Steel Cord Conveyor Belt Manufacturer – Top Factory Service

Steel cord conveyor belts have been instrumental in reshaping numerous sectors, including mining, construction, and large-scale manufacturing.In mining, these belts transport raw materials from underground to the surface, requiring durability and strength, while in construction, they move large volumes of materials over long distances in tough conditions. Steel cord belt conveyor stand out for their ease in handling heavy loads and long-distance transport, efficiently moving large quantities of materials like ores in mining and aggregates in construction due to their design and technology. Moreover, the adaptability of steel cord belt conveyor to various environmental conditions makes them a versatile solution for many industries. Whether it’s the extreme depths of a mine or the open expanse of a construction site, these belts are designed to perform reliably under any circumstance. In summary, steel cord belt conveyor have become a cornerstone in the field of industrial material handling and transportation. Developed by famous steel cord conveyor belt manufacturers as Gram, steel cord conveyor belts have solved numerous logistical challenges and enhanced material handling efficiency and reliability, becoming increasingly vital in evolving industries and reinforcing their impact in material handling.

Technically Superior Products

With over 20 years of expertise in steel cord conveyor belting design and application, our engineers leverage their deep experience to harness state-of-the-art technology. This ensures not only superior product design but also optimal performance for our clients.

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Steel cord conveyor belts are highly wear-resistant and used principally for long-haul conveying, heavy loads and physically demanding applications. They are especially suitable for high-mass or high-volume flows and for abrasive materials.

  • Reinforcement properties

    Made of high-tensile steel cords and various cover grades.

  • Cover grades

    Belts come with various cover grades, all made of high-quality rubber with extremely high resistance to abrasion, cutting and impact.

  • Resistance

    Wear resistant, heat-resistant, and flame-resistant grades available.

  • Sustainability

    Durable conveyor parts designed for long component life.

Specifications of Steel Cord Conveyor Belts

Steel cord conveyor belts are essential for various heavy-duty industrial applications because of their robust construction and longevity. Here are some key specifications commonly associated with these belts:

  1. Tensile Strength: Steel cord conveyor belts are designed to handle significant weight and stress. Their tensile strength, which can range from 500 N/mm to over 5400 N/mm, makes them suitable for mining operations, heavy-load transportation, and other demanding industrial uses.
  2. Belt Width: The width of these belts typically varies depending on the application but can range from about 500 mm to over 3200 mm. Wider belts are used in applications that require the transportation of large volumes of materials.
  3. Cord Diameter and Pitch: The steel cords that form the belt’s core are crucial for its strength. These cords have a specific diameter and are spaced at a designated pitch, which can vary based on the belt’s design and the demands of the application.
  4. Top and Bottom Cover Thickness: Steel cord belts feature top and bottom covers made from rubber compounds, which protect the metallic cords from environmental factors and operational wear. The thickness of these covers is adjusted according to the belt’s intended use, with thicker covers used for belts operating under more abrasive conditions.
  5. Elongation at Break: This specification indicates the belt’s ability to stretch under tension before breaking. Steel cord belts typically have lower elongation rates, which is a beneficial property for maintaining stable operation over long distances.
  6. Cover Grades: The rubber covers of steel cord belts can be customized with various properties such as resistance to abrasion, heat, oil, and flame. These specifications are crucial for belts used in specific environmental conditions, such as those found in mining, quarrying, or chemical processing industries.

These specifications ensure that steel cord conveyor belts meet the rigorous demands of their intended applications, offering durability, efficiency, and performance. For more detailed specifications tailored to specific needs, manufacturers or specific product datasheets can provide comprehensive information.

Specifications of Steel Cord Conveyor Belts

What Sets Steel Cord Conveyor Belts Apart?

Steel cord conveyor belts are a vital component in the material handling sector, especially in industries where bulk material transportation is a critical operation. These belts are distinct from their counterparts, the fabric conveyor belts, in several key aspects. Understanding these differences, along with the specific steel cord conveyor belt specifications and the role of steel cord conveyor belt specifications, is crucial for industries looking to optimize their conveyor systems.

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Unique Construction of Steel Cord Belts

The construction of steel cord conveyor belts is what sets them apart and makes them ideal for challenging industrial applications. The core of these belts is made up of longitudinally arranged steel cords, which are coated with a special rubber compound to firmly embed them in the rubber. This unique construction provides several benefits:

1.High Strength: When the belt operating tension has to be higher than 2500 KN/m, belts reinforced with steel cord are the only alternative; and there are steel cord belts designed for ratings up to 10000 KN/m. Steel cord belts are also an economic alternative to fabric belts with ratings between 1000 KN/m and 2500 KN/m.

2.Lower Factor of Safety: Fabric belts are designed with a factor of safety of 10, but the factor of safety is only 6.67 for steel cord belts. This means that a fabric belt can be replaced with a steel cord belt of a smaller rating, which provides a lifetime savings to the operator.

3.Shorter Takeups: the elongation of a material depends on its elastic modulus; and the superior elastic modulus of steel cord; elongation can be less than 0.25%; which allows for smaller takeup lengths.

4.Long Centre Distances: Steel cable has much lower elongation than fabrics, and this, in addition to the strength, lets belts be designed with long distances between pulleys; and takeups and transfer points are less constraining.

5.Smaller Pulley Diameters: With a much thinner carcass than a fabric belt of the equivalent rating, steel cord belts can be run on pulleys with smaller diameters, which leads to energy savings. The superior dynamic modulus of steel over fabric means that fatigue is much less.

6.High Impact Resistance: Typically, steel cord belt design leads to a greater proportion of rubber in the whole belt compared to textile conveyor belts. Additional rubber means that impact energy is better absorbed by the belt; making steel cord belts a good choice for any application where there can be sudden heavy individual pieces.

7.Excellent Troughability: Even the highest rated steel cord belts trough perfectly on deep troughed idler sites. This ensures easy belt training, and gives the belt a larger effective capacity; allowing the user to either increase throughput, or use a narrower belt.

8.Long Life Expectancy: Steel cord belts can be supplied with a thinner carcass and thicker cover rubber for the same rating as an equivalent fabric belt; which increases the belt life. The carcass also has a greater life than an equivalent fabric carcass.

9.Splice Life and Strength: Properly provided belt splices can last as long as the Belt itself. They can also achieve spliced strength equivalent to almost 100% of the strength of the Belt.

10.Easy Reconditioning : Steel cord belts can be repaired with hot or cold vulcanization and the damaged edges can be restored to their original width by hot repair. Worn out covers can be replaced with fresh rubber, durable enough to completely rejuvenate the belt, delivering even greater economy for the customer.

Comparison Between Steel Cord and Fabric Conveyor Belts

AspectSteel Cord Conveyor BeltsFabric Conveyor Belts
Strength and Durability– Superior tensile strength due to steel cords encased in rubber.
– Capable of carrying heavier loads over longer distances.
– Less prone to stretching, tearing, and wear and tear.
– More reliable and durable for heavy-duty applications.
– Lower tensile strength compared to steel cord belts.
– Less suitable for very heavy loads and long distances.
– More prone to stretching, tearing, and wear and tear.
Efficiency– Handle heavier loads, reducing the number of conveyor belts needed.
– Durability leads to reduced need for replacements or maintenance.
– Overall more cost-effective in the long run for heavy-duty operations.
– May require more belts for the same load due to lower strength.
– Potentially higher maintenance and replacement costs.
Load and Speed– Can operate under higher tension.
– Suitable for longer center distances and higher lift heights.
– Capable of moving large volumes of materials at faster speeds.
– Enhances operational throughput.
– Lower tension operation.
– Shorter center distances and lower lift heights.
– Slower speeds for material movement.
– Less effective in handling large volumes quickly.

Structure of Steel Cord Conveyor Belts

  1. Arrangement of Steel Cords: At the heart of a steel cord conveyor belt is the arrangement of longitudinally placed steel cords, which are the main load-bearing elements. These cords are typically made from high-tensile steel and are laid out in a parallel formation. The number, diameter, and spacing of the steel cords can vary depending on the specific belt specifications and the intended use. This arrangement is crucial for providing the high tensile strength that is characteristic of these belts.
  2. Coating and Embedding of Steel Cords: Each steel cord in the conveyor belt is coated with a special rubber compound, protecting against corrosion, ensuring a strong bond with the rubber, and evenly distributing load, a crucial factor in the belt’s performance and longevity.
  3. Top and Bottom Covers: The belt’s core of steel cords and rubber is encased in top and bottom covers made of rubber or similar materials, offering extra protection against wear, tear, and environmental elements such as moisture, chemicals, and extreme temperatures.

The role of steel cord conveyor belt specifications like Gram is integral in ensuring the quality and performance of these belts. We are responsible for adhering to stringent industry standards and producing belts that meet specific operational requirements. We utilize advanced manufacturing techniques and materials to ensure the belts are of high quality. Furthermore, Gram often provide customized belt solutions, tailoring the steel cord conveyor belt specifications to meet the unique demands of different industries and applications.

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Technical of Steel Cord Belt Conveyor

Steel cord conveyor belts are critical components in heavy-duty industrial applications, known for their strength and durability. Here’s an overview of their technical characteristics:

  1. Structure: Steel cord conveyor belts consist of a core of longitudinally arranged steel wires, embedded in rubber. The steel cords are typically arranged in a regular pattern and are held by a specifically designed rubber compound. The main components are the core, which provides tensile strength, and the top and bottom covers, which protect the core from environmental impacts and wear.
  2. Operational Speed: Steel cord belts are capable of operating at high speeds, making them suitable for efficient material handling over long distances.
  3. Safety Factors: These belts are designed with specific safety factors, generally ranging from 6.7 to 10, which ensure a margin of safety under operating conditions. This factor is the ratio of the belt’s breaking strength to the actual load.
  4. Splice Types: The integrity of splices in steel cord belts is critical for maintaining strength and durability. Splices can be vulcanized or mechanical, with vulcanized splices providing a seamless finish and superior durability.

These technical specifications make steel cord conveyor belts particularly suitable for applications requiring high tensile strength and durability, such as mining, material handling, and heavy industrial processes. For detailed specifications tailored to specific needs, it’s best to consult with manufacturers or technical datasheets directly.

Technical of Steel Cord Belt Conveyor

Manufacturing Process of Steel Cord Belt Conveyor

The manufacturing process of steel cord conveyor belts involves several sophisticated and critical steps to ensure their durability and performance. Here’s an overview of the key stages involved:

  1. Materials Preparation: The process begins with the preparation of materials, primarily steel cords which are the main strength carriers in these belts. The steel cords are specially designed to handle high tensile forces and are treated with anti-corrosive coatings to prevent rust and enhance adhesion to rubber.
  2. Rubber Mixing: Simultaneously, rubber compounds are prepared through a mixing process. Different formulas are used for the top and bottom covers and the core, depending on the belt’s intended use. The compounds often include natural rubber or synthetic polymers enhanced with chemicals for improved resistance against abrasion, heat, chemicals, and oils.
  3. Cord Laying and Calendaring: The steel cords are laid out in parallel and at equal distance on a special laying machine. Then, they are embedded into the rubber using a calendaring process. During calendaring, rubber is pressed into and around the cords under heat and pressure to ensure a strong bond.
  4. Pressing and Vulcanization: The assembled belt then undergoes pressing where it is shaped into its final thickness and width. Following this, the belt is vulcanized in a press or a continuous vulcanization line (CV line). Vulcanization is a curing process where the belt is subjected to heat and pressure to form a solid, durable structure. This step is crucial as it determines the mechanical properties and performance of the finished conveyor belt.
  5. Cooling and Finishing: After vulcanization, the belt is cooled gradually to stabilize its properties. The edges of the belt are then trimmed and sealed to prevent fraying of the steel cords and rubber.
  6. Inspection and Quality Control: The final stage involves rigorous testing and inspection to ensure the belt meets all quality standards. Tests might include checking for proper adhesion between the cords and the rubber, tensile strength, elongation, and resistance to various environmental factors.
  7. Winding and Packaging: Once approved, the belts are wound onto large reels and prepared for shipping. The belts might also be cut into specific lengths as per customer requirements before dispatch.

This complex manufacturing process ensures that steel cord conveyor belts are capable of handling heavy loads and running over long distances with minimal stretch and maintenance. These belts are crucial for heavy-duty applications such as mining, material handling, and bulk transportation.

Manufacturing Process of Steel Cord Belt Conveyor
Manufacturing Process of Steel Cord Belt Conveyors

How to Selecting Your Steel Cord Conveyor Belt

Choosing the right steel cord belt conveyor is a critical decision for any industry that relies on heavy-duty material handling. The process involves understanding the specific requirements of your operation and the unique characteristics of steel cord conveyor belt construction.

Step-by-Step Guide to Choosing the Right Belt

  1. Start by analyzing the characteristics of the materials to be transported, considering their weight, size, and level of abrasiveness. Consider the length and layout of your conveyor system, including load capacity, speed requirements, and environmental conditions such as temperature and chemical exposure.
  2. Understand Steel Cord Conveyor Belt Construction: Familiarize yourself with the key aspects of steel cord conveyor belt construction. These factors, including the conveyor belt’s tensile strength, steel cord diameter and arrangement, and the rubber covers’ type and thickness, all influence its performance and suitability for your requirements.
  3. Determine the Appropriate Specifications: Based on your operational assessment, determine the necessary specifications for your belt. This includes the required tensile strength, belt width, cord diameter and pitch, and the grade of the conveyor belt rubber cover. Ensure that these specifications align with the nature of your operation.
  4. Consult with Steel Cord Conveyor Belt Manufacturers: Engage with Gram for our expertise and advice. We can provide personalized solutions and recommendations based on your specific requirements.

Tips for Maintaining Steel Cord Conveyor Belts

1.Regular Inspections: Conduct regular inspections of the conveyor belt to identify any signs of wear, tear, or damage. Early detection of issues can prevent more serious problems and costly downtime.

2.Proper Cleaning: Keep the belt clean from debris and materials that could cause conveyor belt damage. Regular cleaning helps in maintaining the integrity and longevity of the belt.

3.Follow Manufacturer Guidelines: Adhere to the maintenance guidelines provided by the steel cord conveyor belt manufacturers. They offer specific advice on how to care for their products, ensuring optimal performance and lifespan.

4.Training for Personnel: Ensure that your personnel are trained in the proper handling and maintenance of the belt. Knowledgeable staff can significantly contribute to the belt’s upkeep and longevity.

Investing in a high-quality steel cord belt conveyor, and maintaining it properly, leads to significant long-term cost savings. The durability and low maintenance needs of these belts mean fewer replacements and repairs over time, reducing operational costs. The efficiency and reliability of a well-chosen and well-maintained steel cord conveyor belt also contribute to uninterrupted and productive operations, further enhancing its cost-effectiveness.

Tips for Maintaining Steel Cord Conveyor Belts

Where Steel Cord Belt Conveyor Excels

The steel cord belt conveyor is a remarkable innovation in the field of industrial material handling, known for its robustness and versatility. The unique steel cord conveyor belt construction allows these belts to excel in various demanding environments, from mining to construction. This versatility is further enhanced by the expertise of steel cord conveyor belt manufacturers who continuously innovate and tailor solutions to meet diverse industry needs.

  1. Mining Industry
    In the mining sector, steel cord conveyor belts are essential for transporting large volumes of materials such as coal, ore, and minerals. For instance, in a major coal mine, a steel cord belt conveyor was implemented to transport coal over a distance of several kilometers from the mine to the processing plant. This system not only increased efficiency but also reduced transportation costs and environmental impact. A mining engineer quoted, “The durability and reliability of the steel cord conveyor belt are unmatched. It has significantly increased our productivity and reduced downtime.”
  2. Construction IndustryThe construction industry benefits greatly from the use of steel cord conveyor belts, especially in large-scale infrastructure projects. For example, during the construction of a major dam, steel cord belts were used to transport aggregate materials across the site. The project manager stated, “The strength and longevity of the steel cord belt conveyor were crucial in handling heavy loads and harsh conditions on-site. It was a key factor in keeping the project on schedule.” 3. Other Industries
  3. Other Industries
    Steel cord conveyor belts also find applications in industries like cement manufacturing, power plants, and port facilities. In a cement plant, a steel cord belt conveyor was instrumental in moving limestone from the quarry to the plant over a considerable distance. The plant manager noted, “The steel cord conveyor belt construction withstands the abrasive nature of limestone, ensuring continuous operation and minimal maintenance.”One client from a port facility remarked, “Working with leading steel cord conveyor belt specifications has allowed us to customize the belt to our specific needs, resulting in improved handling efficiency and safety.”
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    FAQs about Steel Cord Conveyor Belt

    Steel cord conveyor belts are used in applications requiring high strength, long-distance transportation, and heavy loads. They are commonly found in mining, quarrying, and heavy industrial environments. The steel cords provide superior strength and durability, allowing the belt to carry large amounts of material over long distances with minimal elongation and sag.

    The thickness of a steel cord conveyor belt varies depending on the application and the size of the steel cords used. Typically, these belts range from about 10 mm to 30 mm in thickness. The design considers factors like the size and abrasiveness of the material, the distance of transport, and the belt’s load capacity.

    The elongation of a steel cord belt is relatively low compared to other types of conveyor belts. Typically, steel cord belts have an elongation of less than 0.25% at their rated tension. This low elongation helps maintain consistent belt length and tension, which is crucial for long-distance conveying and precise control.

    The main difference between fabric and steel cord belts lies in their construction and strength. Fabric belts are made with layers of fabric and rubber, suitable for lighter loads and shorter distances. Steel cord belts, constructed with longitudinal steel cords for reinforcement, are designed for heavier loads, longer distances, and higher tensile strength. Steel cord belts also exhibit lower elongation and better resistance to impact and tearing.

    The best angle for a conveyor belt depends on the material being transported and the type of conveyor. For standard belt conveyors, the maximum incline angle is typically around 20 degrees. However, with cleated belts or belts with high-friction surfaces, steeper inclines up to 30 degrees or more can be achieved.

    The tensile strength of a steel cord belt can vary widely depending on the design and the size of the steel cords. These belts can have tensile strengths ranging from about 500 N/mm to over 5000 N/mm. The high tensile strength makes them suitable for long-distance, high-capacity conveying applications.

    A 4 ply conveyor belt typically ranges from about 5 mm to 15 mm in thickness. Each ply adds to the overall strength and durability of the belt. The exact thickness depends on the materials used for each ply and the intended application of the belt.

    The maximum distance between pull cord switches on a conveyor belt is typically around 30 meters (100 feet). This distance ensures that workers can quickly and easily access the emergency stop mechanism from any point along the conveyor, enhancing safety.

    A good elongation for steel, which indicates its ductility, typically ranges from 15% to 25% for most structural steels. Higher elongation values mean the steel can deform more before fracturing, which is important in applications where flexibility and resilience are required.

    The formula for conveyor belt splicing involves calculating the correct splice length and number of steps or plies. This depends on the belt’s width, thickness, and the splicing method (mechanical or vulcanized). The formula varies based on the specific requirements and standards of the conveyor system and the belt manufacturer.

    A conveyor belt system is used to transport materials and goods efficiently from one point to another in various industrial, commercial, and retail settings. It streamlines processes in manufacturing, packaging, mining, and material handling, reducing labor costs and improving productivity and safety.

    A cable conveyor, often used in material handling, uses cables to transport goods or materials. It is particularly useful for moving items in challenging environments, such as across long distances, through tight spaces, or in areas where traditional conveyor systems are impractical.

    A conveyor cord refers to the steel cords used in the construction of steel cord conveyor belts. These cords provide the belt with tensile strength, making it capable of carrying heavy loads over long distances with minimal elongation.

    A gun belt is specifically designed to carry the weight of a firearm and its accessories, offering greater stiffness and durability compared to a regular belt. It is typically thicker and made from high-quality materials to provide support and prevent sagging. A regular belt, on the other hand, is primarily used for holding up trousers and may not have the necessary strength to securely carry a firearm.