpositionreadyforsplicing.(Figure2).

Lifting and Installation Equipment

Figure 2

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The minimum handling equipment should include:

1. One or more cranes, lifting, or hoisting mechanisms.

2. Pulling source.

3. Hoist sling or lifting device with a spreader bar or yoke wider than the belt and

rounded lifting surface such as a pulley or rolled plate with a surface radius at least equal

to that recommended for the minimum pulley diameters (Figure 3). Both the spreader/

yoke and rounded lifting surface should be 6”-12” (150mm-300mm) wider than the belt.

Beltwall Lifting Devices

Figure 3

4.Leadplatetograsptheleadingendofthebelt(Figure4).

Beltwall Lead Plate

Figure 4

PULLEYROLLEDPLATE

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5. Holding clamp for providing a positive grip if necessary at mid-sections of the belt. The

holding clamp should be fabricated to straddle the sidewall and have a curved lifting surface like

the hoist sling or lifting device (Figure 5).

WARNING!!! If ordinary slings, chokers, or C-clamps are used instead of the appropriate

lifting devices and holding clamps, there is a greatly increased likelihood of permanent

belt damage!

Beltwall Holding and Lifting Clamp

Figure 5

6. Pulling cable or rope.

7. Feed table and/or support rollers for supporting the weight of the belt without dragging

from the crate or container to the loading zone. (Figure 2)

8. Guide sheaves for directing the pulley cable from the conveyor to the pulling source

and for directing the pulling cable through the upturn and downturn bend areas (Figure 2) without

damaging the shafting or putting undue stress on the belt. A special drum may also be used to

guide the pulling cable over the upturn and downturn shafts.

9. Protective sheave to protect pulley lagging as the pulling cable passes over the pulley

surfaces.

10.Feedrolls,similarindesigntodeflectionwheelassemblies,mountedonaframeand

temporarily mounted on the conveyor structure to guide the belt into the framework protecting

both the belt and the conveyor housing (Figure 2).

11. Tape or clip to anchor any excess sidewall lengths to the belt during stringing.

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DIRECTIONOFINSTALLATION

As previously discussed, the preferred method for stringing the belt is to pull the belt from the

tailorhorizontalloadingsectionalongtheconveyorprofileinthedirectionthebeltwilltravelin

operation (Figure 2).

It is understood some conveyors may not permit the preferred loading zone and installation

procedure. If feed-in is required from some other point, or if the belt is lowered from above the

conveyor, careful individual planning and study is absolutely necessary to ensure the proper

installation of Beltwall belting. In any case, the basic protection for the belt as outlined in these

instructions must still be carefully observed.

BELT SPLICING

Wheneverpossible,thebeltsplicingpointshouldbeatthelowerendoftheconveyor.This

permitstheconveyorstructuretosupportthebeltweightandsimplifiesinitialtensioningofthe

belt. Rigging for splicing the belt at any elevated point necessitates special belt clamping and

lashingprovisions.Sucharrangementsalsomakeitmoredifficult topulloutexcessslackso

the start-up setting of the take-up can be more accurately positioned to ensure the belt length

finishedontheconveyorisequaltothecalculatedlengthsupplied.

For hot vulcanized belt splices, the following provisions are required:

A. Access to both sides of the belt from a catwalk or platform.

B. At least 16 feet (5m) of work area along the belt length to permit fold back for preparing

the bottom side of the splice overlap.

C. Overhead clearance to permit workers to stand erect when rigging the vulcanizer and

related equipment.

D. Shelter from weather and temperature extremes.

E. Electric power supply for vulcanizer tools.

F.Liftingassistanceifvulcanizingequipmentcannotbeshifteddirectlyfromthetruckbed

into splicing position.

For mechanical belt splices, DO NOT TRIM the belt edges in the mechanical fastener area. The

fasteners must extend across the full width of the belt. On a system with bends, all of the tension

mustbeabsorbedbytherecessportionofthebeltacrossthefacewidthofthedeflectionwheel.If

the belt edge is trimmed at the fastener, holding ability is lost causing fasteners to pull out.