Choosing a conveyor belt is not a catalog exercise—it’s an engineering decision that affects throughput, uptime, energy use, and safety. This guide walks you through a practical workflow grounded in widely recognized standards so your team can specify a belt that fits the material, duty cycle, environment, and system constraints.
1. Start with application triage
Clarify the job before touching specifications. Capture:
- Material characteristics: bulk density, typical and max lump size, abrasiveness, moisture/oil content, and temperature (material and ambient). Consider dust explosivity where relevant.
- Capacity and duty: target throughput (TPH), surge conditions, steady vs. variable feed.
- Conveyor geometry: width, speed, incline, transfer points, loading zone length, chute design and impact conditions.
- Regulatory context: aboveground factory vs. underground mines; applicable codes and approvals.
Capacity is driven by cross-sectional area, belt speed, and material density. For sizing fundamentals and the A × V × ρ relationships commonly used in practice—along with design factor guidance—see the methods summarized in the CEMA Belt Conveyors for Bulk Materials (7th ed.).
2. Pick the belt family that fits the duty
Choose the carcass and construction that match your conveyor’s tension and environment:
- EP/NN fabric belts (textile carcass): versatile for plant conveyors and easier splicing. “EP” denotes polyester warp and polyamide weft; multi‑ply constructions like EP 630/4 are common. The designation format is explained by ConveyorBeltGuide.
- Steel cord (ST) belts: for long-distance, high‑tension conveyors with low elongation. Selection and splice governance follow ISO 15236‑1 (2016).
- Chevron/profiled belts: add moulded profiles to prevent rollback on inclines.
- Sidewall belts: use corrugated sidewalls and cleats for steep/vertical conveying in specialized installations.
Ask yourself: Is your conveyor’s tension profile and geometry pushing you toward steel cord, or does a textile carcass cover your needs with simpler splicing and lower capital cost?
3. Specify covers and special compounds
Your belt’s covers take the punishment. Select compounds based on the dominant wear mode and special exposures.
Abrasion, cut, and tear
- DIN 22102 cover grades (Y, W, X) are widely referenced in Europe. EN ISO 14890 and ISO 10247 harmonize cover classification with abrasion test method ISO 4649. See overviews in Agg‑Net’s guide to belting standards and the specification ISO 14890:2013.
- Typical industry guidance: general‑purpose Y/L grades serve many factory duties; W/D suits highly abrasive aggregates; X/H adds cut/impact resistance for sharp materials. Numeric thresholds vary by revision and test variant—verify against official tables and supplier certificates.
Heat, oil, and flame resistance
- Heat resistance is assessed under ISO 4195 classes, which use accelerated aging at defined temperatures to check property retention; manufacturers typically indicate Class 1 (~100°C), Class 2 (~125°C), or Class 3 (~150°C) performance in data sheets.
- Oil resistance is manufacturer‑defined (often ARPM/RMA references). Confirm swelling/volume change in ASTM oil tests in the supplier’s documentation.
- Flame resistance involves different regimes: the small‑scale vertical test in ISO 340:2022; underground conveyor safety requirements in EN 14973 (includes drum friction tests and conductivity); and, in U.S. underground coal, approvals per MSHA 30 CFR Part 14.
4. Read and set the tensile/designation correctly
Understanding belt shorthand avoids expensive mistakes. A common textile format:
- EP 630/4 6/2 Y
- EP: polyester warp, polyamide weft (textile carcass)
- 630: minimum breaking strength per unit width (kN/m), often expressed as N/mm
- 4: number of plies
- 6/2: top/bottom cover thicknesses in mm
- Y: cover grade per DIN 22102
Use this to confirm the tensile rating, ply count, and cover thickness align with your tension estimates and wear expectations.
| Element | What it means | Why it matters |
|---|---|---|
| EP | Polyester/polyamide textile carcass | Defines elongation, splice approach, and pulley diameter needs |
| 630 | Tensile rating (kN/m) | Must meet calculated tensions with margin |
| /4 | Number of plies | Influences stiffness and minimum pulley diameter |
| 6/2 | Cover thickness (mm) | Balances wear life and flexibility over idlers |
| Y | Cover grade (DIN 22102) | Matches abrasion/cut/tear profile |
Reference formats are summarized by ConveyorBeltGuide and manufacturer sheets.
5. Size width and speed for capacity
Capacity ≈ cross‑sectional area × belt speed × material density. In practice, teams use A × V × ρ relationships and operate below theoretical capacity via design factors. CEMA’s Belt Book details the geometry (width, trough angle, surcharge angle, idler dimensions) behind the area calculation and recommends running at a fraction of theoretical to prevent spillage and surges. See the CEMA Belt Book (7th ed.) for methodology.
Verification cues:
- Confirm your capacity target against A × V × ρ outputs and apply an underrating factor.
- Check surcharge angle and lump size effects on cross‑section.
- Validate the selected speed against material stability and dust control measures.
6. Check pulley diameter compatibility
Minimum pulley diameters increase with belt thickness and stiffness. Verification should include drive, tail, take‑up, and bend pulleys.
- ISO 3684 provides a general method linking carcass thickness and a carcass factor to minimum diameters; see an overview in the ISO 3684:1990 sample text.
- DIN 22101 offers transition length and pulley group guidance so the belt enters and leaves the trough without overstress.
Practical checks:
- Verify drive pulley diameter vs. carcass flex limits to avoid fatigue and slip.
- Check wrap angles and slack‑side tension to maintain friction.
- Confirm transition lengths so the belt’s edges aren’t overstretched.
7. Choose idler angles and spacing wisely
Idler choices affect sag, power draw, and belt life.
Typical practice:
- Trough angles of 20°, 35°, or 45°; 35° is widely used in plants.
- Carry‑side spacing around 3.5–4 ft, tightened in loading zones to control sag and impact.
Closer spacing reduces sag and spillage risk but increases rolling resistance; steeper troughing reduces sag for a given spacing. Methods derived from CEMA and manufacturer design aids provide sag targets and spacing calculations—see Rulmeca’s tension and sag guidance.
8. Decide your splice strategy
Mechanical fasteners offer rapid installation and removal but lower strength—useful for maintenance access or short belts. Hot or cold vulcanized splices deliver higher strength and durability but demand skilled crews and controlled conditions. For steel cord belts, follow the geometry and performance requirements in ISO 15236‑1; manufacturers provide splice instructions that must be followed.
9. Build in energy efficiency
On long conveyors, indentation rolling resistance (IRR) often dominates running resistance because the belt continually deforms over idlers. Engineering sources show low‑rolling‑resistance compounds can materially reduce IRR, translating to lower power demand. For background on IRR mechanisms and evaluation, see ConveyorBeltGuide’s energy saving overview.
Design tactics:
- Specify low‑rolling‑resistance cover compounds for long, high‑duty conveyors.
- Use quality, well‑aligned idlers with appropriate diameters and seals.
- Maintain belt tracking and tension to avoid extra resistances.
10. Address safety and compliance early
Factory conveyors must meet guarding and energy‑control rules and follow consensus safety standards.
- Lockout/Tagout: OSHA 29 CFR 1910.147 governs control of hazardous energy for maintenance.
- Machine guarding and power‑transmission: OSHA 29 CFR 1910.212 and 1910.219 cover pinch points, belts, pulleys, and shafts.
- Consensus standard: ASME/ANSI B20.1 (2024) provides guidance on design, installation, maintenance, controls, guards, warnings, and inspection.
- Underground coal in the U.S.: belts must be approved under MSHA 30 CFR Part 14.
Coordinate with your safety team and local regulations; integrate audible warnings, emergency stops, and qualified personnel oversight into procedures.
11. Practical workflow example (neutral brand mention)
Scenario: A plant needs a belt for conveying abrasive aggregate at ambient temperatures with a 15° incline, 600 TPH target, 35° troughing, and frequent transfer points.
Workflow:
- Family: Textile EP belt is sufficient for the tension profile and allows straightforward splicing.
- Covers: Choose a high‑abrasion grade (DIN W / ISO D) to handle aggregate wear; consider X/H if sharp impact is severe.
- Designation: EP 800/4 with 8/3 covers could be appropriate; verify tensile vs. calculated tensions and check minimum pulley diameters.
- Capacity: Calculate A × V × ρ with CEMA methods; apply underrating; set belt speed to limit rollback on a 15° incline (chevron profiles may be considered if rollback occurs).
- Idlers: Use 35° troughing; tighten spacing in loading zones to control sag.
- Splice: Specify hot vulcanized splices; include inspection intervals in maintenance plans.
A supplier like BisonConvey can support this with EP/NN belts, chevron options for incline control, and compatible idlers and pulleys. Disclosure: BisonConvey is our product. Selection must still be validated against standards and plant conditions.
12. Final checklist before you issue a PO
- Belt family vs. duty: EP/NN for general plant; steel cord for long/high tension; chevron/sidewall for incline/steep.
- Cover grade: pick Y/L, W/D, or X/H based on abrasion and cut/impact; add heat/oil/flame compounds as needed.
- Designation: confirm tensile rating, ply count, and cover thicknesses; map to minimum pulley diameters.
- Capacity: size width/speed via CEMA methods; apply design factor; check surcharge angle and lump size.
- Pulleys: verify diameters and transitions per ISO/DIN; check wrap and slack‑side tension.
- Idlers: set trough angles and spacing to meet sag targets; reinforce loading zones.
- Splicing: choose mechanical vs. vulcanized; follow manufacturer procedures; steel cord per ISO 15236.
- Energy: specify low‑rolling‑resistance compounds and quality idlers for long conveyors.
- Safety: implement OSHA LOTO and guarding; follow ASME B20.1 practices; MSHA approval for U.S. underground coal.
Think of this as your belt‑spec “gate review.” A little rigor up front prevents costly downtime later. Ready to dig in with your team?
