www.fenaplast.com

The World’s LeadingConveyor Belt Company

Fenaplast

Material handling systems are the backbone of a modern mining operation – without efficient conveying,

mine production can be severely affected. The efficiency of any conveyor depends largely on the trouble-

free working life of the belt itself, yet the conditions under which it has to operate can be extremely

arduous, having to resist ripping, impact, abrasion, bacteria, acid, water and general mechanical damage.

With over 50 years’ experience in the manufacture of conveyor belting coupled with our innovative

leadership in product design, manufacturing, application engineering and technical support plus a total

dedication to customer service, Fenner Dunlop is the first choice for conveyor belting products and

services.

Fenner Dunlop Europe is a member of Fenner Dunlop Conveyor Belting Worldwide, the world’s

largest manufacturer of conveyor belting for mining and industrial applications. With twelve manufacturing

facilities on five continents, Fenner Dunlop is uniquely positioned to provide the most comprehensive

conveyor belting service available today.

TheAdvantagesof Fenaplast

First launched in the 1950s and developed continuouslyever since, Fenaplast is Fenner Dunlop Europe’s flagshipproduct. Our extensive knowledge of conveyor beltapplications, fabric weaving and polymer technology arecombined in this market-leading range that has been atthe forefront of development for over half a century.

Fenaplast solid woven monoply belting, the firstchoice of countless mines throughout the world, has anumber of significant advantages including

u fire resistant and anti-static properties which meet the most stringent safety standards in the world

u greater flexibility than press-manufactured belts, making it easier to trough and track when installed

u a solid woven one piece carcass with no risk of ply separation

u covers which form an integral bond preventing any form of belt delamination

u high resistance to longitudinal tears

u high dynamic and static vulcanised jointproperties

u excellent retention of mechanical fasteners

u high resistance to impact damage

u impervious to attack from acid, water, oil,bacteria and chemicals

u high resistance to edge wear

CARCASSIn many respects the carcass is the most important partof a conveyor belt since it provides the tensile strengthnecessary to move the loaded belt, absorb the impact ofmaterial falling on to it, provide the bulk and lateralstiffness required for load support and be of adequatestrength for bolt and/or fastener holding.

The Fenaplast solid-woven carcass is a highlycomplex design, utilising warp yarns interlocked and tiedinto one single mass by means of a uniquely designedbinder warp system. Nylon or polyester load bearingwarp yarns and nylon or nylon/cotton weft yarns areusually used in conjunction with the weave design.Various combinations of these synthetic and naturalfibres ensure that the requirements for impact resistance,belt elongation, flexibility (for troughing and wrappinground small diameter pulleys), load support and fastenerretention are met. Where there is a specific need, cottonpile warp yarns may be included to further improveimpact resistance. Additional edge reinforcement isincluded where required.

The solid-woven fabric is impregnated with PVC to makethe finished carcass. Fenner Dunlop’s unique, patentedimpregnation system renders the carcass impervious toattack from moisture, dirt, chemicals, bacteria and oils.

The countless options in the Fenaplastcarcass construction enable a user to define specificoperational requirements and receive a custom-built beltexactly suited to a specific application.

BeltConstruction

COVERSFollowing the impregnation process, PVC covers areapplied to the top (carrying) and bottom (drive) surfacesof the belt to protect the carcass and extend service life. Cover type, quality and thickness are matched to specificcustomer requirements.

PVC covers can be formulated to meet anyworldwide fire resistance specification and to offerresistance to other hazards, such as oils and chemicals.Special compounds can also be used to give improvedabrasion resistance or a higher coefficient of friction.

For use above and below ground and where ahigher coefficient of friction is required, rubber covers canbe vulcanised to the parent belt. These can be fire-resistant if required. Rubber covers are recommended forshort-centre, high trip rate, high tonnage installationssuch as coal preparation plants, coke works and for hardrock conveying applications.

SPECIAL APPLICATIONSTailor-made, low stretch Fenaplast belting is suitable fora variety of specialist applications, including bucketelevators and similar installations where take-up islimited. Other application-specific belts can be designedand custom built with the assistance of a Fenner Dunlopengineer, ensuring the correct selection of beltconstruction and covers every time.

Solid-woven carcass prior to PVC impregnation

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RETOUCH

FENAPLAST FRMeeting or, in many cases, exceeding the fire-resistanceand anti-static requirements of all worldwide safetystandards, Fenaplast FR belting is designed primarily foruse underground and in other potentially hazardoussituations. PVC compounds, with cover thicknesses of upto 4mm can be varied to suit any specific application.Fenaplast FR belting has a proven superior service life incoal mining and similar applications where high,continuous output depends on belt reliability.

The PVC covers give excellent cleaning propertiesand, together with the advantages of a solid-wovencarcass, provide a belt ideal for conveying coal, potash,phosphate, fertiliser, salt, gypsum and clay, as well as foruse in the timber industry and other applications wheremoist, sticky materials are handled.

FENAPLAST FRSR/PVG/CRGWhere a high level of fire resistance is required, togetherwith special cover properties, more achievable withsynthetic rubber compounds, Fenaplast FRSR is theideal solution. This belting is Fenaplast FR with theaddition of single or double rubber covers, of up to 6mmthick. Increased belt life, steep gradient and high trip rateconveying are the main advantages of this type ofbelting. It is generally used on high tonnage drift andtrunk conveyors, power stations, and coal preparationplants.

FENAPLAST SRWhere there is no requirement for fire resistance,Fenaplast SR is offered as a rubber-covered belt forconveying abrasive or difficult minerals. A durable rubbercover, compounded for maximum abrasion resistance upto 6mm thick, combined with our PVC impregnated solid-woven carcass has proven ideally suited to high impactinstallations such as the conveying of aggregates andsimilar hard, sharp materials.

TheFenaplastRange

FENAPLAST HI-VISFenaplast High Visibility (Hi-Vis) yellow covered beltingprovides improved safety and inspection capabilities,particularly on underground conveyors. The enhancedvisibility of the yellow covers significantly improves thesighting of the conveyor's moving parts and structureagainst the belt, allowing easier inspection and makingthe conveyor itself more conspicuous. In use in the UK,Scandinavia and Canada, the advantages of Hi-Visbelting have been recognised by engineers as a usefulfeature in improving safety around conveyors - always anarea of concern.

Fenaplast Hi-Vis belting is a product innovationdriven by the need for improved safety and is especiallyadvantageous on man-riding conveyors, making the beltedges and conveyor moving parts more obvious to therider.

Fenaplast belting is also available in a range ofother colours to assist in belt identification.

SPECIAL CARCASS PROPERTIESFenaplast carcass designs can be customised to includeone or more of the following features

u increased fastener holding efficiency for high speed/tonnage applications

u improved lateral stability to further enhance resistance to longitudinal splitting on high capacity/deep trough conveyors

u high tear and rip resistance for arduousapplications where belts are difficult to align and maintain

u additional carcass mass to allow the belt to negotiate small radius catenary curves which would normally require steel cord belt (this helpsto prevent the belt lifting off the structure under no load conditions)

u the ability to operate at temperatures well in excess of 90°C (the normal limit for standard constructions)

u improved edge wear protection for extensible and similar applications

FENAPLAST SPECIAL COVERSCertain applications require conveyor belts with specialproperties and our highly experienced in-house researchand development team has developed a range of PVCcompounds for Fenaplast covers, all of which areavailable with fire-resistant properties. Our range of PVCcovers include

u hard, highly abrasion resistant covers for conveying underground in high ambient temperatures

u thick covers with an easily cleaned surface for handling wet, sticky materials such as chalk, clay and lignite

u high coefficient of friction covers for high grip on pulleys and for load retention on inclines

u covers suitable for low temperatureenvironments

u special elevator belt covers

CustomisedFenaplast

www.fennerdunlop.com/europewww.fenaplast.com

Our UK facility is the worldwide Centre of Excellence for Fenner Dunlop solid-woven conveyor belting and

as such is at the forefront of research and development. Externally certified to ISO 9001:2000, the Centre

of Excellence is constantly seeking ways to make product and process improvements as well as

researching new manufacturing techniques and materials. It is staffed by experts in engineering, chemistry,

polymers and textile technology.

A key function of the Centre of Excellence is thecontinual testing of Fenaplast products to ensure that thevery highest standards are met. Conveyor belting,particularly for use in underground applications, issubject to rigorous safety testing in our state-of-the-artfacilities to ensure that all belts meet the most stringentrequirements. Our in-house Dynamic performance testingensures every belt is “fit for purpose”.

SAFETY TESTINGThe Fenner Dunlop approach to fire safety testing isbased on the premise that a belt should never be thecause of a fire, should be difficult to ignite, and if ignitedby an external fire source, should not propagate the fire.

Whilst fire resistance specifications vary fromcountry to country, Fenaplast belts can be formulated tomeet any fire performance specifications in the world.

The tests carried out on conveyor belts to assesstheir compliance with fire safety standards are associatedwith four particular hazards.

The Fenaplast Centre ofExcellence

ProductTesting

1. Drum Friction TestThe danger associated with a stalled belt and adriven rotating drum or pulley resulting in frictionalheat build up.A test piece of conveyor belt, suitably mounted andtensioned, is wrapped half way around a rotating steeldrum, simulating a stalled belt. The test is continued atspecified tensions for a given time period, or until the beltbreaks. The presence, or absence, of flame or glow isnoted and the temperature of the drive drum ismeasured. The test is conducted in still air and/orin moving air. This test has probably been the majorsingle contributor to mine safety in respect to conveyorfire prevention.

2. Laboratory Flame TestThe possibility of igniting the considerable mass of aconveyor belt with a relatively small ignition source.This hazard is usually assessed by the application of asmall "Bunsen" type flame to a belt sample andobservation of the effect. The time taken for all flameand/or glow to self-extinguish is noted.

Fenner Dunlop solidwoven conveyorbelting for useunderground conforms toall major internationalstandards includingBS 3289

QUALITY TESTINGAll Fenner Dunlop belting is produced within our QualityManagement System which is compliant with ISO9001:2000. As part of this system, the quality of all belt isverified prior to despatch by a programme ofcomprehensive testing.

Typically this testing will include

u dimensional measurements

u warp and weft tensile strengths

u tear strength

u elongation

u cover adhesion

u small scale safety tests (laboratory flame and electrical resistance)

u abrasion resistance

u transverse stability

DYNAMIC PERFORMANCE TESTINGIn addition to the tests outlined above it is necessary toensure that every belt will meet our customers’ require-ments and be "fit for purpose" in its specific application.The belt’s ability to be joined, either by the use ofmechanical fasteners or vulcanised splices, as well as it’sability to conform to the required idler configuration andto operate with acceptable transition distances.

Our testing facility is equipped with a range ofdynamic test rigs enabling us to perform

u accelerated life testing on both the belt and related joining methods

u field problem simulation

u troughing/transition distance evaluations

u product and material development testing

u specific belt testing to individual customer requirements

Our mission is to achieve total customer satisfaction. Whilst the above paragraphsprovide an indication of Fenner Dunlop’s commitment to product quality, we believe

that the key to achieving this goal is the establishment of excellent working partnerships with our customers. Ourcommitment does not stop with the sale of a belt. Our technical personnel are always available to help customers get themost from our products and achieve safe, economical conveying.

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3. Gallery Fire TestThe possibility of a belt, ignited from a larger ignitionsource, spreading the fire to other areas (oftenreferred to as fire propagation).This hazard can only be assessed by a Gallery Fire Test.Historically, this was a large scale test that involved theuse of 7.5kg of propane over 50 minutes to ignite a belt.Whilst the testing method was robust, the test itselfrequired large scale facilities and created environmentaland health and safety issues. In 2002, Fenner Dunlopprovided assistance for the UK Health and SafetyExecutive’s, development of the mid-scale high energytest. Accurate correlation with the large gallery test wasachieved and this test was incorporated into theEuropean Standards.

Fenner Dunlop’s in-house test facility is the only onein operation in the UK.

4. Electrical Resistance TestThe possible build-up and subsequent discharge ofstatic electrical charge on moving conveyors.Fenner Dunlop’s PVC and rubber compounds arespecially formulated to ensure that belts are sufficientlyconductive to avoid the build up of static electricity. Theelectrical resistance is determined by passing an electriccurrent of specified voltage between electrodes placedon the surface of the belt. The internationally recognisedacceptance criteria for electrical conductivity is amaximum resistance of 3.0 x 108 Ohms (300M Ohms).

Technical InformationBELT DESIGNATIONBelts can be produced to various tensile specification,using either polyamide (Nylon) or polyester base warpyarn. Some markets still prefer to specify belt typesbased on tensile strength expressed in lbs/in width (theFenaplast Belt Designation uses this term), whilst othersopt for the preferred ISO nomenclature expressed inN/mm. The table below shows typical figures forminimum warp and weft strengths, belt thickness andweight for a selection of belt types, based on 1mm PVCcovers. For thicker covers, add 1.3 kg/m2/mm for PVCcovers and 1.4 kg/m2/mm for rubber covers.

Alternative constructions are available which givevalues higher than those in the table. This is particularlyrelevant to weft strength, where special yarns /designsmay be recommended for improved properties such asfastener holding, load support and weft stability.

The use of such special yarns may increase thebelt weight and thickness which may be critical forshipping purposes or underground transportation. AFenner engineer should always be consulted where thisis likely to be critical.

BELT THICKNESS When considering cover thickness, please be aware ofthe high textile content of Fenaplast and the propertiesafforded by the increased carcass bulk compared torubber plied belting. Consequently, thinner covers maygenerally be chosen than would normally be associatedwith an equivalent plied product, the enhanced textiledensity of Fenaplast providing the necessary loadsupport and resistance to impact.

*Nominal valuesfor specific belt constructionsSpecification sheetsdetailing the actualdata for any beltingsupplied can beforwarded on request.

WEFTSTRENGTH

N/mm

BELTTHICKNESS*

mm

BELTWEIGHT*

kg/m2

MINIMUMRECOMMENDED

DRUM DIAMETERSHigh tension mm Low tension mm

224028003300350040004500500060006500700080009000

100001200015000

400500580630710800875

10001140125014001600180021002625

250275275275300300300350350350350425425425425

5.57.78.08.18.38.58.89.49.5

10.410.511.912.913.914.9

7.310.110.310.511.011.111.211.912.012.213.214.816.117.618.6

250315355400400500500630630750750800800

10001250

225250315315355355355400400450450600600750800

BELT WEIGHTCustomers should remain aware that lower belt weightsmay be advantageous on long conveyors as a means ofreducing power consumption. High lift conveyors canincur a correction for slope tension which may beavoided by careful belt selection to minimise weight,resulting in considerable cost savings on certainapplications, e.g. drift conveyors.

DRUM DIAMETERSThe drum diameters quoted are the minimum generallyrecommended. Given specific information regarding wrapconfigurations, tensions, belt speeds and jointingmethods, it may be possible to recommend smallerdrums.

BELT STRETCHThe unique design and manufacturing process ofFenaplast allows both permanent and elastic stretch tobe kept to a minimum, consistent with good operation.With numerous carcass designs available in both nylonand polyester yarns, it is impracticable to indicate allstretch figures. Further details can be provided onrequest.

OPERATING FACTOR OF SAFETYWith good quality mechanical fasteners or vulcanisedjoints a factor of safety of 10:1 is generally acceptable.However we will be pleased to confirm the recommendedbelt construction and acceptable safety factor for anyspecific application on receipt of the necessary conveyordetails.

lbs/in

BELTDESIGNATION

N/mm

WARPSTRENGTH

Safety andQualityAssuranceSAFETYFenaplast meets the safety requirements of all the majormining nations and has been tested and/or approved bythe appropriate national authorities including

COUNTRY APPLICABLE STANDARD

Australia AS 4606Canada CSA M422-M87China MT914 Czech Republic CSN 26 0372Germany DIN 22109 Part1India IS3181Poland PN-93-05013South Africa SABS 971Spain LOMRussia PD03-423-01Turkey TS 547UK BS 3289Ukraine GSTU 12.0018579.001-99USA Title 30 Part 18

Section 18.65

(Fenaplast conveyor belt can be formulated to complywith the proposed fire propagation test outlined in theMSHA publication, Belt Evaluation Laboratory Test,known as B.E.L.T. ).

QUALITY ASSURANCEIn accordance with the requirements of our majorcustomers, the planning, design, manufacture and qualitycontrol procedures of Fenner Dunlop Europe have beenassessed and are approved to SpecificationISO 9001: 2000, the International Standard for officialapproval of a manufacturer’s quality system.

The system approved under the above standard hasbeen accepted by the USA Mines Safety and HealthCommission, and a similar assessment of Fenner Dunlophas been carried out by the Canadian Federal EnergyMines and Resources Department against the CanadianStandard CAN3Z299, 1-78 “Quality AssuranceProgramme Requirements” and by the Spanish LOMAuthority.

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BELT WIDTHAny width up to 2100mm can be supplied. Whilst werecommend customers to follow the ISO range ofpreferred widths, non-standard widths can be supplied.Slit-edge belting is also available upon request.

ROLL LENGTHSCustomers are asked to specify their maximumacceptable roll diameters and weights so that Fenaplastbelts can be supplied in the most suitable roll lengths,within our safe factory limits, to avoid unnecessary joints.Fenaplast can normally be produced in any required rollsize to suit handling and transit to site.

Single or double coiled rolls can be supplied with fasteners fitted if required. Length tolerance is -0.5%+2%, unless otherwise agreed. Short belts can be splicedinto endless loops as part of the manufacturing process.

OPERATING TEMPERATURE RANGEAbove 90°C PVC softens and the belt properties change.Fenaplast is therefore not recommended for conveyingmaterials above this temperature. Standard Fenaplastcan be used in cold climates at minus 15°C and specialcover compounds are available for operation down tominus 30°C. Where applicable, cold weather detailsshould be supplied to ensure that belting with suitablecoefficient of friction and flexibility characteristics isspecified.

Jointing ofFenaplast

Note: All polymeric materials deteriorate with age and storage. Most materials have an effective life of six months andunsatisfactory splices may result from using old materials. Storage in warm conditions may reduce effective life further.This warning applies to all splicing materials, regardless of supply source or belt types. We will be pleased to advisefurther on the storage of such materials.

BRAND TYPETENSILERANGE

max N/mm

TENSILERANGE

max lbs/in

Mato

Goro

Titan

Flexco

U35AU35U37AU37U38AU38U65AU65U67AU67U68AU68MH22AMH22BMH25AMH25BMH27AMH27BMP27MP28

200120022003

TIOHTIRTIOTI4T2

R5R51/2R6F8F9F11F12F14

105010501400140035003500140014001600160035003500630630

1050105014001400800800

65014003500

12501250140016003500

800114140800

1140114014001400

6000600080008000

20000200008000800090009000

200002000035003500650065008000800045004500

32008000

20000

7000700080009000

20000

45006500800045006500650080008000

BELTTHICKNESS

mm

5-97-118-12

10-1412-1515-186-108-129-13

12-1612-1512-18

5-77-95-77-9

10-1212-14

8-118.5-14.5

5-77-14

10-18

5-146-146-14

9.5-1814-18

6-118-15

10.5-175-86-9

8-119-12

11-14

Fenaplast conveyor belting can be joined in two ways,hot vulcanised finger splicing and by the use ofmechanical fasteners.

SPLICED “FINGER” JOINTINGConventional vulcanising presses are used for thisprocess, in conjunction with a variety of polymeric joiningmaterials developed for maximum joint efficiency. Thistype of splice enables good quality joints to be made withstrengths approaching that of the parent belt. Hotvulcanising offers certain advantages including

u the highest joint strength possible

u a reduced risk of tearing at the splice area

u a smooth joint area for superior performance under scrapers, ploughs, deflectors and minimal impact over pulleys and idlers

u operation through automatic weighing devices and magnetic separators

u reduced maintenance

u resistance to harmful moisture and chemicals

u a superior resistance to abrasion

u easier cleaning

u reduced spillage

MECHANICAL FASTENERSThe thick, high textile content of the Fenaplast solidwoven carcass, combined with the superior PVCimpregnation produced by our unique process, givesexcellent fastener holding properties. A wide range offasteners including Mato, Goro, Flexco and Titan aresuitable for use with Fenaplast. We would be pleased toprovide further advice on fastener use. Mechanicalfasteners are more appropriate in conditions where

u belts are replaced frequently

u belts and conveyors are extendedregularly

u emergency jointing or repairs are required

u take up travel is limited

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FieldService& TechnicalSupportFenner Dunlop’s commitment to our customersdoes not begin or end with the sale of a highquality belt. Our in-house trained and certifiedteam of service engineers are available to offer acomprehensive range of services worldwide, bothabove and below ground, Including

u SITE SURVEYSReports on conveyor systems, belting and vulcanised/mechanical joints

u SITE VULCANISINGOur mobile splicing teams are fullyequipped to carry out splicing work bothunderground and on the surface anywherein the world

u MECHANICAL FASTENERSSupplied and fitted on site

u BELT FITTINGComplete belt changes or belt inserts

u DRUM LAGGINGBoth diamond and plain materials withcold cure system of bonding to drive drums

u BELT COILINGBelting up to 2m width coiled in lengths upto 150m

BELT TENSION CALCULATIONS AThe international Standard ISO 5048 is recommended for the calculation ofbelt tensions and horsepowers, the following showing the basic formula anddata required.

EFFECTIVE TENSIONTe = CfLg (qro+qru+(2qb+qg))+(qgHg) Newtons

TENSION AT DRIVE HEADT1 = TexK

SLACK SIDE TENSIONT2 = T1-Te

POWER REQUIREMENT @ DRUMPa = Texv

where:

C = coefficient for length correction

f = coefficient for friction of moving parts

K = drive coefficient

L = Conveyor length (m)

g = gravity force = 9.81 (m/s2)

H = Vertical lift or fall (m)

v = belt speed (m/s)

Belt CalculationsBELT CAPACITY CALCULATIONSBelt capacity can be calculated using the ISO 5048 formula or more readilyby the simple Fenner Dunlop method indicated below. The installed beltingneeds to be wide enough to carry the required peak tonnage at the designspeed of the conveyor. The equations (below) in conjunctions with the ‘B’factors in Table 1, can be used to ascertain either the width of beltingrequired for a new installation, or the capacity of an existing conveyor.

When selecting belting to carry two or more types of material, it isimperative that capacity calculations are based on the smallest mass perunit volume.

B = P x 1000D x S

P = B x D x S1000

where:P=Peak capacity (t/hr) B=Belt capacity factor (Table 1)D=Material density (kg/m3) Table 2 S=Belt Speed (m/s)

BELT SELECTIONFull details of the installation should be given for Fenner Dunlop engineersto cross-check calculations and to give the most economic and reliable beltrecommendation. It is essential to have some information on the belt tensilerequirement, belt length and width and the material being conveyed.

Where the T1 figure (Tension at Drive Head) is known it should beused as the basis for initial belt selection. Otherwise at least the followinginformation should be given to enable this figure to be calculated

1. Centre distance of conveyor (m).

2. Belt speed (m/s).

3. Peak loading (t/hr).

4. Belt width (mm).

5. Material carried.

6. Type of drive (number of drive pulleys, angle of wrap, and whether steelor rubber lagged) and take up arrangement (e.g. gravity, load sensed orfixed).

7. Net changes in elevation (rise or fall between loading point and delivery point in metres) and maximum gradient (degrees).

8. If known, details of idlers (angle of trough, type of bearings, style of idlers, idler diameters, and pitch).

Alternatively, installed motor power can be used as a rough guide togetherwith belt speed which must be provided. Actual power consumed whilstrunning fully laden is more relevant than installed power.

Details of the material and general conditions are useful

1. Size of material (maximum lump size, proportion fines to lumps).

2. Loading details (height of drop, direction of feed, etc.).

3. Condition of material (dry/wet, temperature, etc.).

4. Exact nature of material (density, nature - sharp or rounded).

The correct belt selection must consider

u Belt Capacity

u Belt tensile strength

u Requirement due to load and conveyor structure

400 50450 68500 88600 125650 150750 202800 230900 300

1000 3751050 4201200 5551350 7251400 7901500 9101600 10501800 13652000 1710

TABLE 1Belt capacityfactor ‘B’

Belt Width mm Factor

TABLE 3 ‘G’ Factors

Belt Idler DiameterWidth 102 127 152/168

mm mm mm mm

400450500600650750800900

100010501200135014001500160018002000

252829343540434752536167

29323540434952657174849396

37414450535962778487

101111114122129144157

TABLE 2Material densities in kg/m3

Ash (dry/wet) 560/880Ashphalt (solid/loose) 1900Basalt 1280/1760Bauxite 830/1360Cement (loose) 1200/1360Chalk (dry/wet) 1040/1360Clay (wet) 1600Coal (R.O.M.) 800Coal (fines) 850Coke 480Copper Ore 2080/2560Foundry Sand 1440/1760Granite 1280/1400Gravel (dry/wet) 1440/2000Gypsum 960/1280Iron Ore 1360/4800Lead Ore 2400/4430Lime (powder) 960Limestone 1280/1750Manganese Ore 2720Peat 320Phosphate (dry) 1200Potash 1390Quartz 1120/2240Sand (dry/wet) 1140/2080Sandstone 1360/1440Slag 1200/1440Slate 1200/2400Stone 2400Sulphur 960/1280Superphosphate 1000Wood Chips 300/900Wood Pulp 480Zinc Ore 2500

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Before the optimum belt type for a given installation can be determined,maximum tension (T1) must be established, and for this, the followinginformation is necessary:

(1) Total power requirement (kW)

(2) Belt width (mm)

(3) Belt speed (m/s)

(4) Take up details

(5) Drive configuration

The maximum tension for which the selected belt must cater can becalculated from the following formula:-

T1 = K x PS kN

where:-K = Drive factor (Table 4)P = Total power requirement (kW)S = Belt speed (m/s)

Once this tension figure has been determined it must be divided by the beltwidth (metres) such that the tension can be expressed in kilonewtons permetre. The appropriate Fenaplast belt type can then be established. Beltselection is based upon the traditional 10:1 factor of safety which hasproved satisfactory over many years of field experience. Nowadays,however, modern synthetic fibres, advanced belt designs and improved jointefficiencies enable lower factors of safety to be considered in certaincircumstances. Fenner Dunlop will be pleased to advise on specificinstallations.

Once the appropriate belt has been selected, drum diameters oughtto be checked against the minimum values.

SLOPE TENSIONTheoretically the cosine of the incline angle should be considered, but sinceat practical conveyor angles this is unity (or near to unity) the incline factorcan be ignored. However, on strong inclines (10° or steeper) it may benecessary to correct T1 to Tmax because of slope tension (Tslope) due tothe belt mass being displaced over the gradient.

Simplified

Tslope = qbxH x g Newtons

when Tslope>T2 then

Tmax = Te+Tslope

and Tmax should be used for belt tensile basis rather than T1.Complex undulating or downhill conveyors should consider the

worst conditions of load carrying in order to ascertain Tmax which may notbe T1 at drive.

BELT TENSION CALCULATIONS BThe Fenner Dunlop formulae on this page will give fairly accurate resultsthough various other factors can affect the total power requirement. Forexample in winter, additional power may be required to overcome initialfriction in the idlers and transmission units. Poor chute design and seizedidlers will also bring about the need for additional power, as well aspromoting unnecessary belt wear. Similarly, if extensive skirt plates arefitted there may be a small additional power requirement, as there will oninstallations where a tripper exists. Wherever the above factors are likely tobe significant Fenner Dunlop should be contacted for advice.

Many similar formulae exist for calculating power requirements all ofwhich are acceptable when correctly applied. It is important however, thatattempts are not made to transpose factors and constants from sourcesother than this catalogue into the Fenner Dunlop formulae, otherwiseinaccuracies are inevitable.

The power required to drive a conveyor is comprised of the sum of threeseparate power elements:-

(a) Power to move load horizontally.= 2.72 x L x F x (C+46) kW

1000

(b) Power to move empty belt.= 9.81x F x G x (C + 46) x S kW

1000

(c) Power to elevate load.= 2.72 x L x H kW

1000where:-

C = Centre distance (m)F = Friction factor (see above)G = Inertia factor (Table 3)H = Change in elevation (m)L = Peak loading (t/hr)S = Belt speed (m/s)

The total power required= (a)+(b)+(c)

However, if the load is to be carried downhill,(c) must be subtracted.

TABLE 4 KAngle of

Wrapdegrees

ScrewBare Lagged

GravityBare Lagged

180200210220240250270300360420430450

2.001.871.811.761.661.631.551.461.341.251.241.22

1.841.721.671.601.551.501.451.371.261.191.181.16

1.641.541.501.461.401.371.321.261.181.131.121.11

1.521.441.401.371.321.301.251.201.131.091.081.07

METRICATIONThe following metric/imperial conversion chart provides useful reference.

Yards to metres x by 0.9144Feet to metres ÷ by 3.28Inches to millimetres x by 25.4lb/ft3 to kgm3 x by 16.02ft/min to m/s ÷ by 197lb to kg ÷ by 2.2046ton/h to t/hr x by 1.016

hp to kW x by 0.746lbf/in to N/mm ÷ by 5.71lbf to Newtons x by 4.4482kgf to Newtons x by 9.81lb/ft to kgm x by 1.49ft2 to m2 ÷ by 10.76kg/cm to N/mm x by 0.981

COEFFICIENTS CL C

<5080

100200500

10002000

4000+

2.501.921.781.451.201.091.051.03

qro = top idler mass per metreqru = bottom idler mass per metreqb = belt mass per metreqg = load mass per metre

= tph 0.278v

FNormally 0.022 can be used butthis may be reduced to 0.018 for wellengineered and maintainedapplications or increased up to 0.030for poor conveyor installations

Inspection and Shipping

FINAL INSPECTIONBefore shipping, belts are 100% inspected and recoiledinto a maximum of 3m diameter rolls (this is themaximum size that can be handled safely through thefactory). Double coils can be supplied if the customer hasheight constraints. At this point, the customers preferredmechanical fasteners can be fitted.

PACKINGCentral cores can be supplied in either wood or steel.Various packaging materials of different durability areused, dependent on transport, site environment andcustomer’s preferences.

ROLL DIAMETER mm & in.

RO

LL

LE

NG

TH

S

20 30 40 50 60 70 80

500 700 900 1200 1600 2000600 800 1000 1400 1800

mm

in.

1000

900

800

700

600

500

400

300

200

10025

50

75

100

150

200

250

300

m. ft. 7 8 9 9.811

12.5

Diameter (mm) =

1.273 x L x t + 0.041000

L = Length (m)t = thickness (mm)

Length m = D2 - 0.04 x 1000 1.273 x tD = diameter of roll (m)

Further information on Fenaplast belt handling and storage is available upon request.

www.fenaplast.com

Applications

Coal Salt

Power generation Man-riding

Potash

Timber

Steep gradients

Gypsum

Marfleet, Hull, England HU9 5RA Tel: +44 (0)1482 781234 Fax: +44 (0)1482 785438

www.fenaplast.com email: sales@fenaplast.com

Registered Office: Hesslewood Country Office Park, Hessle, East Yorkshire HU13 0PW.

Overseas ContactsBELARUS

Alyona FletcherTel: +749 516 02442fletcher1@mail.ru

CANADA

TORROX Garth MacleanTel: +1 902 468 7666gmaclean@torrox.ca

Carter KosickTel: +1 902 468 7666ckosick@torrox.ca

Jeff BaronTel: +1 780 449 4907jbaron@torrox.ca

CZECH REBUBLIC

Vaclav KabrtTel: +420 257 811 408v.kabrt.agency@iol.cz

IRAN

MULTI-CORPORATION INT. LTD.Henry SehayekTel: +44(020) 8451 2411henrysehayek@multi-corporation.com

ITALY

VM-GROUP Umberto VaccaroTel: +329 886 5425vaccaroumberto@virgilo.it

POLAND

Joanna GodlewskaTel: +48 606 128 170joannagodlewska@fennerdunlop.com

RUSSIA

THE KUSBASSSergey BolshakovTel: +790 390 75055sbol@yandex.ru

Oleg DemidovTel: +790 398 43114demidov@lnk.kuzbass.net

MOSCOWAlyona FletcherTel: +749 516 02442fletcher1@mail.ru

SLOVENIA

VM-GROUPIgor Likarigor.likar@vm-group.com

SPAIN

PORTUGAL

IMMSA Enrique VallinaTel: +34 916 345 7102madrid@immsa.netor oviedo@immsa.net

TURKEYMTM Mithat & Bahar DayiogluTel: +312 466 19 50m.dayioglu@mtmmakina.com.tror b.dayioglu@mtmmakina.com.tr

UKRAINE

AUTHORITY Roman RedkoTel:+380 6257 4 19 66

Alyona FletcherTel: +749 516 02442fletcher1@mail.ru

USA

THE MINE SUPPLY CO.Randy BaileyTel: +1 505 887 2888randybailey@theminesupplyco.com

R.J. TRICON Tom BiggioTel: +1 504 522 3891tom.biggio@rjtricon.com

CONVEYOR SERVICES Troy DolanTel: +1 724 459 5261tdolan@conveyorservices.com

XPRESS SERVICE Darryl & Rick HaynesTel: +1 606 248 6900dhaynes@xpress-service.net