AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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CONTENTS 1 2 3 4 4.1 4.2 4.3 4.4 4.5 4.6 5 6 SCOPE TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER DEFINITIONS REQUIREMENTS SUPPORTING STEELWORK IDLERS PULLEYS TAKE-UPS CHUTES AND SKIRTS BELT CLEANERS QUALITY ASSURANCE PROVISIONS TESTS AND INSPECTIONS

APPENDIX A: RELATED DOCUMENTS APPENDIX B: RECORD OF AMENDMENTS

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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This document supersedes AAC Specification 373005 Rev 2

SCOPE
This specification details the tolerances to be observed when erecting conveyor belt systems and accessories.

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

The following information shall be specified in all tenders, contracts or orders: Reference number, title, date and issue of this specification

DEFINITIONS
For the purposes of this specification the following definitions shall apply: DEAD LOAD : The self weight of a structure excluding all installed equipment and machinery.

The following terms are defined in the General Conditions of Contract: Anglo American, Approved, Company, Contractor, Engineer

REQUIREMENTS
All tolerances stated in this specification are for the dimensions detailed on the relevant drawings.

4.1
4.1.1

SUPPORTING STEELWORK
In plan view, the idler mating bolt holes shall align with each other within 5.0mm longitudinally and within 2.0mm laterally (See Figure 1)

2.0mm FIGURE 1

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Pitch

5.0mm

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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4.1.2

The stringers shall not deviate laterally from the centreline by more than 3.0mm in any 3m length and by more than 25.0mm over the full length of the conveyor stringers (See Figure 2)

C.L Conveyor

3.0mm over any 3.0m length 25.0mm over all stringers

FIGURE 2

4.1.3

The vertical misalignment at the stringer joints shall not be greater than 3.0mm neglecting dead load deflection (See Figure 3)

3.0mm max

Stringer

FIGURE 3

4.1.4

In addition, the difference in levels between opposite stringers (super-elevation) shall be as follows (See Figure 4): not greater than 1/600th of the dimension over the stringers for fixed form idlers not greater than 1/300th of the dimension over the stringers for link suspended idlers.

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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W/600 or

Dimension over stringers W

FIGURE 4

4.1.5

Overland Systems

4.1.5.1 Where the stringer modules in an overland system are subject to undulating ground conditions, (See figure 5) the total difference in the slope between two adjacent modules, irrespective of the gap between the stringer modules, shall not exceed 3 ( 55 : 1000), with the radius limitations as stipulated below. 4.1.5.2 The radius of the belt catenary curve, formed by the difference in slope between two adjacent modules, shall not cause the belt to lift out of the idlers, in the concave case, nor cause a convex radius smaller than the minimum determined for the particular conveyor belt tensions.

W/300

FIGURE 5

4.1.5.3 The alignment of adjacent idler modules shall be such that the overall loading on an individual idler roll or idler set, accounting for any vertical misalignment and including the loads derived from the belt mass and material linear loading at the design capacity for the conveyor system, shall be limited to a value such that the idler L10h bearing life shall be not less than 40 000 hours. In addition, the idler shaft deflection shall remain within the limits of bearing misalignment, including manufacturing tolerances, as stipulated by the bearing manufacturer.

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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4.2
4.2.1

IDLERS
The maximum vertical misalignment between any two adjacent idlers shall be 1mm (See Figure 6)
1.0mm max Pitch FIGURE 6

Pitch

4.2.2

The maximum angular misalignment of any idler shall be 0.5 (See Figure 7)

0.5 ax

Pitch

FIGURE 7

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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4.3
4.3.1 4.3.2

PULLEYS
The angular misalignment of the pulley in relation to the belt centreline shall not exceed 1 in 1000 (0 3' 26") The angular misalignment of the pulley in relation to the horizontal centreline shall not exceed 1 in 1000 (0 3' 26") See Figure 8.

0-3-26 max

PLAN VIEW

0-3-26 max

VIEW A - A
FIGURE 8

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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4.4
4.4.1 4.4.2 4.4.3

TAKE-UPS
The misalignment of pulleys on manual take-ups or on carriages shall comply with the requirements of Clause 4.3 Carriages shall not show any torsional displacement and all wheels of horizontally mounted carriages shall be in contact with the rail under the dead load condition. The greater of L1 and L2 shall not exceed the lesser by more than 0.2% of the wheel gauge (See Figure 9)

L1

L2

Wheel Base FIGURE 9

4.4.4

The maximum deviation from the wheel gauge shall not be greater than 2.0mm and the maximum deviation of the rails and upper guides (if fitted) shall not be greater than 1.0mm in both the horizontal and vertical planes. (See Figure 10)
1.0mm 2.0mm

1.0mm

FIGURE 10

4.4.5 4.4.6 4.4.7

The bottom rail at the joints shall not deviate vertically and horizontally by more than 0.5mm. The rails and wheel treads shall be free from imperfections and weld spatter. The maximum deviation in straightness of rails shall be 1.0mm in any 1.0m length (See Figure 11)
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Wheel gauge

AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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1000mm

1.0mm max

FIGURE 11

4.5
4.5.1 4.5.2

CHUTES AND SKIRTS

When fitted, chutes and skirts shall be fitted so that the deviation from the centreline of the conveyor is not greater than 1.0mm in any 1.0m length (See Figure 12) Skirts shall be clear of the belt.

4.6
4.6.1 4.6.2

BELT CLEANERS
The framework of belt scrapers shall be installed at 90 to the centreline of the conveyor belt within a maximum deviation of 1. Where single return strand plough scrapers are fitted, the return strand plough shall be adequately supported by means of suitably spaced flat idlers arranged so that they can be adjusted to compensate for the detraining effect of the single plough. Where rappers and squeezers are used the alignment shall comply with the requirements of Clause 4.3.
1:1000 (0-3-26)

4.6.3

FIGURE 12

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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QUALITY ASSURANCE PROVISIONS

The requirements of AA STD 100 shall apply.

TESTS AND INSPECTIONS

Conveyor systems and supporting steelwork shall be inspected for compliance with this specification in accordance with the Contractor's Approved procedures. A certificate of compliance with this specification, signed and dated by the Contractor, shall be submitted to the Engineer.

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AA SPECIFICATION INSTALLATION TOLERANCES FOR BELT CONVEYORS AND STRUCTURES

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APPENDIX A: RELATED DOCUMENTS

AA SPEC 373005 Installation Tolerances for Belt Conveyors and Structures

The latest issue of the following documents is deemed to form part of this specification: AA STD 100 : Quality Requirements for Suppliers of Critical Equipment

APPENDIX B: RECORD OF AMENDMENTS Issue 0 : New documents based on AAC Specification 373005 Rev 2 with general updates (P Nel; November 2009)

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