Manufacturers of Heavy Weight Industrial Conveyor Belting Montgomery, Alabama USA

Transcription

1 FIELD MANUAL Manufacturers of Heavy Weight Industrial Conveyor Belting Montgomery, Alabama USA

2 PRC BELT LINES CONTENTS HyFlex...1 RMA Grade I...2 RMA Grade II X-TRA...3 Grade II BeltMaster...4 PRC Grade II...5 MOR Woodchip...6 Price Cleat/ Multi-Chevron...7 MSHA/Abrasion...8 MSHA/ Underground...9 MSHA/ Nitrile...10 MSHA/ Climatic F. High Heat F. Hot Asphalt F. Hot Material...14 Polar Bear F...15 Waste Treatment...16 Alumina...17 Price Flex...18 Price Steel...19 Splice Material...20 Splice Kits...21

3 H Y F L E X COMPOUND # 29 ABRASION RESISTANT Certain applications require a belt to stand very high abrasion and remain highly flexible over a wide temperature range. This compound was designed precisely for such applications. This belt has become widely accepted in handling ores, sand, powders and fines especially bauxite, gold and silver ores. Adhesions are especially high, while the abrasion resistant covers often outwear other belts by 25% or more over a wide range of temperatures and are often made with specially treated fabrics to stand acid washes common in ore separating and processing. Recommended for handling bauxite, gold and silver ores over a broad range of weather and temperature conditions. Choose any carcass fabric to carry the load. tailor-make your belt precisely for the intended application. will High Flexibility & Abrasion Resistant Belting For Today s Toughest Applications! 3000 lb. Tensile 630% Elongation 65 Duro/85 DIN All Synthetic Fabrics. Popular for handling ores! 1

4 COMPOUND: # 29 HYFLEX SBR (STYRENE BUTADIENE RUBBER) TENSILE ELONGATION MODULUS TEMP. DURO/ DIN SPECIFIC ( PSI ) ( % ) (300%) RATING HARDNESS ABRASION GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width / 35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

5 RMA GRADE I COMPOUND # 21 GOUGE RESISTANT This is the Premium Grade of belt in the conveyor market. It is made with the highest tensile compound and the strongest adhesions of any belt offered. These higher physicals are intended to produce a belt that is outstanding in resistance to cutting, gouging, and general abrasion. Like premium off-the-road earthmover tires, this compound imparts cut and tear resistance to the covers that is not yet duplicated by lower grade elastomers. Since the life of any conveyor belt is directly related to the abrasion resistance of the covers and the flexible adhesions of the carcass plies, this premium compound generally yields more life per dollar than lesser grades. Especially recommended for the most severe applications, such as heavy rock, slag, cullet, sharp stone, granite and other truly sharp and heavy materials. The slightly higher initial cost is more than offset by the added life of the belt lb. Tensile 580% Elongation 64 Duro/110 DIN All Synthetic Fabrics. Outstanding Performance Against Cutting, Gouging, & General Abrasion! Used in Granite, Iron Ore, Quarries, Bauxite, Slag, and Heavy Rock! 2

6 COMPOUND: # 21 RMA GRADE I SBR (STYRENE BUTADIENE RUBBER) TENSILE ELONGATION MODULUS TEMP. DURO/ DIN SPECIFIC ( PSI ) ( % ) (300%) RATING HARDNESS ABRASION GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/ 35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

7 RMA GRADE II X-TRA COMPOUND # lb. Tensile 640% Elongation 60 Duro/125 DIN All Synthetic Fabrics. HEAVY SERVICE Long the workhorse of the conveyor belt market, this grade of belt serves in more systems than any other grade. All synthetic fabrics are put together with 2400 lb. tensile rubber stocks to yield up to 85 lb. adhesions between carcass. The compound goes all the way through the belt to form a homogenous product that is difficult to get apart or to wear out. This belt has a reputation unmatched in the industry. RMA GRADE II X-TRA is used in a very broad spectrum of industry to handle everything from sand and gravel to fertilizer and lead ore. mixes this compound with enough antioxidants and anti-ozonants to make it last for years in sunlight and weather! Some of the world s largest belts have been made from this stock up to 18' in diameter and weight of 115,000 lbs. in one piece can be produced in our Montgomery Factory they don t come any bigger or last any longer! World s Most Popular Grade of Belt! Made to Width and Length, Price Belts Run True From the Start! 3

8 COMPOUND: # 22 RMA GRADE II X--TRA SBR (STYRENE BUTADIENE RUBBER) TENSILE ELONGATION MODULUS TEMP. DURO/ DIN SPECIFIC ( PSI ) ( % ) (300%) RATING HARDNESS ABRASION GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/ 35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

9 GRADE II BELTMASTER COMPOUND # 93 MEDIUM SERVICE One of the nicest things to happen in a belt plant in a long time! This conveyor belt will save some money and give incredibly long service. It is made from an all-the-way through compound especially designed for greater flexibility, tremendous adhesion, and superb weather resistance at a price you cannot afford to ignore. Used in all medium service conveyor applications from fines to hunks of clay, sand, gravel, fertilizer, and in general industry as a utility belt. Fabrics Are All Polyester All American Made! 2400 lb. Tensile 640% Elongation 60 Duro/125 DIN All Synthetic Fabrics. RMA GRD II Compound. This RMA GRADE II belt can be made from any carcass fabric, but the most popular fabric is polyester warp and filler. These fabrics are strong and flexible with good fastener holding ability. Like all Price belts, the BeltMaster line is tailor-made to width and length to run true from the very start... The BeltMaster Line... For the Man Who Knows Belt! 4

10 COMPOUND: # 93 GRADE II BELTMASTER SBR (STYRENE BUTADIENE RUBBER) TENSILE ELONGATION MODULUS TEMP. DURO/ DIN SPECIFIC ( PSI ) ( % ) (300%) RATING HARDNESS ABRASION GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) 2/220 3/330 4/440 Fabric Type Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% Elastic modulus (piw) 14,400 21,600 28,800 Recommended Fastener Plate BR10 Hinge R2 R2 R5 TROUGHABILITY (Minimum Belt Width) (in.) Idlers 2/220 3/330 4/ degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) 2/220 3/330 4/440 Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 2/220 3/330 4/ lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

11 PRC GRADE II COMPOUND # 95 GENERAL PURPOSE PRC GRADE II is compounded with the same high tensile strength elastomer as GRD II X-TRA and our BeltMaster belt lines. Specially constructed on a 100% polyester carcass (warp & weft) for superior fastener retention and load support, PRC GRADE II is designed to exceed the quality and still compete with the glut of unknown/ off-shore belting at an economical! Longer flex-life with exceptional physicals make PRC GRADE II the professional s choice for moderate service applications where is a factor! Stocked in all the most popular constructions, can also prep, punch, and lace on cut piece Traffic at slab roll pricing for same day service when you need it yesterday! Smooth or Textured Covers! Made to Width/Made in U.S.A! PRC GRADE II... GUARDING AMERICAN SHORES! 2400 lb. Tensile 640% Elongation 60 Duro/125 DIN All Synthetic Fabrics. RMA GRD II Compound. 5

12 COMPOUND: # 95 PRC GRADE II SBR (STYRENE BUTADIENE RUBBER) TENSILE ELONGATION MODULUS TEMP. DURO/ DIN SPECIFIC ( PSI ) ( % ) (300%) RATING HARDNESS ABRASION GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) 2/220 3/330 Fabric Type Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% Elastic modulus (piw) 10,500 17,500 Recommended Fastener Plate Hinge R2 R2 TROUGHABILITY (Minimum Belt Width) (in.) Idlers 2/220 3/ degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) 2/220 3/330 Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width / 35º Troughers) (in.) 2/220 3/ lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

13 MOR WOODCHIP COMPOUND # 24 MODERATE OIL RESISTANT This compound contains about three times as much Nitrile as other manufacturers use, to yield a general purpose oil resistant belt, widely used in the vegetable market. For handling pine chips, cracked corn, soybeans and other oily materials, this belt serves in a wide range of applications. Generally, this elastomer is put on a fairly light carcass of 2 or 3 plies of 75 or 110 lb. polyester, but can be supplied on any weight necessary to carry whatever load the system requires. Many industries use this product. We have supplied it in rough top patterns and in Price Cleat Top. Any belt can be made with this compound lb. Tensile 600% Elongation 62 Durometer All Synthetic Fabrics. 6

14 COMPOUND: # 24 MOR WOODCHIP SBR / NITRILE BLEND TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width / 35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

15 PRICE CLEAT // MULTI -- CHEVRON COMPOUNDS # CLEATED INCLINE This type of belt has become very popular in recent years because it can be made in slabs and slit to the desired width, preserving the entire pattern. Generally, this type of belt is available up to 60" wide in slab form with cut edges. But, if the quantity is sufficient, will tailor-make just about any construction. PRICE RUBBER makes this type of belt in the same fashion as all other belting any compound, any carcass, and nearly any width and length lb. Tensile Factory Stocked in GRD II & MOR. All Synthetic Fabrics. May be supplied in any compound and any carcass with slider bed or smooth rubber bottom. The cleats are a full 1/4" x 1/4", on 45 degree angle, every 6" down the belt with each row offset 3" from the next. This pattern is slittable to any width, with the pattern showing where to cut. The belt may be run in either direction, to carry a material up an incline, or to allow proper drainage if run in the opposite direction. 7

16 C O M P O U N D S PRICE CLEAT / MULTI - CHEVRON SBR / NITRILE BLEND TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

17 MSHA // ABRASION COMPOUND # 32 ABRASION RESISTANT A GRADE II MSHA compound especially designed for greater resistance to abrasion, weathering, and aging characteristics. Excellent flexibility even at low temperatures with outstanding performance against cuts and gouging while maintaining flame resistance. Available in ABOVE and BELOW ground compounds where maximum tons per hour is the name of the game! # 32 -A (ABOVE GROUND) ULTRA-VIOLET / FLAME / ABRASION RESISTANT 2100 lb. Tensile 525% Elongation 65 Durometer All Synthetic Fabrics. #28-53/11 Accepted # 32 -B (BELOW GROUND) HI-FLEXIBILITY / FLAME / ABRASION RESISTANT 8

18 COMPOUND: # 32 MSHA / ABRASION RESISTANT MSHA / SBR BLEND TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

19 MSHA // UNDERGROUND COMPOUND # 33 MINE SERVICE A special flame-out designation #28-53/9 makes this belt acceptable for underground coal mining service. The compound is a SBR recipe, with enough special materials added to cause the belt to be self-extinguishing when any flame is removed. It will not support combustion by itself. Coal mining is Big Business in America, where major operators keep a sharp eye on the price of oil and work constantly to automate their operations for greater production at lower cost lb. Tensile 540% Elongation 66 Durometer All Synthetic Fabrics. #28-53/9 Accepted Nothing moves coal like conveyor belt and, nothing moves more tonnage than PRICE RUBBER conveyor belt. In mines all over America, this product is moving mountains of coal everyday! Meets All Surface Conductivity Tests Defined by ASTM D257 and Required by OSHA. 9

20 COMPOUND: # 33 MSHA / UNDERGROUND MSHA / SBR BLEND TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width / 35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

21 MSHA // NITRILE COMPOUND # 35 COAL PREP Flame-Out! & GRAIN Static Conductive! A flame-out, oil resistant belt has become standard for many grain elevators and utilities in recent years, because both have oil associated with the handling of their product, and both are painfully aware of the danger of fire. This flame-out compound designated #28-58/10 contains far more Nitrile than most belts offered for this service. Utilities spray coal with fuel oil to hold down dust, while elevators handle corn, soybeans and other vegetable oil products. This MSHA designated product has served well in many utilities and grain elevators. It is offered in any combination of carcass fabrics, designed specifically for each application. Oil/Ozone Resistant! 2000 lb. Tensile 500% Elongation 65 Durometer All Synthetic Fabrics. #28-58/10 Accepted PRICE RUBBER has manufactured this type of belt on carcasses with strengths of up to 1500 pounds per inch of width. An explosion at an elevator can be disastrous, but putting out the resulting fire can be very difficult if ordinary belt is set on fire. This flame-out compound can save a ton! Designated #28-58/10 by the Mine Safety and Health Administration of the U.S. Department of Labor. 10

22 COMPOUND: # 35 MSHA / NITRILE - COAL PREP & GRAIN MSHA / NITRILE BLEND TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

23 MSHA // CLIMATIC COMPOUND # 36 WEATHER RESISTANT Arid Climate, High Altitude, Strong Sunlight & Ultra-Violet Rays will oxidize almost any elastomer and it won t take very long! Because of severe oxidizing elements in certain above ground conveyor systems, developed this SUPER MSHA compound. Antioxidant and antiozonant chemicals are added to this recipe, along with the required flame-out ingredients. Extensive hot oven aging tests indicate this compound will stand any climate in America even in Death Valley! It helps to run em in the shade, but if there is no shade, it will make little difference to this special belt cover stock. Available on any fabric carcass, any cover thickness, any width with cut edges lb. Tensile 450% Elongation 70 Durometer All Synthetic Fabrics. #28-53/8 Accepted Meets All Surface Conductivity Tests Defined by ASTM D257 and Required by OSHA. 11

24 COMPOUND: # 36 MSHA // CLIMACTIC MSHA / SBR BLEND TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

25 300ºº F.. HIGH HEAT COMPOUND # 23 HIGH TEMP/SBR A little extra antioxidant than the normal GRD II SBR belt stock will turn it into a heat resistant compound that will take temperatures as high as 300º F. This is a low-cost compound that will improve a product used in moderate temperatures or difficult weather conditions where normal compounds give short life lb. Tensile 580% Elongation 63 Durometer All Synthetic Fabrics. This Belt Does the Job... Even in the Mojave Desert! 12

26 COMPOUND: # º F. HIGH HEAT SBR (SPECIALLY BLENDED) TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /300º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 BR10 BR14 * VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width / 35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

27 350ºº F.. HOT ASPHALT COMPOUND # 61 NITRILE Used on systems handling hot and oily material. This is the only heat and oil compound that can stand the strain of high temperature and petroleum saturation in hot asphalt service. The recipe is 100% Nitrile polymer, with no other type elastomer. It will stand temperatures of up to 350º F., and it will take all the petroleum oil you can put on it. Truly a quality product for this severe service, this Premium Compound is welded to the all synthetic carcass with adhesions far above anything else on the market. The finished conveyor belt is Nitrile, all the way through lb. Tensile 500% Elongation 62 Durometer All Synthetic Fabrics F. Super Oil Resistant! Anywhere either oil or heat, or any combination of the two, are a problem this belt is worth its weight in Gold! 13

28 COMPOUND: # º F. HOT ASPHALT NITRILE TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /350º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width / 35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

29 400 ºº F.. HOT MATERIAL COMPOUND # 16 CHLOROBUTYL Hot Material Belts are offered in several different compounds, each with a claim of doing something extraordinary. We too have made various belts that should have done wondrous things, but always, we have returned to this all-chlorobutyl compound to handle temperatures not manageable by other elastomers. Special fabric treatments are necessary to gain adequate adhesions, but it is well worth the trouble. This belt is made in any carcass weight up to 72" wide, with cut and cemented edges. It is suitable for both conveyors and elevators. Chlorobutyl will handle temperatures that approach the melting point of the fabrics. Slow to oxidize, this is the finest over-all compound we know for these severe applications. There is no better belt in America for handling hot foundry castings, hot cement manufacturing, or hot sand drying conveyor systems lb. Tensile 650% Elongation 65 Durometer Black All Synthetic Fabrics. Clinker Nitrates Sinter Kiln Sand Phosphates Slag High-Temperature Resistant Belting For Today s Modern Foundries & Cement Plants! 14

30 COMPOUND: # ºº F.. HOT MATERIAL CHLOROBUTYL TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /400º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

31 POLAR BEAR -- 80ºº F.. COMPOUND # 31 LOW TEMPERATURE - 80º F. Belting for use in the far north must be specially compounded to provide flexibility at temperatures well below zero. This compound will serve at - 80º F. No other belt will remain usable at such low temperatures. Adhesion is extremely high for any belt, and certainly is outstanding for this severe service. Build it the way you need it it will take more cold than anybody can stand! 2590 lb. Tensile 560% Elongation 63 Durometer All Synthetic Fabrics. Sub-Zero Performance! Maximum Cold Weather Performance! 15

32 COMPOUND: # 31 POLAR BEAR - 80º F. SBR (SPECIALLY BLENDED) TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

33 WASTE TREATMENT COMPOUND # 37 MUNICIPAL DISPOSAL Waste processing, recovery, recycling, and just plain getting rid of it have become big, Big Business in America. This belt is used where sewerage, animal waste, oils, fats, tars and sludge are moved in volume. There is no application with a broader range of products to convey. Every major municipality and every large industrial plant has disposal problems. A special rubber compound is required to handle the wide variety of trash Americans discard everyday and it is getting bigger. This belt does the job! 2200 lb. Tensile 510% Elongation 62 Durometer All Synthetic Fabrics. This Compound Does a Good Job in a Terrible Business... a Belt That Lasts! 16

34 COMPOUND: # 37 WASTE TREATMENT SBR (SPECIALLY BLENDED) TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

35 ALUMINA COMPOUND # 38 DESICCATION RESISTANT Precision engineered to handle Alumina, Bauxite, Dried Kiln Clays, Kaolin or other SUPER DRY materials that will extract moisture from any source it contacts. This compound is specifically designed to resist the drying action of these type materials. The covers do not become hard, cracked or brittle, but remain flexible after prolonged exposure to dry materials. This compound is field tested to greatly extend the service life of a belt in comparison to general purpose belts running in the same conditions. The success of this compound has been proven worldwide over other competitor brands! 3000 lb. Tensile 550% Elongation 65 Durometer All Synthetic Fabrics. This Belt Does the Job, Period! 17

36 COMPOUND: # 38 ALUMINA ALUMINA / SBR (SPECIALLY BLENDED) TENSILE ELONGATION MODULUS TEMP. DURO/ SPECIFIC ( PSI ) ( % ) ( 300% ) RATING HARDNESS GRAVITY /220º CARCASS / 100% POLYESTER ( PLAIN WEAVE, WARP & FILL) Fabric Type Poly Poly Poly Poly Poly Poly Poly Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Avg. Permanent Elongation (%) 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% 1.5% Elastic modulus (piw) 16,000 24,000 26,800 32,000 40,200 53,600 67,000 Recommended Fastener Plate BR10 BR10 * BR10 BR14 VULC. Hinge R2 R5 R5 R5 R5 1 2 R6 RAR8 TROUGHABILITY (Minimum Belt Width) (in.) *VULCANIZE 20 degree idlers degree idlers degree idlers MINIMUM PULLEY DIAMETERS (in.) Over 80% Tension % to 80% Tension LOAD SUPPORT *(Maximum Belt Width/35º Troughers) (in.) 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft Over 120 lbs./cu.ft

37 PRICE FLEX COMPOUNDS # Flex I & II is engineered and designed to provide high tear and impact resistance in a flexible/reduced weight carcass system. This system combines great strength, low elongation and proper load support, while providing good troughability that results in improved tracking capabilities GRD I GRD II MOR COAL/ GRAIN Straight Warp polyester yarns provide high strength and low stretch Direction of Travel Binder Warp Locks the carcass together Fill Yarns provide strength, stability under load, and excellent rip and impact resistance Flex Straight Warp carcasses provide SUPERIOR impact and tear resistance due to a unique three component multi-warp construction utilizing high-strength yarns locked together with a special binder system. Flex s impact resistance can be as high as three times greater than standard plied belting while tear resistance is improved up to five times in some constructions. These improvements result in a belt that has exceptional life expectancy in highly abusive applications. Top Cover: Any Thickness from 3/32'' to 3/4'' 21 BALANCED COVERS STRAIGHT WARP SINGLE/DUAL UNIT Top Cover: Any Thickness from 3/32'' to 3/4'' Carcass: Single Unit Bottom Cover: Any thickness from 3/32'' to 3/8'' Price Flex I Carcass: Dual Unit Skim: Bottom Cover: Any thickness from 3/32'' to 3/8'' Price Flex II Factory Stocks RMA GRD I Single Unit 440 1/4'' X 1/8'' in 36'', 42'', 48'', 60'' & 72'' wide rolls for immediate delivery and service! 18

38 C O M P O PRICE FLEX U N SBR (STYRENE BUTADIENE RUBBER) D TENSILE ELONGATION MODULUS TEMP. DURO/ DIN SPECIFIC S ( PSI ) ( % ) (300%) RATING HARDNESS ABRASION GRAVITY /220º /220º /220º /220º CARCASS: STRAIGHT WARP (POLY, POLY, NYLON) 1/330 1/440 2/660 2/800 Fabric Type PPN PPN PPN PPN Vulc. & Fastener Rating (piw) Carcass Gauge (in.) Carcass Weight (lbs/sq.ft.) Approx 1/32 cover wt (lbs/sq.ft.) Max. Permanent Elongation(%) Elastic modulus (piw) TROUGHABILITY (Min. Belt Width) '' Idlers 20 degree idlers 35 degree idlers 45 degree idlers MINIMUM PULLEY DIAMETERS '' Over 80% Tension 60% to 80% Tension LOAD SUPPORT *(Max. Belt Width / 35º Troughers) '' 0-40 lbs./cu.ft lbs./cu.ft lbs./cu.ft. Over 120 lbs./cu.ft % 1.7% 1.7% 1.7% 26,500 28,000 60,000 66,500 1/330 1/440 2/660 2/ /330 1/440 2/660 2/ /330 1/440 2/660 2/ It is recommended that Single Unit Straight Warp belting be manufactured with the pulley cover gauge at least one half of the carry cover gauge. This provides balance between the pulley covers, carcass and carry covers. EXAMPLE: 3/16'' X 3/32'', 1/4'' X 1/8'', 5/16'' X 7/32'', ETC. P R I C E F L E X I S I N G L E U N I T P R I C E F L E X I I D U A L U N I T

39 P R I C E S T E E L COMPOUNDS # SERIES GRD I GRD II HYFLEX MINE SERVICE Steel Belting is ideally suited for high-tension/low stretch applications such as overland conveyors, ship loading, and slope belts. Manufactured with specially coated cables for superior rubber to metal bonding, steel cord provides unsurpassed durability under heavy/high-speed runs. Steel offers all the standard features of but with the added benefit of a cross rigid/transverse reinforcer, forming an anti-tearing IRON-RING structure which provides increased rip and penetration resistance while extending belt life. Top Cover Core Rubber Steel Cord A DVANTAGES... HIGH-TENSION/LOW STRETCH! PRE-TENSIONED/ STRAIGHT TRACKING! MINIMUM LOAD DISTURBANCE! MAXIMUM IMPACT RESISTANCE! EXCELLENT SPLICE EFFICIENCY! Bottom Cover Steel Cord Transverse Reinforcement 19 Top Cover Core Rubber Bottom Cover *OVAL RACE PACKAGE

40 PRICE STEEL SPECIFICATIONS Cord Cord Operating Modulus Min. Belt Weight Min. Diameter Pitch Tension PIW Belt Cover Standard Pulley Diameter (inches) Thickness Covers Type of % of Rated Belt Tension (mm) (mm) (Lbs/in) (kn/m) (000's) (inches) (mm) (Lbs.In/Ft) (kg/cm/m) Spilce ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step ST / Step Cord Cord Operating Modulus Min. Belt Weight Min. Diameter Pitch Tension PIW Belt Cover Standard Pulley Diameter (inches) Thickness Covers Type of % of Rated Belt Tension (mm) (mm) (Lbs/in) (kn/m) (000's) (inches) (mm) (Lbs.In/Ft) (kg/cm/m) Spilce GX / Step GX / Step GX / Step GX / Step GX / Step GX / Step GX / Step GX / Step GX / Step GX / Step GX / Step Other ratings and constructions are available upon request including 6300, 7000, and 7500 series. 96'' maximum width and constructed from 300'-4500' per roll in either circular reinforced steel cradles or optional oval race packaging for longer lengths.

41 SPLICE MATERIAL Universal Splice Materials are specially designed and formulated to yield maximum bond and adhesion to all compounds and belt carcasses, including NR, SBR, BR, IR, CIIR, NBR and blend s of polymers such as NR/SBR. Factory constructed from the same rubber stocks as our belt lines, Splice Kits are manufactured and stocked under strict laboratory control, dated, and kept under cool room temperatures to ensure near or greater adhesions than original belt produced from our factories. A A CE DVANTAGES... HIGH INITIAL BONDING STRENGTH! INCREASED SHELF LIFE FOR ALL SPLICING MATERIALS! INCREASED WORKING TACT OFFERS ADDITIONAL SAFETY DURING ASSEMBLY! EASIER & FASTER APPLICATION SAVES VALUABLE TIME & LABOR COSTS! COMMON COMMERCIAL ASTM ELASTOMER DESIGNATIONS: NR-Natural Rubber, SBR-Styrene-Butadiene Rubber, BR-Polybutadiene Rubber, IR-Synthetic Polyisoprene, CIIR-Chlorobutyl Rubber, NBR-Nitrile Elastomers *For complete cross-reference and compatibility, refer to backside chart, or contact Technical Support for Job Matched Performance:

42 SPLICE KITS Splice Kits are individually prepared at time of order and Factory Built to ensure both freshness and expediency with your order. Appropriate cover stocks and gums are matched along with correct cements in our Universal series: Universal Vulcanizing Cement (UVC) SBR Based & Universal Vulcanizing Cement Special (UVC-S ) for compounds containing NBR. Each kit also contains the appropriate solvent & includes a special fabric primer which is designed to re-activate former textile coats and dips when the carcass is over buffed from stripping or old from age. SPLICE MATERIAL SELECTION CHART Main Belt Lines Compounds Cover/Tie Gum Cement Solvent HyFlex # 29 SBR UVC Toluol RMA GRD I # 21 SBR UVC Toluol RMA GRD II # 22 SBR UVC Toluol GRD II BeltMaster # 93 SBR UVC Toluol PRC GRD II # 95 SBR UVC Toluol MOR Woodchip # 24 SBR/NBR UVC-S Xylene MSHA/Abrasion # 32 SBR Based UVC Toluol MSHA/Underground # 33 SBR Based UVC Toluol MSHA/Nitrile # 35 SBR/NBR UVC-S Xylene MSHA/Climatic # 36 SBR Based UVC Toluol 300º F. Hi-Temp. # 23 SBR Blend UVC Toluol 350º F. Hot Asphalt # 61 NBR UVC-S Xylene 400º F. Hot Material # 16 CIIR/SBR UVC Toluol Polar Bear 80º F. # 31 SBR Blend UVC Toluol Waste Treatment # 37 SBR Blend UVC Toluol Alumina # 38 SBR Blend UVC Toluol Universal Splice Kits; cements, calendered cover stocks, primers, solvents, & tie gums, have a dated shelf-life of at least six months. However, if refrigerated (preferably < 50 deg. F. ), then useful life can be extended up to twelve months. Store these materials in a cool, dark place and always out of direct sunlight/ozone, high-heat, humidity, and other forms of radiant energy sources. 21

43 Installation / Operation Trouble Shooting CONTENTS Storage Handling Installation Training Training Sequence Loading Load Support Transition Pulley Diameter Squaring Vulcanizing Step Lengths Cure Rates Trouble Shooting Calculations Field Notes Warranty/ CD IBC

44 STORAGE New conveyor belt should be stored upright in the factory package until used, preferably on a dry surface. Block it safely so it can t accidentally roll or tip over. Do not lay on its side or lean against a wall! Keep belting out of direct sunlight or where ozone is present as it will deteriorate exposed rubber over time. Belts should not be stored in excessively wet places or in areas where oils, acids, and other chemicals are present. Motor-control rooms, welding shops, and other places where ozone is generated should like-wise be avoided. Excessive temperature variations should also be avoided and can have an adverse effect on a belt over time. Low temperatures or prolonged storage can harden or stiffen the compounds. If installed in this stiffened state, the belt may not train well until it adjusts or warms up to the system. During longer periods of storage, heavier rolls weighing more than 10,000 lbs. should be placed in an A-Frame or if left standing, rotated a quarter turn every three months to avoid flat spots from its own weight. Do Not Lay On End! 22

45 HANDLING Factory packaging is designed to protect your conveyor belt during normal shipping and handling. When your belt arrives, be careful unloading it. Don t drop or handle it roughly as this could break the packaging and cause the belt to telescope. Once scoped it is nearly impossible to re-roll. Do not roll the slab. If there is no other way to move the belt, then roll it in the direction the belt is wound. Rolling in the opposite direction can cause it to loosen and telescope. The optimum way to move a belt is to slip a sturdy hoisting bar through the center core. Then, lift the belt with a spreader bar with chains or strong cables. Protect the belt edges against rubbing by using a spreader bar that is wide enough or with wood planks/old belting next to chains or cables. Spreader Bar Core Bar 23

46 INSTALLATION Mount roll of belting on a suitable core bar for unrolling and threading on to the conveyor system. Conveyor belting is normally rolled at the factory with the carrying side out. Consequently, when mounting the roll the belt must lead off the top of the roll if it is being pulled onto the troughing idlers but off the bottom of the roll if it is being pulled on to the return side. In certain cases, where head room does not permit maneuvering of a roll, the belt may have to be pulled off the roll and reefed. Extreme care should be exercised to see that the loops have large bends to avoid kinking or undue strain on the belt, and no weight should ever be placed on the belt when in this position or the belt can be laid on a turn table with a vertical spindle. The belt will make a 90º twist as it is spun off. In this procedure, care must be exercised to avoid excessive abrasion to the belt edges. No Weight To Be Placed On Top Keep Bends Large To Prevent Breaking Carcass 24

47 T R A I N I N G Training of a conveyor belt is the process of adjusting idlers, pulleys, and loading conditions in a manner which will correct any tendency of the belt to run other than centrally. Once installed on the conveyor, problems of design, manufacture, erection, and other abnormalities become apparent. All too often these conditions are considered belt problems. IT IS IMPORTANT TO REALIZE THAT BELT TRACKING IS A SYSTEM PROBLEM AND SHOULD BE APPROACHED FROM A SYSTEMS POINT OF VIEW! If designed, manufactured, slit and cut properly, the belt will go where directed by the conveyor system as designed and built. The conveyor belt serves as an indicator and should be so regarded. Rarely is a belt at fault and is more likely reacting to a structural defect or maladjustment to the system. Price Rubber alleviates this condition since all products are made to width, not slit from a slab where camber can occur. When all portions of a belt run off through a part of the conveyor length, the cause is probably in the alignment or leveling of the conveyor structure, idlers, or pulleys in that area. If one or more portions of the belt run off at all points along the conveyor, the cause is more likely the belt itself, in the splice or in the loading of the belt. When loaded off-center, the center of gravity of the load tends to find the center of the troughing idlers, thus leading the belt off its lightly loaded edge. Effects of Off-Center Loading 25

48 T R A I N I N G S E Q U E N C E The basic primary rule when tracking a conveyor belt is simple: THE BELT MOVES TOWARD THAT END OF THE ROLL/IDLER IT CONTACTS FIRST! Initial installation of conveyor equipment should ensure proper alignment of all pulleys, troughing and return idlers, i.e., and should be placed at right angles to the direction of belt travel, leveled and centered on a straight line. The best procedure in starting the training sequence is to start with the return run and work toward the tail pulley: 1. 1 Move from idler to idler in direction of belt travel Shift only one idler at a time. Shifting subsequent idlers may cause over correction. 3.) 3 Make slight adjustments rather than extreme ones. 4.) 4 Wait for at least 2 or 3 revolutions before making further adjustments. 5.) 5 Try never to adjust pulleys for belt training. 6.) 6 Apply the Handle Bar method to each of these indicators. This will help ensure early centering of the belt on the tail pulley so that it can be centrally loaded. If the empty belt troughs readily, not erratic, training should be complete. Should the belt tend toward stiffness and erratic running, place some load onto the belt. The added weight will help control the belt and aid during Break-In. Transverse Stiffness Correct Troughing 26

49 L O A D I N G Receiving material off center will cause the belt to move sideways after loading as the center of the load seeks the lowest point in the troughing idlers. This can be corrected by proper chute arrangement provided, of course, that the belt is centered as it enters the loading point. The loading point of any conveyor is nearly always the critical point, the life determining point of the belt. Here the conveyor receives its major abrasion, and practically all of its impact. The ideal condition is to have the material pass from chute to belt at the same speed and direction of travel as the belt with a minimum amount of impact. The width of the receiving end of the loading chute should be great enough to accept material lying on the extreme edge of the preceding belt or feeder, and its position determined by the trajectory of the material coming into it. At no place should the chute be less than twice the size of the largest lumps, if fines are present, and 3-1/2 times the size of lumps, if uniform. The discharge width of the chute thus determined should not exceed about 2/3 of the receiving belts width. Simple Conveyor Loading Points 27

50 L O A D I N G The slope of the chute is determined by the nature of the material, its entering velocity and length of the chute. This value varies with each particular installation, but about 35 degrees has been found satisfactory for most dry industrial materials such as rock and coal. An attempt to approach the above ideal condition should be made continually by adjusting the chute arrangement. Optimum loading and transferring through chutes still requires considerable experimental adjustment in the field. Skirt boards should be used to further center and settle the load as it leaves the loading point. The steel structure of the chute and skirts never should be placed closer to the surface of the belt than 1''. This distance to be made increasing in the direction of belt travel to free any material trapped between the belt surface and the skirt. Skirt boards are usually 4 or 5 times the belt width in length, but may vary considerably due to belt speed, type of material and lump size. 1'' Minimum Increasing in direction of travel Usually 4 to 5 x Belt Width A B C Backup Plate Skirtboard rubber held in compression Backup Plate Skirtboard rubber held in compression Skirtboard rubber Variable Variable Variable Idler Idler Idler Angle Angle Angle Sample Skirtboard Arrangements 28 Backup Plate

51 L O A D S U P P O RT Most conveyor belts carrying free flowing materials operate over troughed idlers. The troughing angle of these idlers will usually vary from 20 to 45 degrees... and beyond. The trough-angle affects the belt by creating a line along which the belt is constantly flexed. The greater the trough angle, the greater the flexing action. When the belt is fully loaded, the portion of the load (X) directly over the idler junction gap forces the belt to flex to a shorter radius. The heavier the load, the smaller the radius through which the belt must flex. Further, at higher troughing angles (like 45 degrees), gravitational force is exerted on the portion of the belt in contact with the wing idler. All these forces are trying to pull that belt down into that idler junction gap. Consequently, consideration must be given to designing the belt with sufficient transverse rigidity and flex life so that for a given idler angle and load weight, premature belt failure will not occur. This is done by designing the belt with sufficient transverse stiffness to bridge the idler junction gap with a satisfactory radius. This specification is detailed in the load support section of the Belt Tables. The load support number refers to the maximum width possible for a given belt construction at a given troughing angle carrying material of a specific density. Single-plied belt constructions do well on idler sets up to and including 35 degrees. Plied constructions are generally thicker for a given belt tension rating, and therefore, appear to perform better on 45 degree troughing idler sets. 20º 45º Proper Bridging of Idler Junction Differential in Radius Between Idlers Proper Bridging of Idler Junction 29

52 T R A N S I T I O N Transition distance is defined as the distance from the center line of the first fully troughed idler system to the center line of either the head or tail pulley. The geometry of the situation, causes the edge of the belt to be stretched since it is following the hypotenuse of a right triangle. The distance from the pulley to the top of the wing roll is greater than the distance from the pulley to the center roll of the troughing set. If the transition distance is too short, the edge of the belt can be overstretched. This will adversely affect the load support and belt life. A good rule of thumb regarding transition distance is: degree troughing systems - 3 times belt width. 35 degree troughing systems - 4 times belt width. 45 degree troughing systems - 5 times belt width. This differential in distance creates higher tensions in the edge of the belt than the center of the belt, which can create belt problems. The most common of these problems are: If transition is too short at the head pulley: Idler junction gap failure. Splice failure (from the outside in). Belt folding up in the center and folding over on itself. If transition is too short at the tail pulley: Splice failure (from the center out). Premature wear or failure in the center of the belt. 30

53 T R A N S I T I O N 45º 35º 20º If a particular conveyor system has shorter transition distances than those above, there are modifications to the system that can help reduce the stress on the belt: A B Elevate the terminal pulley in the system relative to its height verses the center roll of the troughing idlers in the system. Remove first high angle idler in the transition area and use a variable angle troughing idler, adjust it to support the belt without added stress. 31

54 P U L L E Y D I A M E T E R The smallest pulley diameter the belt will encounter in the conveyor system is a primary consideration in selecting the proper conveyor belt. When a belt travels around a pulley, the outer plies of the carcass traverse a greater distance than the inner plies. It is important that as the belt wraps around that pulley, under tension, the stress in the belt is below the fatigue limit of the bond between the belt components. Over stressing the belt, particularly the bond between the individual plies and the skim, can result in ply separation and premature belt failure... especially, at the belt splices. In some applications, due to system limitations, smaller than recommended pulleys may be used. This will affect the service life of the belt and will result in more frequent splice replacements. A given belt construction has a characteristic flexibility in the lengthwise direction. In most applications where a mechanical fastener is used to splice the belt, the minimum recommended pulley diameter for the fastener will be the limiting factor. This by virtue of the fact that rubber and fabric is more flexible than metal. Also, it should be noted that if a conveyor system utilizes a Winged or Veined type terminal pulley, that pulley should be 25% greater in diameter than the minimum pulley diameter normally recommended. 32

55 S Q U A R I N G Accurate squaring of the belt ends prior to lacing is essential to correct belt tracking and helps distribute stress evenly throughout the joint. It is important It is important to note to that note belt that ends belt are ends not are necessarily not necessarily square when square they when are they shipped. are shipped. Further, the Further, width-wise the width-wise fabric wales fabric are wales not necessarily are not necessarily square to square the belt s to the longitudinal belt s longitudinal axis. These axis. cannot These be cannot used as be guides used to as cut guides theto cut belt the ends. belt ends. TO PROPERLY SQUARE THE BELT ENDS, USE THE CENTER LINE METHOD! To establish the belt center line, start near the belt end as shown. Measure the belt width at five points approximately 10 apart. Divide each measurement in two and mark the center points. Using these five center points draw the resultant average center line. Next, using a carpenter square or T square, draw a cut line across the width of the belt near the belt end as shown. It is also a good idea to mark several right angle reference lines across the belt surface for use as guidelines later on. Using the cut line as the guide, cut off the end of the belt with a razor knife. Make sure that the cut is clean and straight. This operation should then be repeated on the other end of the belt. *Keep in mind that the final belt length may need to include an allowance for such things as diagonal splice, skive taper length, skive overlap, fastener extension, etc.... depending upon what kind of splice is being performed. BELT CENTERLINE. MARKING OF CUT-LINE AND OTHER RIGHT ANGLE GUIDE LINES. 33

56 V U L C A N I Z I N G TEN BEST PRACTICES On a properly engineered, well maintained conveyor system, a vulcanized splice performed correctly should last for many years and in some cases last the life of the belt. Utilizing and understanding these TEN BEST PRACTICES in conveyor belt splicing is the best way to assure the success and performance of your splice. 1.) 1 PROCESS CONTROL OF VULCANIZING TEMPERATURE, TIME, AND PRESSURE IS CRITICAL. Thermocouples provide precise temperature monitoring at the platen-belt interface. Thermostats on many vulcanizers do not indicate the actual temperature. Without precise monitoring, the temperature can fluctuate drastically, resulting in a splice that is either over or under cured. Either condition will limit the life of the splice. Top Splicers will use such thermocouples to monitor and gather cure temperature data. A record of this data can then be supplied to to assure that the curing process was performed properly. 2.) 2 USE PROPER KNIVES AND SKIVING TECNIQUES TO AVOID NICKING OF FABRIC PLIES. Nicking the adjacent fabric plies with a knife effectively reduces the tension rating of the belt carcass because the tension members (warp cords) are disabled if they are cut or nicked. Use quality tools such as single-ply knives designed specially for this procedure. 3.) 3 PERFORM MINIMAL BUFFING OF THE EXPOSED FABRIC PLIES. The fabric plies of all PRC belts are coated with RFL (resorcinol-formaldehyde-latex) or other special coatings to enhance the adhesion of the rubber to the fabric. These dip coats should not be buffed off when preparing the belt splice or reduced ply and cover adhesion will result. If residual rubber must be buffed off after stripping down the step, it must be done carefully so that 34

57 V U L C A N I Z I N G 4 stripping down the step, it must be done carefully so that the buffer the wheel buffer does wheel not actually does not touch actually the touch fabric. the Severe fabric. overbuffing Severe overbuffing reduce belt will strength reduce belt and strength integrity and by integrity damaging by both damaging the warp both and the will warp fill cords. and fill Buffer cords. wheel Buffer should wheel not should exceed not 2000 exceed RPM RPM. ALLOW CEMENTS TO DRY COMPLETELY BEFORE ASSEMBLING AND CURING THE SPLICE. When a belt splice is assembled and cured before the cement has had sufficient time to dry, the heat from the vulcanizer will cause the solvents and carriers in the cement to vaporize and form bubbles. If the surface area of these ply or cover blows is large enough, the strength of the splice is severely limited. Ply separations can also occur when cements and solvents are not allowed to come up to room temperature after removal from cold storage because of water condensation occurs on cold surfaces. Additionally, try not to accelerate the drying process by using heat guns or hair dryers that can cause a skin to form on the surface of still wet cements. Space heaters can be used to accelerate the drying time provided safety is not compromised in any way. 5.) 5 AVOID OVERPRODDING THE FABRIC WHEN LIFTING THE PLIES. Use the right tools and methods to assure that the fabric plies are not damaged when they are lifted. Prodding tools should have smooth, rounded corners. Do not use screwdrivers! 6.) 6 USE SPECIFIED STEP AND FINGER LENGTHS. When step lengths are shortened by more than an inch or two to accommodate vulcanizers that are not large enough for the job, splice strength and integrity is severely reduced. It is recommended to cure the splice in one heat, but if the vulcanizer is too short to cure the splice then multiple heats can be used as long as the fill-in strips are completely cured in a single heat. See pages for splice dimensions/recommended cure rates or contact Technical Support for further information & guidelines:

58 V U L C A N I Z I N G WORK CLEAN TO HELP ASSURE A CLEAN ASSEMBLY. Experience has shown that almost anything can end up inside a vulcanized splice from sand, rocks, trash, even work gloves left on the inside of failed splices. For these reasons, the splicing work area must be clean and protected. Tents, awnings, tarps, or temporary plywood walls and ceilings should be used depending on the particular circumstances or where conditions allow. These added measures will help avoid contamination in the splice. NEVER USE CEMENTS OR TIE GUMS THAT ARE OUT OF DATE. NEVER USE CEMENTS OR TIE GUMS THAT ARE OUT OF DATE. Universal Splice Materials are manufactured to the highest standards. Part of this quality control comes from our custom mixing division,. There, materials are produced and recorded by date, and then refrigerated to ensure maximum freshness and longevity. Splice materials should never be stored in sunlight, hot-humid conditions or left in a prolonged state at room temperature. When unused materials reach life limits, dispose of properly in accordance with federal, state, and local ordinances. USE CORRECTLY SPECIFIED GUMS & CEMENTS. For best adhesions and splice longevity, conveyor belts should be spliced with our Universal Splice Materials. The same compounds and stocks used in the production of our belt lines are supplied to our customers to assure complete compatibility and highest performance. Even with our materials, care must be observed to ensure that the correct gums and cements are used. For complete cross reference/splice recommendation, please refer to page 21, or call Technical Support: ALIGN THE SPLICE SQUARELY AND PROPERLY. Splices that are not aligned cause many problems! Tracking and training problems can frequently be traced back to splices that are not square. Additionally, splices that are out of square do not distribute the tension load evenly across the splice, which can cause premature splice and belt failure. 36

59 S T E P L E N G T H S PLIED BELTING VULCANIZED SPLICE DIMENSIONS Step Fill-In Overall Splice ''Outer'' Belt No. of Length Length Length (in) Ply Joint Style Plies (Inches) (Inches) w/o bias angle Type Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt Butt When the TEN BEST PRACTICES in conveyor belt splicing previously referenced are incorporated into your S.O.P. and the system is properly engineered and well-maintained, a dependable, long splice life can be achieved. 37

60 CURE RATES Because most conveyor belt splicing is done on the job, portable, electrically-heated, vulcanizers are used. Curing time depends on belt thickness, rubber compound, and type of vulcanizer being used. The following chart of curing times can be used for either splice or repair work: CURING TIME FOR CONVEYOR BELTING GRADE I & II NITRILE OR NEOPRENE BUTYL (EPDM) (IN MINUTES AT 287 deg. f) (IN MINUTES AT 287 deg. f) (IN MINUTES AT 287 deg. f) Thickness of Belt or Repair Depth 1 Heated Platen 2 Heated Platens 1 Heated Platen 2 Heated Platens 2 Heated Platens 3/16'' and less /4'' /16'' /8'' /16'' Use 2-27 Use /2'' platen 28 platen /16'' press 29 press /8'' above 30 above /16'' 5/16'' 31 5/16'' /4'' Over 314 : Add 2 minutes for each 1/16 of additional thickness. *This curing schedule is intended for portable vulcanizers under average field conditions. For Belt Repair Shops having permanent repair presses in heated buildings, the time can be reduced 5 minutes from the schedule shown for Natural or SBR. Generally, vulcanizers are heated to 287 degrees F. After vulcanizer is clamped on the belt, platen temperature will drop. Let it return to 287 degrees before initiating recommended cure cycle. The curing temperature (287 F.) must be maintained throughout time of vulcanization. If it drops, allow more curing time; if it rises, a shorter time will do: CURING TIME FOR BELT JOINT SBR/NATURAL RUBBER OILPROOF Length of Heat - Minutes Thickness of Belt Vulcanizer with 2 Heated Platens Vulcanizer with 1 Heated Platen Vulcanizer with 2 Heated Platens Vulcanizer with 1 Heated Platen 3/16'' and under /4'' /16'' /8'' /16'' /2'' /16'' /8'' /16'' /4''

61 CURE RATES UNDERCURING / OVERCURING Undercured rubber is soft and lacks resilience. To test: Press end of prodding tool into rubber. If indentation remains, rubber is probably undercured and additional time in vulcanizer is needed. Overcuring, up to a degree, is indicated by too much hardness as compared with rest of belt rubber. Extreme overcuring can cause softening (known as reversion) which becomes worse if further curing is attempted. OVERLAPPING HEATS When vulcanizer platens will not cover entire splice, two or more heats or cooks are necessary. Each heat should overlap proceeding one about 1-1/2. A common practice is to cure top cover fill-in first, then proceed in overlapping steps toward bottom cover fill-in. COOLING SPLICE Rubber compounds loose tensile strength at temperatures used during vulcanizing. Therefore, allow belt splice to cool to normal air temperature before maximum belt tension is applied. This is important when operating tensions are 80 to 100 percent of maximum permissible tensions. BLOW-UPS / BLISTERS A blow-up or blister that appears when platens are removed is caused by moisture in the belt or by trapped air in new material. Moisture may be water that was in the belt carcass, or in the solvents being used in cleaning off skimcoat rubber. To prevent blow-ups, allow vulcanizer platens to cool below steam temperature (212 degrees at sea level) before releasing platen pressure. If a blow-up or blister does occur, repair work must be done in affected area. Simply reapplying vulcanizing heat and pressure will not remedy the condition as cement and tie gum already have been fully cooked and further curing will not cause them to adhere. 39

62 TROUBLE SHOOTING PROBLEM CAUSE: in order of probable occurrence. Conveyor runs to one side at given point on structure Particular section of belt runs to one side at all points on conveyor. 6 7 Belt runs to one side for long distance or entire length of conveyor Belt runs off at tail pulley Belt runs off at head pulley Belt slip Belt slip on starting Excessive belt stretch. Grooving, gouging or stripping of top cover Excessive top cover wear, uniform around belt Severe pulley cover wear Longitudinal grooving or cracking of bottom cover Covers harden or crack. Cover swells in spots or streaks. Belt breaks at or behind fasteners; fasteners pull out Vulcanized splice separation Excessive edge wear, broken edges Transverse breaks at belt edge. Short breaks in carcass parallel to belt edge, star breaks in carcass. Ply separation. Carcass fatigue at idler junction. Cover blisters or sand blisters. Belt cupping-new belt. Belt cupping-old belt (was OK when new)

63 TROUBLE SHOOTING 11. Idlers or pulleys out-of-square with center line of belt: readjust idlers in affected area. 22. Conveyor frame or structure crooked: straighten in affected area. 3. Idler stands not centered on belt: readjust idlers in affected area. 4. Sticking idlers: free idlers and improve maintenance and lubrication. 5. Buildup of material on idlers: remove accumulation; improve maintenance, install scraper or other cleaning devices. 6. Belt not joined squarely: remove affected splice and resplice. 7. Bowed belt: for new belt this condition should disappear during break-in; in rare instances belt must be straightened or replaced; check storage and handling of belt rolls. 8. Off-center loading or poor loading: adjust chute to place load on center of belt; discharge material in direction of belt travel at or near belt speed. 9. Slippage on drive pulley: increase tension thru screw take up or add counterweight; lag drive pulley; increase arc of contact. 10. Material spillage and buildup: improve loading and transfer conditions; install cleaning devices; improve maintenance. 11. Bolt heads protruding above lagging: tighten bolts; replace lagging; use vulcanized-on lagging. 12. Tension too high: increase speed, same tonnage; reduce tonnage, same speed; reduce friction with better maintenance and replacement of damaged idlers; decrease tension by increasing arc of contact or go to lagged pulley; reduce Counterweight to minimum amount. 13. Skirt boards improperly adjusted or of wrong material: adjust skirt board supports to minimum 1 between metal and belt with gap increasing in direction of belt travel; use skirt board rubber (NOT OLD BELT)! 14. Belt spanking down under load impact: install cushion idlers. 15. Material hanging up in or under chute: improve loading to reduce spillage; install baffles; widen chute. 16. Impact of material on belt: reduce impact by improving chute design; install impact idlers. 41

64 TROUBLE SHOOTING 17. Material trapped between belt and pulley: install plows or scrapers on return run ahead of tail pulley. 18. Belt edges folding up on structure: same corrections as for 1, 2, 3; install limit switches; provide more clearance. 19. Dirty, stuck, or misaligned return rolls: remove accumulations; install cleaning devices, use self-cleaning return rolls, improve maintenance and lubrication. 20. Cover quality too low: replace with belt of heavier cover gauge or higher quality rubber. 21. Spilled oil or grease, over-lubrication of idlers: improve housekeeping; reduce quantity of grease used; check grease seals. 22. Wrong type of fastener, fastener too tight or too loose: use proper fastener and splice technique; set up schedule for regular fastener inspection. 23. Heat or chemical damage: use belt designed for specific condition. 24. Fastener plates too long for pulley size: replace with smaller fastener; increase pulley size. 25. Improper transition between troughed belt and terminal pulleys: adjust transition in accordance with Field Manual, pages Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius. 27. Excessive forward tilt of trough rolls: reduce forward tilt of idlers to no more than 2 degrees from vertical. 28. Excess gap between idler rolls: replace idlers; replace with heavier belt. 29. Insufficient transverse stiffness: replace with the proper belt. 30. Pulleys too small: use larger diameter pulleys. 31. Counterweight too light: add counterweight or increase screw take-up tension to value determined from calculations. 32. Counterweight too heavy: lighten counterweight to value required by calculations. 33. Pulley lagging worn: replace pulley lagging. 42

65 TROUBLE SHOOTING 34. Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt cleaning devices. 35. System underbelted: recalculate belt tensions and select proper belt. 36. Excessive sag between idlers causing load to work and shuffle on belt as it passes over idlers: increase tension if unnecessarily low; reduce idler spacing. 37. Improper storage or handling: refer to pages for proper storage and handling instructions. 38. Belt improperly spliced: resplice using proper method as recommended by. 39. Belt running off-center around the tail pulley and through the loading area: install training idlers on the return run prior to tail pulley. 40. Belt hitting structure: install training idlers on carrying and return run. 41. Improper belt installation causing apparent excessive belt stretch: pull belt through counterweight with a tension equal to at least empty running tension; run belt in with mechanical fasteners. 42 Improper initial positioning of counterweight in its carriage causing apparent excessive belt stretch: contact for recommended initial position. 43. Insufficient counterweight travel: contact for recommended minimum distances. 44. Structure not level: level structure in affected area. 45. Cover cuts or very small cover away from carcass: make spot repair with vulcanizer or self-curing repair material. 46. Excessive cover gauge ratio: use a belt with a lower gauge ratio and/or a thicker carcass. FOR OTHER PROBLEMS / OBSERVATIONS IN THE FIELD, CONTACT THE FACTORY OR YOUR PRC FIELD ENGINEER FOR SYSTEM ANALYSIS AND ENGINEERING SUPPORT:

66 CALCULATIONS BELT WEIGHT.375 LBS. PER SQ. FT. PER 1/16'' THICKNESS ROLL LENGTH FEET = D 2 d T D IS OUTSIDE DIAMETER OF ROLL (IN INCHES) d IS CORE DIAMETER (IN INCHES) T IS BELT THICKNESS (IN INCHES) BELT THICKNESS COVER THICKNESS +CARCASS GAUGE BELT THICKNESS ROLL DIAMETER.325 T X L T IS BELT THICKNESS (IN INCHES) L IS BELT LENGTHS (IN FEET) BELT TENSION HP (1 + K) 33,000 TU= S X W TU UNIT TENSION K DRIVE FACTOR* S BELT SPEED (FT. PER MINUTE) W BELT WIDTH (INCHES) HP NAMEPLATE HORSEPOWER ON DRIVE MOTOR *DRIVE FACTOR K GRAVITY, BARE =.84 GRAVITY, LAGGED =.38 SCREW, BARE = 1.2 SCREW, LAGGED =.8 NOTE:OTHER FACTORS TO CONSIDER ARE TROUGHABILITY, LOAD SUPPORT, PULLEY DIAMETER, AND TRANSITION DISTANCE. (SEE PRC ENGINEERING TABLES) Conveyor Belt Calculators are just the tool for complete conveyor design. Easy to use, these little gems will check you out for most jobs. Call to receive your s FREE and for instant computer help on design problems. BELT CALCULATOR ROLL CALCULATOR 44

67 FIELD NOTES 45

68 FIELD NOTES 46

69 W A R R A N T Y All merchandise is guaranteed against material defect and workmanship for the life of the product. Any product found to be faulty by our laboratory will be replaced or credited, our choice on a prorata basis. Claims must be addressed to the General Manager of the plant where produced, and a Returned Goods Authorization (RGA) must be used in prepaying all merchandise claims to the factory. Freight will be refunded if claim is allowed. Usually, examination in the field by a factory representative, with a sample to the laboratory, is sufficient to settle any differences. Call the factory concerned for prompt attention.

70 2733 Gunter Park Drive West Montgomery, Alabama Watts (800) Fax (334) EARTH EARTH MOVINGTHE MOVINGTHE MAD E M AD E I N I N PRC-2008 U.S.A! U. S.A!