Aac Spec 377006

AAC SPECIFICATION 377006
ISSUE 1
SOLID WOVEN CONVEYOR BELTING
COPYRIGHT
CONTENTS PAGE
1 SCOPE 2
2 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER. 2
2.1 BELT WIDTH 2
2.2 BELT CLASS 2
2.3 COVER THICKNESS AND MATERIAL 3
2.4 LENGTH OF BELTING 3
3 DEFINITIONS 3
4 REQUIREMENTS 3
4.1 CARCASS CONSTRUCTION 3
4.2 COVER ADHESION 3
4.3 MINIMUM PULLEY DIAMETER 3
4.4 SAFETY FACTORS AND SPLICE STRENGTH 4
4.5 WEFT DENSITY 5
4.6 TROUGHABILITY 5
5 QUALITY ASSURANCE PROVISIONS 5
6 TEST AND INSPECTION REQUIREMENTS 6
6.1 FIRE PERFORMANCE AND FLAME RESISTANCE 6
6.2 DRUM FRICTION TEST 6
6.3 ELECTRICAL RESISTANCE TEST 6
6.4 TEAR STRENGTH TEST 6
6.5 STATIC TENSILE STRENGTH TEST FOR MECHANICAL JOINTS 7
6.6 DYNAMIC LIFE TEST FOR MECHANICAL JOINTS 8
6.7 STATIC TENSILE STRENGTH TEST FOR VULCANISED JOINTS 11
6.8 DYNAMIC TENSILE STRENGTH TEST FOR VULCANISED JOINTS 11
6.9 RECORDS 13
7 PACKING AND MARKING 13
7.1 PACKING MUST BE IN ACCORDANCE WITH SANS 971. 13
7.2 WHEN BELTING ARRIVES AT THE MINE, 13
APPENDIX A : RELATED DOCUMENTS 14
APPENDIX B : RECORD OF AMENDMENTS 14
AAC_SPEC_37700601 APPROVED 9 March 2006 Page 1 of 14
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
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1 SCOPE
This specification details the requirements for the manufacture and supply of solid woven
belting with PVC or Nitrile covers for the use on belt conveyors, both on surface and
underground. Unless otherwise stated, all belting shall conform to SANS 971 - 2003
2 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER.

2.1 BELT WIDTH
Belting shall be one of the following widths, as required by the Engineer.
a. 900mm
b. 1050mm
c. 1200mm
d. 1350mm
e. 1500mm
f. 1800mm
2.2 BELT CLASS

Belting shall be one of the following classes, as required by the Engineer.
Minimum breaking strength Approximate belt

Belt class thickness
Longitudinal Transverse
(mm)
(kN/m width) (kN/m length)
1 000 100 220 9
1 250 125 250 10
1 400 140 300 11
1 600 160 350 11,5
Table 1
The maximum elongation in the longitudinal direction, produced by the maximum longitudinal
load shall be limited to 3%
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2.3 COVER THICKNESS AND MATERIAL

Cover material shall be specified as either PVC or Nitrile, or a combination of both, to suit the
required application. If cover material and thickness are not specified, the belt shall have a
minimum of 0,8mm PVC covers. If Nitrile covers are required, they shall have a minimum
thickness of 3mm top and 2mm bottom over and above the 0,8mm (minimum) PVC cover.
The carcass shall be impregnated with a fire retardant compound and have a constant
thickness with the variation in thickness not exceeding 5%.
2.4 LENGTH OF BELTING

The length of belting required must be specified to the potential suppliers in metres.
3 DEFINITIONS
Approved : Approved by the Engineer in writing
The following terms are defined in the General Conditions of Contract:
Company, Engineer, Contractor
4 REQUIREMENTS
4.1 CARCASS CONSTRUCTION
The fabric reinforcement of the carcass shall extend over the full width of the belting and shall
have no joints, transverse or longitudinal. The carcass shall be free of folds, tucks, knots and
any foreign matter that may impair the long-term serviceability of the belting.
4.2 COVER ADHESION

The result of a separation test for the adhesion between the carcass and the covers of a belt
shall not be less than 5 N/mm. (The test method is specified in point 3.4.1). If a Nitrile cover
is used on top of a PVC cover, the minimum result from a separation test will be no less than
5 N/mm.
4.3 MINIMUM PULLEY DIAMETER

The following table displays minimum pulley diameters in accordance with manufacturer’s
specifications. Minimum pulley diameters are based on the smallest pulley diameter that the
belt can safely negotiate with a mechanical splice. It is important to note that the diameters
shown are indications only and that the mechanical design will reflect the minimum pulley
diameter for a particular application.
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Drive / high tension Snub / Low tension

Belt class
(mm) (mm)
1 000 630 500
1 250 800 400
1 400 800 400
1 600 1 000 630
Table 2
4.4 SAFETY FACTORS AND SPLICE STRENGTH

The design safety factor (SF) for all mechanical splices is 12.
The design safety factor (SF) for all vulcanised splices is 10.
The method of selecting the belt class is as follows:
T(max) ⋅ SF
Class =
W
where: T(max) = Maximum belt tension in the system (kN)
SF = Design safety factor
W = Belt width (m)
Belt rated Mechanical joint Vulcanised joint

Belt
tension
class Min. strength % of new belt Min. strength % of new
(kN/m)
(kN/m) strength (kN/m) belt strength
1000 100 600 900 90
1250 125 750 60 1125
1400 140 840 1250
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1600 160 960 50 1440
Table 3
Note: For mechanical joints the actual safety factor is 7,2 (60% of the design safety factor of
12) and for vulcanised joints the actual service factor is 9 (90% of the design service
factor of 10). Mechanical joints for a class 1600 belt to be used in an emergency only.
In the case of solid woven belts, a vulcanised joint refers to a splice known as a ‘finger
splice’ and each supplier must provide their preferred method of constructing such a
joint.
Example:
If a class 1400 belt is used for a particular application and a mechanical joint is used, the
maximum tension that can be applied to this belt is 116,67kN/m, in accordance with a
standard safety factor of 12. However, in accordance with this specification, the breaking
strength of the joint is 840kN/m (60% of new belt strength). Therefore, the actual safety
840
factor in this instance will be a minimum of = 7.20, if the belt is loaded to its full
116,67
breaking strength.
4.4.1 Plate and bolt type fasteners are not preferred. Belting manufacturers or suppliers of
belting must demonstrate that vulcanised splices and mechanical joints meet both the static
and dynamic requirements as specified in this document. Belting manufacturers must also
specify the recommended type of clips to be used with their belts to achieve maximum
strength.
4.5 WEFT DENSITY

Weft density shall be such that minimum standards of SANS 962 part 2 is satisfied.
4.6 TROUGHABILITY
The manufacturer will be required to inform the user if in his opinion a certain class of belting
specified for a certain belt width will contribute towards mistracking as a result of poor
troughability. All belts will be required to trough at 35°. At times a 45°-troughing angle will be
required and specified accordingly by the user.
5 QUALITY ASSURANCE PROVISIONS

QAP 100 shall apply.
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6 TEST AND INSPECTION REQUIREMENTS

6.1 FIRE PERFORMANCE AND FLAME RESISTANCE
Fire performance and flame resistance to be as stipulated in SANS 971.
6.2 DRUM FRICTION TEST

Drum friction tests must be performed in accordance with specification SANS 971.
6.3 ELECTRICAL RESISTANCE TEST

Electrical resistance tests should be performed as stipulated in SANS 971
6.4 TEAR STRENGTH TEST

Tear strength of the finished belting shall be measured as described and the average values
shall not be less than those shown in table 5. This test to be performed in accordance with
ISO 505
Belt class Tear strength (kN)
1 000 1,60
1 250 1,60
1 400 1,60
1 600 1,60
Table 5
6.4.1 The force required to extend a cut made in a test piece taken from a sample of
conveyor belting with covers intact must be determined by means of a suitable tensile
testing machine.
6.4.2 Preparation of test piece.
Cut two test pieces parallel to the length of the belt each being a rectangular strip of the full
thickness of the belt and measuring 50mm wide and 300mm long. Cut each piece down the
centre, parallel with the sides, for a length of approximately 100mm from the end so as to
form the two legs as shown in figure 2. Also mark in white paint the direction of travel of the
belt and mark the top cover with the letter ‘T’.
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CUT
T
100
10
30
Figure 2
6.4.3 Test procedure
Clamp the two legs of a test piece in the grips of the testing machine, one in each grip.
Clamp the legs, with the inner cut edges located at the centre of the grips and the legs set
parallel to the direction of the weft cords. Separate the grips at a constant speed of
50mm/min. and make a graph recording of the force required to separate the belt a further
100mm. Ignore the initial rise of the trace on the graph recording and determine the mean
tearing force from the record over a length of trace corresponding to not less than 75mm of
tearing.
6.5 STATIC TENSILE STRENGTH TEST FOR MECHANICAL JOINTS

6.5.1 Procedures
Test Method
Belts shall be tested in accordance with BS 4890 – “Test Methods for Mechanical Joints in
Conveyor Belting” until such time as this standard is superseded by the harmonised Standard
BS EN ISO 1120” – “Determination of strength of mechanical fastenings – Static Test
Method”. The belt shall then be run for a minimum of 100 000 revolutions on a dynamic test
machine and the test repeated. Results from the second test shall be equal or higher than
90% of the original test.
Requirement
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For new belting, the mean value obtained shall be not less than 60% of nominal tensile
strength (see table 3).
6.5.2 Test report
The test report shall include the following particulars:-
i. Belt type
ii. The tension at which the joint failed in both cases
iii. The type of joint pin
iv. The fastened width (Width over fasteners)
The number and type of fastener used
vi. The details of failure of the joints
6.6 DYNAMIC LIFE TEST FOR MECHANICAL JOINTS

6.6.1 Testing machine
In order to accurately test the belting the testing machine requires the following:-
a. A means of measuring the tension in the belt through the force exerted by the belt on
one of the pulleys.
b. A means of obtaining and maintaining the required tension in the belt and for
accommodating the changes in loop length that occur during the course of the test.
c. A means of measuring the running time of the testing machine, thereby enabling the
user to accurately calculate the final number of revolutions of the belt.
6.6.2 Test tension
The test tension shall be determined as follows:
Tb ⋅ W
Ttest =
Fs
where: Tb = Belt class designation (kN/m)
Fs = Belt service factor (see point 2.8)
W = Test belt width (m)
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Example:
Class 1250 belt
Service factor of 12
Test piece is 250mm (0,25m) wide
1250 ⋅ 0,25
Ttest = = 26,04kN
12
6.6.3 Preparation of test pieces
• The number of test pieces required for each test is 2.
• Test pieces shall be prepared not less than five days after the date of manufacture of the
belt.
• The width of each test piece shall be the fastened width + 50mm ± 1,5mm. The fastened
width will vary on the pitch of the fastener used, but shall be as near as possible to
250mm.
• Each individual test piece in the loop must be clearly marked for identification purposes
during the test.
• Good craft practice in joining the belt should be observed and careful attention should be
paid to the instructions of the fastener manufacturers. Open ends of the belting to be
cleanly cut and perpendicular to the edge of the belting before the insertion of fasteners.
6.6.4 Preparation of test loop
To form a test loop, test pieces must be joined by means of a fastener, as recommend by the
belting manufacturer.
6.6.5 Test procedure
a. Assemble test loop into the testing machine in the appropriate configuration.
b. Apply a tension approximately equal to half the test tension to the belt and start the
testing machine. Gradually increase the tension in the belt until the full test tension is
reached. Measure the time for 20 cycles of the testing machine and calculate the time
for one cycle.
c. Continue the test without interruption until one joint breaks.
d. Record the time elapsed from the time the test machine was first started and calculate
and record the number of cycles completed by the failed joint.
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e. Record the mode of failure of the joint.
f. Remove the two halves of the broken joint by cutting a length of 60mm from the ends of
the test pieces adjacent to the broken joints. Insert a replacement joint in the manner
described above
g. Re-start the testing machine and measure the new cycle time as described above.
Continue the test until the next joint breakage occurs. Record the additional elapsed
time and the additional number of circuits of the testing machine. Calculate the total
number of circuits the testing machine endured by the joint at break and record the
value as the joint life of that joint. Also record details of the mode of failure of the joint.
h. Continue the test until each original joint has failed. If a second breakage occurs at any
joint, re-join the test pieces and maintain the joint but keep no record of its life. Record
details of the total number of circuits for each joint and the mode of failure.
6.6.6 Calculation and expression of results
T ⋅ 3600
a. Calculate the mean joint life using the following formula: JL =
S
where: JL = Individual joint life in cycles
T = Elapsed time in hours for joint to

fail
S = Cycle time in seconds
b. Test Report
The test report shall include the following particulars:-
i. Belt type
ii. The mean joint life
iii. The type of joint pin
iv. The fastened width.
v. The number and type of fastener units inserted in each end of the test pieces.
vi. The details of failure of the joints.
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6.7 STATIC TENSILE STRENGTH TEST FOR VULCANISED JOINTS

6.7.1 Testing machine
The machine shall have a capacity of not less than 2MN and be capable of jaw separation at
30mm/min. It shall be fitted with cylindrical drum attachments, free to rotate about their
vertical axis. The machine shall be accurate to not less than Grade 2 of BS1610.
6.7.2 Preparation of test pieces.
One loop shall be prepared, containing two spliced joints. The loop shall be 300mm wide and
have a length of 5m + the length of each joint.
6.7.3 Procedure
The loop shall be positions over the two cylindrical drums such that the joints are positioned
centrally between the drums.
Sufficient tension shall be given to the loop to enable it to remain positioned on the centre line
of the drum with its longitudinal axis horizontal.
After starting the test machine, load shall be applied until the belt breaks. The belt shall then
be run for a minimum of 100 000 revolutions on a dynamic test machine and the test
repeated. Results from the second test shall be equal or higher than 90% of the original test.
6.7.4 Test Report.
i. The belt type
ii. Breaking load
iii. Breaking load expressed as a percentage of nominal tensile strength.
iv. Method of failure.
6.8 DYNAMIC TENSILE STRENGTH TEST FOR VULCANISED JOINTS

Testing machine
In order to accurately test the belting the testing machine requires the following:-
a. A means of measuring the tension in the belt through the force exerted by the belt on
one of the pulleys.
b. A means of obtaining and maintaining the required tension in the belt and for
accommodating the changes in loop length that occur during the course of the test.
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c. A means of measuring the running time of the testing machine, thereby enabling the
user to accurately calculate the final number of revolutions of the belt.
6.8.1 Test tension
The test tension shall be determined as follows:-
Tb ⋅ W
Ttest =
Fs
where: Tb = Belt class designation (kN/m)
Fs = Belt service factor (see point 2.8)
W = Test belt width (m)
Example:-
Class 1250 belt
Service factor of 10
Test piece is 250mm (0,25m) wide
1250 ⋅ 0,25
Ttest = = 31,25kN
10
6.8.2 Preparation of test pieces
Prepare the test loop to suit the machine that is to be used to perform the test. The loop shall
be at least 300mm wide and contain two equally spaced vulcanised joints from the sample of
belting under test.
6.8.3 Procedure
Dynamic assessment
Fit the test loop on the testing machine. Apply tension to the belt equal to half the test tension
and start the testing machine. Gradually increase the tension in the belt until the full test
tension is obtained.
Measure the time for 20 cycles of the testing machine and calculate the time for one cycle.
Continue the test without unnecessary interruption until one joint breaks or until 100 000
cycles has been attained.
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Residual Tensile Strength.
Loops that successfully complete the required number of cycles are tested for residual tensile
strength by the method given for static tensile strength.
Test Report
The test report shall contain the following particulars:-
i. Belt type
ii. The joint life to failure, express in cycles, together with a description of the type of
failure, or
iii. Verification of the attainment of the required number of cycles as applicable together
with the residual tensile strength of the test loop (expressed as a percentage of the
nominal tensile strength of the belt).
6.9 RECORDS
Test results as required in Clause 6.0 shall be maintained by the Supplier for the life of the
belt and shall be produced on request by the Engineer or his representative.
7 PACKING AND MARKING

7.1 PACKING MUST BE IN ACCORDANCE WITH SANS 971.
7.2 WHEN BELTING ARRIVES AT THE MINE,
the mine must install an electronic data tube in each roll of belting and clearly mark the point
of installation with yellow paint to indicate its location. Each data disc contains a unique serial
number that will refer to a database. The database will contain information such as
manufacturer, belt class, and all relevant belt details and test results of belting when it was
new. Similar discs must be installed and programmed by the mine when doing splices in
order to keep track of splice life. In each instance a 2,5mm hole must be drilled into the side
of the belt, around 60mm deep, the electronic tube inserted and the hole sealed with silicon
or similar suitable sealant.
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APPENDIX A : RELATED DOCUMENTS
Unless otherwise specified the latest issues of the following documents shall be deemed to form part
of this specification:
BS 1610 : Materials testing machines and force verification equipment
BS 4890 : Test methods for mechanical joints in conveyor belting
BS EN ISO 1120 : Determination of strength of mechanical fastenings - Static test method
ISO 284 : Conveyor belts – Electrical conductivity spec and method of testing
ISO 505 : Conveyor belts – Method for determination of tear propagation resistance
of textile reinforced conveyor belting
QAP 100 : Quality requirements for critical and major products
SANS 962 : Mechanical fasteners for conveyor belts
SANS 971 : Standard specification for fire-resistant textile-reinforced conveyor belting

(for use in fiery mines)
APPENDIX B : RECORD OF AMENDMENTS
Issue 0 : Editorial version 27 January 2004
Issue 1 : Revised on 23 February 2004

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AAC SPECIFICATION 377006

AAC_SPEC_37700601 APPROVED 9 March 2006 Page 1 of 14

2 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER.

2.2 BELT CLASS

Minimum breaking strength Approximate belt

1 000 100 220 9

1 250 125 250 10

1 400 140 300 11

1 600 160 350 11,5

AAC_SPEC_37700601 APPROVED 9 March 2006 Page 2 of 14

2.3 COVER THICKNESS AND MATERIAL

2.4 LENGTH OF BELTING

Approved : Approved by the Engineer in writing

The following terms are defined in the General Conditions of Contract:

Company, Engineer, Contractor

4.2 COVER ADHESION

4.3 MINIMUM PULLEY DIAMETER

AAC_SPEC_37700601 APPROVED 9 March 2006 Page 3 of 14

Drive / high tension Snub / Low tension

1 000 630 500

1 250 800 400

1 400 800 400

1 600 1 000 630

4.4 SAFETY FACTORS AND SPLICE STRENGTH

The method of selecting the belt class is as follows:

where: T(max) = Maximum belt tension in the system (kN)

SF = Design safety factor

W = Belt width (m)

Belt rated Mechanical joint Vulcanised joint

1000 100 600 900 90

1250 125 750 60 1125

1400 140 840 1250

AAC_SPEC_37700601 APPROVED 9 March 2006 Page 4 of 14

1600 160 960 50 1440

4.5 WEFT DENSITY

5 QUALITY ASSURANCE PROVISIONS

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6 TEST AND INSPECTION REQUIREMENTS

6.2 DRUM FRICTION TEST

6.3 ELECTRICAL RESISTANCE TEST

6.4 TEAR STRENGTH TEST

Belt class Tear strength (kN)

6.4.2 Preparation of test piece.

AAC_SPEC_37700601 APPROVED 9 March 2006 Page 6 of 14

6.4.3 Test procedure

6.5 STATIC TENSILE STRENGTH TEST FOR MECHANICAL JOINTS

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6.5.2 Test report

The test report shall include the following particulars:-

ii. The tension at which the joint failed in both cases

iii. The type of joint pin

iv. The fastened width (Width over fasteners)

The number and type of fastener used

vi. The details of failure of the joints

6.6 DYNAMIC LIFE TEST FOR MECHANICAL JOINTS

6.6.2 Test tension

The test tension shall be determined as follows:

where: Tb = Belt class designation (kN/m)

Fs = Belt service factor (see point 2.8)

W = Test belt width (m)

AAC_SPEC_37700601 APPROVED 9 March 2006 Page 8 of 14

Class 1250 belt

Test piece is 250mm (0,25m) wide