Underground Conveyor Design Guide

THERMAL COAL
IMPLEMENTATION [2014-03-03]
UNDERGROUND CONVEYOR DESIGN GUIDE

DOC NO AATC000860
UNDERGROUND CONVEYOR
DESIGN GUIDE
AUTHORISATIONS
NAME
POSITION
Ferreira, Ian
Mechanical Engineer
REVIEWED BY
Schmidt, Thinus
Principal Mechanical
Engineer
REVIEWED BY
Mathews, Darren
AATC Head Opencast

Engineering
REVIEWED BY
Maapola, Phanki
AATC Head of
Engineering,
Underground
Operations
APPROVED BY
Ford, Julian
AATC Head of
Engineering,
Technical Services
and Projects
AUTHOR
SIGNATURE
DATE
Refer to the AATC Document Management System for the latest version of the document. Copyright resides with the
company.
Page 1 of 44
IMPLEMENTATION [Date]

DOC NO AATC000860
CONTENTS
Page
AIM
SCOPE
DEFINITIONS
UNDERGROUND MINING SYSTEM
CONVEYORS
5.1
Section Conveyors
5.2
Trunk Conveyors
5.3
Shaft Conveyors
BUNKER FEEDERS/ UNDERGROUND SILOS
BELT FEEDERS
MATERIAL DESIGN PARAMETER
SUPPORTING STRUCTURES
10
9.1
General Layout
10
9.2
Section Conveyor Drive
10
9.3
Trunk Conveyor Drive
12
9.4
Section Belt Tail Section
13
9.5
Trunk Belt Anchor Point
14
9.6
Shaft Bottom Layout
15
9.7
Section Conveyor Stool and Stringers
16
9.8
Trunk Conveyor Stool and Stringers
17
9.9
Belt Crossings
18
9.10
Belt Skys (Tractor Road Bridge)
18
9.11
Walk under Protection
19
9.12
Section Conveyor Take-Up Structures
19
9.13
Trunk Conveyor Take-Up Structures
20
9.14
Lifting Beams
21
9.15
Civil Design Considerations
22
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10
11
TRANSFER POINTS
23
10.1
Chutes Design Considerations
23
10.2
Chutes Performance
23
10.3
Chutes
24
10.4
Impact Idlers
27
10.5
Skirts
27
10.6
Belt Scrapers and Nip Angles
28
POWER PACK INSTALLATIONS
30
11.1
Drive Specifications
30
11.2
Drive Type Selection
32
12
OVER BELT MAGNETS
32
13
SAFETY AND ENVIRONMENTAL
33
13.1
Illumination
33
13.2
Water
33
13.3
Conveyor Isolation and Protection
34
13.4
Designated Areas
34
13.5
Fire Protection
34
13.6
Dust Control
34
13.7
Guarding
35
13.8
Brakes and flywheels on Conveyors
35
13.9
Fabrication, Construction and Installation
35
13.10 Commissioning
35
14
REFERENCES
37
15
REVISION HISTORY
37
16
APPENDICES
37
APPENDIX A STANDARDS AND SPECIFICATIONS
38
APPENDIX B TRANSITION DISTANCE FOR CONVEYOR BELTS
41
APPENDIX C STANDARD DRAWINGS
42
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DOC NO AATC000860
AIM
The AATC underground conveyor design guide is intended to serve as a best practice reference
to all designers of underground conveyor systems with no specific reference to either
mechanical, structural or civil components but rather to provide an overview to all aspects that
need to be considered in the design of a successful underground conveyor system.
This document shall be read in conjunction with the relevant Anglo American
Specifications as quoted, which shall be issued as part of the equipment and/or contract
enquiry documents.
In project specific cases where the need arise to deviate from any item in this document a
concession must be submitted to and approved by the Engineer in writing.
Where an item is specified with a note stating or equivalent, the Engineer shall be
requested in writing to grant permission to use such an alternative.
SCOPE
This document is to serve as a design guide for all underground conveyor systems.
Although design parameters are given for shaft conveyors, this design guide is focused
more on section and trunk conveyor systems. With regards to shaft conveyors reference
can be made to AATC000859.
DEFINITIONS
Term
Definition
AATC
Anglo American Thermal Coal
CEMA
Conveyor Equipment Manufacturers Association
CM
Continuous Miner
CMA
Conveyor Manufacturers Association
Engineer
AATC Discipline Engineer assigned to the project
FCT
Flexible Conveyor Train
MCC
Motor Control Centre
PFD
Process Flow Diagram
SANS
South African National Standard
RoM
Run of mine
VSD
Variable Speed Drive
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DOC NO AATC000860
UNDERGROUND MINING SYSTEM
Figure 1 Typical underground mine layout (Refer drawing 0000-0000-MED-0097)
CONVEYORS
a)
b)
c)
Normative reference specifications are listed in Appendix A.

All underground conveyors and structures shall be designed and approved by an ECSA
registered professional with the relevant experience.
For conveyor designs, ISO 5048 will take preference over CEMA requirements.
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DOC NO AATC000860
5.1
Section Conveyors
Low Production
Medium Production
High Production and

FCT
800 tph
1000 tph
1200 tph
1200 mm
1200 mm
1350 mm
2 - 4 m/s
2 - 4 m/s
< 4 m/s
Design capacity
per section
*Recommended
belt width
*Recommended
belt speed
Belt type
Belt line
Solid woven (Fire

Solid woven (Fire
Solid woven (Fire
retardant)
retardant)
retardant)
The recommended belt line height is 1000mm
*Recommended
minimum belt class
Class 1250
Belt cover
Splicing
Throughing idlers
Return idlers
Class 1250
0.8 mm PVC, 3 mm top and 2 mm bottom nitrile cover when required

Mechanical clips
The following is a list of preferred mechanical clips for the use on section
conveyors:
Splice
identification
Class 1250
Flexco
Mato Industries
Titan
Not required for section conveyors
35, 127 mm, Series 35, 127 mm, Series

35, 127 mm, Series 25
25
25
(including FCT)
45 Idlers where additional capacity can be justified. Consideration should
also be given where section belt could potentially be used as future trunk
belt.
Two roll V-return
*Recommended pulleys sizes for head, drive and tripper pulleys:

630 mm
630 mm
800 mm, 900 mm
*Recommended pulley sizes for tail and take-up pulleys:
500 mm
500 mm
500 mm
*Recommended pulley sizes for low tension snub and bend pulleys:
400 mm
400 mm
400 mm
Bearing centres
Narrow
Narrow
Narrow
Rubber is the preferred material for lagging pulleys. Alternative is
Lagging/ Crowning
ceramic lined pulleys.
Tail pulleys shall preferably be crowned.
Modular take-up structure shall be used with a rear mounted electric winch
Take-up and winch
(See Take-up section for more details).
*Recommendations are given to the designer and section engineer as a nominal starting
point. The final selection shall be based on the outcome of the detail design.
The use of motorized pulleys shall be advised.
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5.2
Trunk Conveyors
Trunk Conveyor Design Criteria
Design capacity
Belt width
*Recommended belt
speed
Belt type
Belt line
*Recommended belt
class
Belt cover
Splice type
Splice identification
Throughing idlers
Conveyor design capacity to be validated by a simulation study.

Belt width selection to be based on the maximum load profile
anticipated. Recommended belt widths are 1200 mm, 1350 mm,
1500 mm and 1800 mm.
<4 m/s
Solid woven + nitrile cover (Fire retardant)
The recommended belt line height is 1000mm.
Class 1250
0.8 mm PVC , 3 mm top and 2 mm bottom Nitrile cover when
required
Finger splice (hot splice) and mechanical splices under emergency
conditions
0.5 mm Deep, 150 mm from the edge of the belt, within 2.0 m from
the splice, contractors name, unique splice number, month and year
completed
35, 127 mm, Series 25 (152 mm where required)
45 Idlers where additional capacity can be justified
*Head, drive and tripper

pulleys (recommended)
*Tail and take-up
*Low tension and snub
Bearing centres
630 mm, 800 mm, 900 mm, 1000 mm

500 mm
400 mm
Narrow
Rubber is the preferred material for lagging pulleys. Alternative
Crowning/ Lagging
is ceramic lined pulleys.
Tail pulleys shall preferably be crowned.
Fixed take-up structure shall be used with a rear mounted electric
Take-up and winch
winch (Preferred). Side mounted will also be accepted.
* Recommendations are given to the designer and section engineer as a nominal starting
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5.3
Shaft Conveyors
Shaft Conveyor Design Criteria
Design capacity
Belt width
*Recommended belt
speed
Belt type
Belt line
Belt class
Belt cover
Splice type
Splice identification
Throughing idlers
*Head, drive and tripper

*Tail and take-up
*Low tension and snub
Bearing centres
Conveyor design capacity to be validated by a simulation study.

Belt width selection to be based on the maximum load profile
anticipated is not to exceed 75% - 85% of its loading capacity.
< 4 m/s
Solid woven + Nitrile cover (recommended)/ Steel cord (Fire
retardant)
The recommended belt line height is 1000 mm.
Class 1250 (Minimum)
Solid woven: Minimum cover = 3 mm Top and 2 mm bottom. Steel
cord: Minimum cover = 4 mm Top and 2 mm bottom (Final selection
of belt cover to be project specific).
Solid woven: Finger splice (Hot splice) Steel cord: Hot vulcanised
splice
0.5 mm Deep, 150 mm from the edge of the belt, within 2.0 m from
the splice, contractors name, unique splice number, month and year
completed
35, 127 mm, Series 25 (152 mm where required)
45 Idlers where additional capacity can be justified
Anti-runback idlers on incline section > 6 (According to OEM
specifications) Belt clamps may be used as an alternative.
630 mm, 800 mm, 900 mm, 1000 mm
630 mm
400 mm
Wide centres
Rubber is the preferred material for lagging pulleys. Alternative
Crowning/ Lagging
is ceramic lined pulleys.
Tail pulleys to be crowned.
Take-up structure and winch shall be situated on surface. The takeTake-up and winch
up configuration shall have a horizontal travel with a vertical take-up
structure. No tail end take-ups will be considered.
* Recommendations are given to the designer and section engineer as a nominal starting
BUNKER FEEDERS/ UNDERGROUND SILOS

a)
b)
Underground bunkers or silos may be required in order to supply a constant feed of RoM
material onto the shaft belt.
The surge capacity of underground bunkers shall be determined through a bulk flow
simulation.
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DOC NO AATC000860
BELT FEEDERS
a)
b)
c)
d)
e)
f)
Belt feeders will be used to withdraw coal from the underground bunker or silo onto the
shaft belt.
Belt drives shall be fitted with a mechanical drive with either an automated or manual
control system.
The design shall take into account all permanent loads and other loads according to
SANS 10160.
The Contractor shall calculate all horizontal and vertical, static and dynamic loads arising
from start-up, operation, and stopping of the belt feeder. These loads shall be calculated
for full burden depth, or any other operational condition that might lead to greater loads.
Allowance shall be made to take into account high impact from falling material.
The design must consider allowance for removal and installation of belting (designated
pulling, lifting and rigging anchoring points) and standard maintenance routines.
MATERIAL DESIGN PARAMETER

The values tabulated below shall be used as a guide only. Actual values to be confirmed for
the specific reserve.
The plant and equipment shall be designed
Duty
to operate 24 hours a day, 7 days a week
with one 8 hour maintenance shift week.
ROM coal generated from continuous miner
(CM) through feeder breaker. Consideration
shall be given to contamination.
Material handled
Long wall mining and FCT continuous
mining operations must consider additional
volumes of material conveyed.
The run of mine coal will contain
approximately 10% free stone and tramp
metal from the mining operations.
Contamination
Long wall mining and FCT continuous
mining operations will contain approximately
12% free stone and tramp metal.
The particle size distribution will be typical of
material sized to have a maximum top size
Particle size distribution (PSD)
of 300mm. A small amount of material
(<0.5%) of up to 900mm x 700mm x 250mm
may however occur.
*Bulk density (Volumetric)
850 kg/m
*Bulk density (Mass)
900 kg/m
Average 12%
*Moisture content
Dry season 8%
*Material surcharge angle
Wet season 20%

15 - 20
Maximum angle of belt inclination u.o.s.
13
* To be confirmed in the design phase

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DOC NO AATC000860
SUPPORTING STRUCTURES
9.1
General Layout
a)
b)
c)
d)
e)
9.2
Refer to drawing 0000-0000-MED-0097 for a typical layout of an underground mine.

Refer to drawing 0000-0000-MED-0098 for underground civil layout.
Refer to drawing 0000-0000-MED-0099 for underground lighting layout.
Refer to drawing 0000-0000-MED-0100 for underground sub-station layout.
Refer to drawing 0000-0000-MED-0101 for underground substation and sump area layout.
Section Conveyor Drive

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Where space allows, pulleys shall be designed to be fixed on stools to facilitate removal.
A 100mm concrete slab is to be cast around transfer area to facilitate cleaning around
drive unit. Refer to section on civil design considerations.
The head section drive is to be securely anchored to the floor. Refer to AA Spec Ground
anchor bolts for underground coal conveyors.
Section conveyor drive to be skid mounted to allow easy relocation with a modular take-up
structure to compensate belt extensions.
All head sections shall be provided with a means of providing safe access to conveyor
idlers and pulleys.
Head sections shall be designed in such a way that all mechanical equipment can be
inspected and safely maintained with minimal effort.
All conveyor drives shall include a wash down point with the provision that all polluted
water will report to a sump fitted with a pump that reports to the central water reticulation
system (Also refer to civil section for more details).
A belt bridge or any other form of access shall be provided for at both sides of the head
section to allow access to the opposite side of the receiving conveyor belt.
Consideration must be given to equipment size to allow for ease of underground
transportation.
Approximately 150 mm belt clearance is required around structures to prevent the belt
from being damaged in the case of belt misalignment.
Figure 2 - STD ACCWS section conveyor belt drive (ACCWS-051005/4).

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DOC NO AATC000860
Figure 3 - Photo of ACCWS belt drive.
Figure 4 - Photo of ACCWS take-up winch on belt drive.
Page 11 of 44
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DOC NO AATC000860
9.3
Trunk Conveyor Drive

a)
b)
c)
d)
e)
f)
g)
h)
i)
Where possible, pulleys shall be designed to be fixed on stools to facilitate removal.

A 100mm concrete slab is to be cast around the head section to facilitate cleaning around
drive unit. Refer to section on civil design considerations.
All major conveyor support structures shall be fixed to a reinforced concrete foundation
that will safely resist all the loads exerted by the conveyor belt during start-up and normal
operating conditions.
All areas fitted with mechanical equipment higher than1.5m that will require regular
inspection or maintenance shall be fitted with access platforms.
Access platforms shall be provided all around the head chute to facilitate inspection and
maintenance of all mechanical equipment and plate work.
All trunk conveyor drive sections shall include a wash down point with the provision that all
polluted water will report to a sump fitted with a pump that reports to the central water
reticulation system (Also refer to civil section for more details).
A belt bridge or any other form of access shall be provided for at both sides of the head
section to allow access to the opposite side of the receiving conveyor belt.
The power pack of the trunk conveyor should preferably be positioned at a split to allow
ease of access to power packs and pulleys.
Where possible, allowance shall be made for the installation of a lifting beam in order to
facilitate the removal of power packs and pulleys. The mono rail shall be load tested when
installed.
Figure 5 Typical layout of a drive station indicating the required guarding as per the
designated area.
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DOC NO AATC000860
Figure 6 - Cross section through a typical drive station indicating walkways
9.4
Section Belt Tail Section

a)
b)
c)
d)
Where possible, pulleys shall be designed to be fixed on stools. This is to assist with the
removal of pulleys.
Refer to AA Spec Ground anchor bolts for underground coal conveyors with regard to the
fixing of conveyor tail ends.
Tail sections shall be designed in such a way that all mechanical equipment can be
inspected and maintained with minimal effort e.g. tail end bearings to be fitted with an
extended grease point to access from outside of guarding.
Tail-end structure must be stand-alone and fitted with adjustable legs.
Figure 7 - High seam : ACCW-05-894C
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DOC NO AATC000860
Figure 8 - Photo of high seam tail end
9.5
Trunk Belt Anchor Point

a)
b)
c)
d)
e)
f)
Where possible, pulleys shall be designed to be fixed on stools. This is to assist with the
removal of pulleys.
A 100mm Concrete slab is to be cast around tail section to facilitate cleaning around drive
unit. Refer to section on civil design considerations.
Anchor point to be securely fixed to the ground as per AA Spec Ground anchor bolts for
underground coal conveyors (Note: comply to minimum number of anchor bolt
requirements).
The anchor point shall be designed in such a way that all mechanical equipment can be
inspected and maintained with minimal effort.
The anchor point should preferably be positioned in a split section to allow easy access
for maintenance e.g. anchor point bearings to be fitted with an extended grease point to
access from outside of guarding.
Guarding shall be constructed from Flatex welded in a rigid angle iron frame.
Page 14 of 44
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DOC NO AATC000860
g)
As far as reasonably practical, the weight of each individual guard shall not exceed 25 kg.
Figure 9 - Anchor point: ACCW-05-911I
Figure 10 Typical layout of a fixed anchor point also showing the guarding as per designated
area.
9.6
Shaft Bottom Layout

a)
b)
A sump shall be installed in accordance with water balance in order to provide adequate
drainage that reports to the central water reticulation system. Refer to Appendix C for
details on the standard layout of a sump area.
Refer to drawing 000-000-0116 for a typical shaft bottom layout.
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DOC NO AATC000860
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
9.7
All areas around the tail end of the inclined/decline shaft must be free draining.
Storm water and or washing down water that are accumulated at the tail end of the shaft,
must be treated as polluted water.
The polluted water from the tail end must be transported to either the underground water
storage area by means of gravity feed or pumping, or to the surface pollution control dam
by means of pumping.
Gravity feed systems: Polluted water can be managed by feeding into the underground
water storage area trough gravity. V-shaped lined or unlined canals must be designed and
constructed to transport the water to the storage area.
Pumping systems: Polluted water can drain into a constructed sump near the tail end of
the shaft. The polluted water can then be pumped either to the underground storage area
or to the surface pollution control dam. Ensure access for cleaning the sump by means of
mobile equipment.
Install a wash down point at tail ends and transfer points with the provision that all polluted
water will report to a sump fitted with a pump that reports to the central water reticulation
system (Also refer to civil section for more details).
All equipment installations shall comply with fire suppression installation standard (Refer
to AATC fire standard for underground conveyors).
Where the shaft accommodates vehicle access, an arrester sand bed and emergency
crash barrier will be allowed for in the design.
Tail sections and transfer points in the shaft bottom shall preferably be installed in a split
in order to accommodate access and maintenance.
Install reinforced concrete foundations as required for tail ends and transfer stations.
Refer to civil section for more details.
Install adequate illumination. Refer to section on illumination for more details.
Section Conveyor Stool and Stringers

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
Conveyor stools shall be designed to allow for one belt size up on the return idler design.
All run of conveyor will be floor mounted. Exception will be given to roof slung stringers
where it can be proven that floor mounted structures are not practical due to the floor
conditions and where the roof declared competent by the rock engineer (mine specific).
No guarding is required on run of conveyor.
All stool and stringer structures are to be painted as per AAC 164051.
Stringers will be fixed to the stool mounting with M16 bolts and nuts.
Idler spacing: Carry side = 1500mm, return side = 3000mm.
V-return idler frame shall be adjustable to assist with belt training.
Maximum length of stringer shall not exceed 3.0m. The deflection limit shall be L/300.
Each stool structure shall make allowance to fit a pigtail to support the pull key wire.
Height adjustment will be done using a two-bolt system to allow for infinite adjustment.
Garland type idler frames will not be considered in the design of underground conveyors.
Idler frames shall be constructed of tubular cross-sections.
Section conveyor stringers shall be constructed from standard tubular cross-sections.
Section conveyor stringers shall be fitted with two 10mm round bar carry handles.
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DOC NO AATC000860
Figure 11 - Standard stool and stringer arrangement (See Appendix C for standard drawings).
9.8
Trunk Conveyor Stool and Stringers

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
Conveyor stools shall be designed to allow for one belt size up on the return idler design.
All run of conveyor will be floor mounted. Exception will be given to roof slung stringers
where it can be proven that floor mounted structures are not practical due to the floor
conditions and where the roof declared competent by the rock engineer (mine specific).
All trunk conveyor stringers shall be constructed from channel cross-sections.
No guarding is required in non-designated areas.
All stool and stringer structures to be hot dipped galvanized. Paining will be allowed on all
mine employee constructed trunk belts.
Stringers will be fixed to the stool mounting with M16 bolts and nuts.
Height adjustment will be done using a two-bolt system to allow for infinite adjustment.
Idler spacing: Carry side = 1500mm, return side = 3000mm.
V-return idler frame shall be adjustable to assist with belt training.
Maximum length of stringer shall not exceed 4.5m. The deflection limit shall be L/300.
The return belt shall not be less than 500mm from the ground where roof height allows for
it.
Concrete boxed stool specifications:
12 Stools from the tail-end/ anchor point.
12 Stool from the drive/ head pulley.
12 Stool either side of the transfer points or other structures located between these fixed
points.
All stools mounted on a gradient shall be boxed and anchored to the floor.
Every 5th stool is to be boxed and anchored to the floor.
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DOC NO AATC000860
Figure 12 - Trunk run-of-conveyor.
9.9
Belt Crossings
a)
b)
c)
Belt crossings to be supplied as per the mine risk assessment considering belt length and
roof height.
All belt crossings and belt bridges shall be securely anchored to the floor.
Belt crossings shall be adequately illuminated for personnel to safely cross-over.
Figure 13 - Belt bridge (ACCWS-05-1045-2.3m and ACCWS-05-948-2.6m).
9.10
Belt Skys (Tractor Road Bridge)

a)
b)
c)
All belt skies shall be securely anchored to the floor.

Belt sky shall be fitted with access walkways on both sides to allow safe access to
conveyor idlers where ever possible.
The adjacent run-of-conveyor structures should form a gradual angle of approach over the
Page 18 of 44
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DOC NO AATC000860
d)
e)
f)
belt sky in order to minimize the load on the idler rolls.

The design of the belt radius should be such that it will not reduce the life of the rollers.
Use 20 deg troughing idlers across belt sky.
Belts skies shall be guarded in order to prevent personnel from passing underneath the
belt at the graded sections.
Figure 14 - Belt sky /Tractor bridge - used for vehicle crossing (Refer to ACCWS-998).
9.11
Walk under Protection

a)
The walk under protection shall be securely anchored on to the floor.
Figure 15 - Walk under protection (ACCW-05-968).
9.12
Section Conveyor Take-Up Structures

a)
b)
c)
d)
e)
f)
g)
Section belts shall be fitted with a modular take-up structure design.

A guarded electric winch mounted at the rear of the take-up structure shall be used to
apply the required tension.
The take-up structure shall be fixed to the floor according to AA Spec Ground anchor
bolts for underground coal conveyors.
The take-up trolley shall be spragged with four heavy duty chains. Two chains on either
side of the take-up trolley to prevent movement in the long travel direction.
An alternative spragging mechanism is to use a locking bar that passes through the takeup structure and trolley.
Take-up structure guarding shall be constructed from light weight mesh.
As far as reasonably practical, the weight of each individual guard shall not exceed 25Kg.
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DOC NO AATC000860
250
2.0
500
2.5
750
2.75
Conveyor length (m)

1000
1250
4
5
1500
6.5
1750
8.5
2000
10
Table 1- Minimum take-up lengths for section conveyors based on splicing allowance (1.2W) +
elastic stretch
Figure 16 - ISO view of ACCWS modular take-up structure: ACCWS-05-972/2
Figure 17 - ACCWS take-up: side view
9.13
Trunk Conveyor Take-Up Structures

a)
b)
c)
d)
Long belts shall be fitted with a loop take up system.

In the case of FCT and long wall continuous mining operations, additional belt storage may
be achieved with a 4 or 6 lap belt storage system.
As far as reasonably practical, allow for 5 belt splices.
The take-up trolley shall be spragged with four heavy duty chains. Two chains on either
side of the take-up trolley to prevent movement in the long travel direction. The design and
selection of the spragging chains will be in accordance with acceptable engineering
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DOC NO AATC000860
e)
f)
g)
h)
i)
j)
practices and shall be approved by the mechanical discipline engineer.

An alternative spragging mechanism is to use a locking pin that passes through the take-up
structure and trolley. The design of the spragging pin will be in accordance with acceptable
engineering practices and shall be approved by the mechanical discipline engineer.
An electric winch shall be used and preferably positioned in a split section to allow for easy
access and maintenance.
Take-up structure guarding shall be constructed from a light weight mesh.
As far as reasonably practical, the weight of each individual guard shall not exceed 25Kg.
Guarding shall be placed around the take-up rope.
The in-line winch type is preferred.
Figure 18 - Side mounted take-up winch.
Figure 19 - In line winch.
9.14
Lifting Beams
a)
b)
c)
d)
See figure below for details on mounting crawl beams from the roof.
Use 20mm roof bolts with a 190kN load rating.
Fastloc resin to be used (15 Sec curing time).
All design involving roof anchoring shall be approved by a rock engineer.
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DOC NO AATC000860
Figure 20 - Typical arrangement for mounting crawl beams.
9.15
Civil Design Considerations
9.15.1
Structural concrete
a)
b)
c)
d)
e)
f)
g)
9.15.2
All other concrete

a)
b)
9.15.3
All structural concrete is to be designed by a professional civil engineer;

All structural concrete is to have a minimum compressive strength of 30 MPa at 28 days;
All steel reinforcement cover is to be a minimum of 50mm;
All horizontal surface finishes are to be wood float finishes;
All concrete slabs are to drain off the slab at a minimum fall of 1% in the direction of the
collection dam;
All underground slabs (tail ends, transfer tower or head end etc.) is to be cast at least
200mm above the surrounding ground level, ensuring drainage to the collection dam/sump.
Refer to the relevant standards in Appendix A and Appendix C for standard drawings.
All other (non-structural) concrete is to have a minimum compressive strength of at least 20

MPa at 28 days.
Refer to the relevant standards in Appendix A.
Surface Run-off
a)
b)
c)
d)
Concrete ramp on the incline is have a fluted finish at 45 degrees, ensuring self cleaning
in the event of rain or washing
The concrete ramp at the portal is to have a cut-off trench with pump sump to catch and
pump water caught, running down the ramp
All underground transfer points tail-ends etc. - shaping of surrounding ground is be done
to minimum fall of 1% to maintain gravity fed drains to a silt trap sump before entering the
dam.
Refer to the relevant standards in Appendix A.
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DOC NO AATC000860
9.15.4
Dams
a)
10
All underground dams and/or plugs (refer drawing/s). This standard is currently under
review.
TRANSFER POINTS
All transfer points must be treated as critical and must be engineered accordingly in order to
contain the flow of material and ensure continuity from the discharge point to the downstream
equipment.
10.1
Chutes Design Considerations

The following must be considered in the design of chutes and transfer points:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
10.2
Discharge models
Trajectories
Impact models
Free fall models
The specific material properties (moisture content, adhesive stresses, friction angles, etc.)
must be classified.
The flow of material must be represented graphically.
All chutes shall be fitted with lifting lugs.
Liners shall be designed for high impact and high abrasion resistance in underground
conveyor transfers. Liners shall be VRN 400 with a minimum thickness of 12 mm (16 mm
on high impact). Tiles will not be considered for underground operations.
The mass of any individual liner shall not exceed 25 kg.
All steel plates used for structural support shall be 8 mm thick.
All steel plates used for the control of spillage shall have a minimum thickness of 6 mm
fitted with a steel liner.
All steel plates used for covers or dust suppression shall have a minimum thickness of 3
mm.
All transfer points will be fitted with an access platform to allow for inspection and
maintenance.
Allowance must be made for overrun into chute from feed conveyor onto receiving belt.
Chutes Performance
The performance of any transfer point must be determined based on the following factors:
a)
Zero spillage
b)
Minimize material degradation
c)
Efficient dust suppression mechanism that is in accordance with the specific mine
standards.
d)
Engineered to prevent blockages
e)
Minimal impact and abrasion wear
f)
Low noise level
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DOC NO AATC000860
g)
h)
i)
Low maintenance
Accessible to maintain and inspect
Must be easy to clean
Figure 21 - Liner attachment detail
10.3
Chutes
10.3.1
Spiral chutes - Section conveyors

a)
b)
c)
This is the preferred transfer chute for section conveyors up to and including 2200 tph
Adequate dust suppression is required to minimize fugitive material from being released
into the surrounding air.
The chute assembly must be fitted with a working platform for access around pulley and
bearings.
Figure 22 - Spiral chute installation with walkways.

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DOC NO AATC000860
10.3.2
Spiral chutes - Trunk conveyors

a)
b)
c)
This is the preferred transfer chute for trunk conveyors up to and including 2200 tph. When
material transfer exceeds 2200tph, a special transfer chute arrangement shall be
considered (see drawing below).
The chute assembly shall be fitted with a working platform for access around pulley and
bearings.
Figure 23 - Spiral chute installation with walkways.
Figure 24 - Alternative chute for material transfer in excess of 2200 tph.
Page 25 of 44
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DOC NO AATC000860
10.3.3
Open Hood and spoon type

a)
10.3.4
No hood and spoon transfer chutes will be used on underground conveyors where slabs
are anticipated. Special concession must be obtained from the discipline engineer to install
a hood and spoon chute.
Trough chutes (Ski-jump transfer)

a)
b)
c)
d)
A troughing chute may be used for angled installations and piggy back arrangements.
Liner shall be 16mm VRN 400.
Chute must be fitted with a working platform for access around pulley and bearings.
Figure 25 - In line transfer chute with access walkway and also showing impact idlers.
Figure 26 - In line transfer chute with the drive and take-up spaced apart to allow ease of access
and maintenance.
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DOC NO AATC000860
10.4
Impact Idlers
a)
b)
c)
d)
e)
f)
The quick release type impact idlers as seen below are preferred.
Impact beds will not be considered.
Impact rollers shall be installed at all transfer points.
Impact rollers shall be Series 30, 159mm diameter.
Impact idlers shall be spaced at 500mm 750mm centers. The final spacing shall be
verified in the final design phase.
45 Troughing idlers to be used for all impact idlers.
Figure 27 - Quick release type troughing idler.
10.5
Skirts
a)
b)
c)
d)
e)
f)
g)
h)
All skirt boards shall be designed in order to prevent any material from falling of the belt
within the settling zone.
Deep troughed idler frames (45, 60, 80) may be used at transfers with skirt boards,
however, material properties shall be taken into consideration to ensure continuous
material flow.
All skirt boards shall be fitted with a 12mm VRN 400 liner.
Skirt boards shall be designed to allow for easy replacement.
The skirt board length and height shall be adequate to allow for complete settling of the
material.
Minimum skirt board length shall be in accordance with the table below. Specific skirt
design shall be based on actual material size and flow requirements.
The edge of the skirt shall be placed 6mm from the belt at the loading point to 12mm at the
discharge point.
The thickness of the skirt board must be sufficient to withstand pressures from blocked
chute conditions (6mm for light construction and 10mm for heavy construction).
Page 27 of 44
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DOC NO AATC000860
i)
j)
k)
l)
Skirt boards must be stiff enough to prevent side movement that could damage the belt.
Skirt boards shall be supported on structural steel frames.
Caution must be given to belt lift under the skirt board.
No covers will be placed over the skirt boards.
Figure 28 - Typical skirt board layout.
Belt width
1050
1200
1350
1500
1800
1.5
2.4m
2.4m
2.4m
2.7m
3.0m
Belt speed, m/s.

2.0
2.5
3.0m
3.6m
3.0m
3.6m
3.0m
3.6m
3.3m
3.9m
3.6m
4.2m
3.0
4.2m
4.2m
4.2m
4.5m
4.8m
Table 2 - Minimum skirt length for underground belt conveyors.
10.6
Belt Scrapers and Nip Angles
10.6.1
Primary scraper
Primary scrapers are not usually fitted to underground conveyor pulleys.
10.6.2
Secondary scrapers
a)
b)
c)
All head pulleys will be fitted with a double bladed secondary belt cleaner.
The belt scraper must me positioned according to supplier specific requirements.
Ensure that the selected belt scraper is capable of sweeping over the splice that has been
installed on that belt.
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DOC NO AATC000860
10.6.3
10.6.4
Tail protection
a)
Bias plough
A bias plough must be fitted when it is required to scrape material to one side of the
belt only.
The plough must be positioned to allow for clear inspection and quick replacement of
worn scraper blade.
Plough must be of a flexible pressure type.
Plough must be fitted to the main structure with a safety chain in case of mounting
failure.
The plough must provide full belt coverage.
The plough must be positioned that the ejected material can safely be cleaned and
placed back on the belt. Material shall not be scraped of the belt near walkways and
belt crossings or into the tail frame guarding.
b)
V-Plough belt cleaner

Mounted ahead of the tail pulley and nip angle.
Must be spring loaded to apply constant pressure.
Plough must be fitted to the main structure with a safety chain in case of mounting
failure.
The plough must provide full belt coverage.
The plough must be positioned that the ejected material can safely be cleaned and
placed back on the belt. Material shall not be scraped of the belt near walkways and
belt crossings or into the tail frame guarding.
Nip angles
a)
b)
Refer to: AA 375001 Conveyor best practice guide line.

The design of nip angles shall consider access for maintenance and must be adjustable
from the outside.
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DOC NO AATC000860
11
POWER PACK INSTALLATIONS
11.1
Drive Specifications
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
Power packs shall always be positioned as close to the ground as possible.

All power packs will be shaft mounted.
The installation of the power pack will be such that the torque arm will be in
compression.
A 3 ton (minimum) safety chain will be placed over the reducer unit in order to prevent
rotation of the power pack in the opposite direction.
The selection of power packs will be done in consideration of the specific mine standard.
Operations must be consulted to align new designs with existing standards.
Conveyor reducers shall be fitted with a sight glass as a means of level inspection.
Conveyor reducers shall be fitted with an inspection cover to inspect gears.
Conveyor reducers shall be fitted with a sampling port (clearly marked).
Conveyor reducers shall be fitted with a breather
Conveyor reducers shall be fitted with a 3 micron breather in a raised position.
Guarding should preferably be designed to allow visual inspection of fluid coupling
without removing the guard.
Plumber blocks shall preferably be accessible without removing guards. Alternatively,
allowance shall be made for a grease pipe in order to grease bearings.
During the design the design of the conveyor drive bases, provision must be made for
the forklift tines.
Labelling and numbering of drives must be clear and aligned with MCC labelling. All
labelling must be clearly visible.
Figure 29 - Sampling valve on reducer.
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DOC NO AATC000860
Figure 30 - Different sampling ports on reducers: Split type (preferred), Bend type (preferred)
and the straight type (not preferred).
Figure 31 - Approved sampling port installation.
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DOC NO AATC000860
Figure 32 - Approved installation of a raised breather and sampling port.
11.2
Drive Type Selection

The selection guideline table for drive preference on various conveyor applications is shown
below.
Type of conveyor
VSD
Fluid Coupling
U/G - Section
Not permitted
1 choice
U/G - Trunk > 1500 m long
1 choice
Shaft - 50 m+ Lift
1 choice
12
Soft Start
Remark
st
Not permitted
Dusty, Low tech
nd
Not permitted
Variable Speed (variable

loading)
nd
Not permitted
Start up and inspection
st
2 choice
st
2 choice
OVER BELT MAGNETS

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
No oil cooled magnets may be used in underground coal mine operations.

Magnets shall be of the self-air-cooled, self-cleaning in-line type.
Magnet coil to be disc wound with anodized aluminum strip conductor material.
Over belt magnets shall preferably be placed on permanent installed trunk conveyors.
Ensure that over belt magnet is installed and wired according to supplier
recommendations.
Shall be placed in a split to allow easy removal of tramp metal
Isolation numbering must be clearly visible and match upstream MCC feeder panels.
Structure must be secured on a concrete foundation.
Magnets shall be height adjustable.
Support structure shall be designed to allow the magnet to be moved away from the
conveyor for ease of maintenance.
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DOC NO AATC000860
Figure 33 Over-belt magnet support structure.
13
SAFETY AND ENVIRONMENTAL
13.1
Illumination
a)
b)
c)
13.2
Refer to STD.AATC.CON.03 - Haulage Lighting Installation Standard

AATC.ELE.01 - Perform Illumination of Work Area Operations
Illumination specification must comply with MHSA unless otherwise stipulated and
AC.OH.STD.001 Anglo Coal Illumination Standard.
Water
a)
b)
c)
d)
e)
f)
g)
h)
i)
Allowance shall be made for wash down water and provision shall be made for all dirty
water to report to the central dirty water reticulation system.
Allowance shall be made for dust suppression water. The quality of the water shall be
such that any pollutants in the water shall not cause to dust suppression spray nozzles
to block up.
Allowance shall be made for fire protection water as per AATC fire standard for
underground conveyors and equipment.
Section water supply pipes will be placed on the floor right next to the structure to
prevent any obstacle in the walkway next to the belt.
Trunk belts and shaft belts water supply pipes shall be fixed to the run-of-conveyor
structures.
Refer to drawing 0000-0000-MED-0114 for services on section conveyors.
Refer to drawing 0000-0000-MED-0115 for services on trunk and shaft conveyors.
Refer to AA_SPEC_415003 for high pressure mine water reticulation system design.
Refer to AATC_00859 for general mechanical requirements on pipe installations.
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DOC NO AATC000860
j)
k)
l)
13.3
Refer to IM STD 7 Installation and maintenance of sprinkler and other water based
systems.
Refer to IM STD 10 Installation and maintenance of water storage tanks.
Refer to IM STD 11 Installation and maintenance of water spray fixed systems.
Conveyor Isolation and Protection

AAC_SPEC_673018: Conveyor belt protection systems
13.4
Designated Areas
The designated area means the drive section, take-up tension section, snub-pulley section,
transfer point section and tail pulley sections. The drawing below is a good indication of a
typical transfer station showing all relevant guarding requirements.
Figure 34 - Representation of a typical transfer area showing required guarding.
13.5
Fire Protection
Refer to: AATC000169 - Anglo Fire protection Standard for Conveyors and Coal Transfers.
13.6
Dust Control
a)
b)
c)
d)
e)
f)
g)
Dust control is required for health reasons and to reduce the risk of creating an explosive
environment. Refer to AATC mandatory code of practice for an occupational health
program on personal exposure to airborne pollutants (AATC document number to be
advised).
Reduce the air speed in chutes to less than 1.3 m/s.
A passive dust control system is required at all conveyor loading and unloading points.
Low velocity water sprays will be used to increase the cohesive force between particles
(10 50 liter per ton).
Ensure that drop height of material flow is kept to a minimum in order to reduce the
induced airflow at the transfer point.
Where possible, design chutes so that the exit of the material flow is in the same
direction as the receiving belt.
Avoid abrupt changes in material flow.
Ensure that adequate skirting is provided to minimize air from escaping around the belt
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DOC NO AATC000860
and chute interface.
13.7
Guarding
Ref to: AA_BPG_ 375001 Conveyor guarding best practice guide.
Guard panel type
Fixed
Swivel
Light weight
removable
Frame
construction
Guard mesh
Flatex type 348 /

Eq.
Flatex type 348 /
50x50x6L
Eq.
100x20x3
None
Specimesh M389 /
Eq.*
*Aperture size subject to specific application.
50x50x6L
Total mass
50 kg
50 kg
<25 kg
Table 3 - Recommended guarding and mesh detail for underground conveyors.
13.8
Brakes and flywheels on Conveyors

a)
b)
c)
d)
13.9
Brakes must only be installed where absolutely necessary to satisfy design and legal
requirements.
In the event of decline applications, brakes might be considered under a risk assessment
process.
At all times braking systems on u/g conveyor installations should be regarded as high
risk items and all controls thereof shall be approved by the mine.
Flywheels will only be considered under specific conditions as determined by the design
engineer and approved by the AA discipline engineer.
Fabrication, Construction and Installation

AA_SPEC_114002 - Construction of structural steelwork
13.10
Commissioning
a)
b)
The designer of the conveyor system shall develop a full commissioning procedure for
each conveyor belt.
Additionally, refer to conveyor belt extension procedure AADC000474.
Page 35 of 44
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DOC NO AATC000860
Page 36 of 44
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DOC NO AATC000860
14
REFERENCES
15
REVISION HISTORY
Version No.
00
16
Reason for Change

New Document
Date
17/02/2014
APPENDICES
Appendix A
Standards and Specifications
Appendix B
Transition distance for belt conveyors
Appendix C
Standard drawings
Page 37 of 44
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DOC NO AATC000860
APPENDIX A STANDARDS AND SPECIFICATIONS

Document No.
AA_SPEC_114001
AA_SPEC_114002
ACSA_114012
AA_SPEC_114010
AA_SPEC_114011
AA_SPEC_164000
AA_SPEC_164050
AA_SPEC_164051
AA_SPEC_166005
AA_SPEC_166014
AA_SPEC_248002
AA_SPEC_254001
AA_SPEC_255004
AA_SPEC_371001
AA_SPEC_373001
AA_SPEC_373005
AA_BPG_375001
AA_SPEC_377002
AA_SPEC_377003
AA_SPEC_377005
AA_SPEC_377006
AA_SPEC_377008
AA_SPEC_377010
AA_SPEC_415003
AA_SPEC_421017
AA_SPEC_673018
AA_SPEC_999022
AATC000168
AATC000169
SANS 14
SANS 62-1
SANS 121
SANS 719
Description / Title
Design of Steel Structures
Construction of structural steelwork
Design Fabrication, Installation and Maintenance of Open
Grid Grating for Floors, Stairways and Hand railing
Design of Concrete Structures
Construction of concrete work
Users guide for corrosion prevention: System selection
Corrosion Protection of Steelwork with Coatings
Plant colour coding
Lubricants specific requirements for industrial gear oils
Lubricants specific requirements for greases
Materials handling Machines Structural Components
Specification.
Stacking and Reclaiming Equipment Mechanical and
Structural
Apron Feeders
Conveyor pulleys and shafts
Belt conveyor idlers and rolls
Installation tolerances for belt conveyors and structures
Conveyor guarding best practise guideline
Steel cord reinforced conveyor belting
Splicing of steel cord reinforced conveyor belting
Splicing of textile reinforced conveyor belting
Solid woven conveyor belting
Splicing of PVC and nitrile covered Solid Woven Conveyor
Belting
Cold Splicing of Plied (Textile) Conveyor Belting
High Pressure Mine Water Reticulation Systems
General Purpose Valves
Conveyor Belt Protection Systems
Mechanical Standards
Fire protection for buildings and structures
Fire protection for conveyors and coal transfer
Ground anchor bolts for underground coal conveyors
Underground STD 5: Underground conveyors
Electrical Design Criteria
Electrical Substation Specification
Malleable cast iron fittings threaded to IS0 7-1
Steel Pipes Part 1: Pipes suitable for threading and of
nominal size not exceeding 150 mm
Hot dip galvanized coatings on fabricated iron and steel
articles - Specifications and test methods
Electric welded low carbon steel pipes for aqueous fluids
(large bore)
Page 38 of 44
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DOC NO AATC000860
Document No.
SANS 971
SANS 1123
SANS 1173
SANS 1313
SANS 1669
SANS 1366
SANS 1431
SANS 4427
SANS 10083
SANS 10086-2
SANS 10103
SANS 10400
ISO 1461
ISO 5048
AWS D1.1
DD CEN/TS
13001-3-2
PD 5403
BS 21
BS 436-5
BS466
BS 545
BS 1640
BS 3381
BS 3974
BS 3799
BS 6129: Part 1
BS EN 10226-1
BS EN 10241
BS EN 10253-2
Description / Title
Fire retardant textile reinforced conveyor belting (Solid
Woven PVC)
Pipe Flanges
General purpose textile reinforced conveyor belting
Conveyor idlers
Conveyor belt pulleys
Steel cord reinforced conveyor belting
Weldable structural steels
Polyethylene (PE) pipes for water supply
The measurement and assessment of occupational noise
for hearing conservation purposes
The installation, inspection and maintenance of equipment
used in explosive atmospheres Part 2; Electrical
equipment installed underground in mines
The measurement and rating of environmental noise with
respect to land use, health, annoyance and speech
communication
The application of the National Building Regulations
Hot dip galvanized coatings on fabricated iron and steel
articles -- Specifications and test methods
Continuous Mechanical handling Equipment Belt
conveyors with carrying idlers calculation of operating
power and tensile forces
American Welding Society - Structural Welding Code
Cranes General design - Part 3-2: Limit states and proof
of competence of wire ropes in reeving systems
Guidance on safe use of machinery
Pipe threads for tubes and fittings where pressure-tight
joints
are made on the threads (metric dimensions)
Spur and helical gears. Definitions and allowable values of
deviations relevant to radial composite deviations and runout information
Specification for power driven overhead travelling cranes,
semi-goliath and goliath cranes for general use
Specification for bevel gears (machine cut)
Steel butt-welding pipe fittings
Specification for spiral wound gaskets for steel flanges to
BS 1560
Specification for pipe supports. Large bore, high
temperature, marine and other applications. (Withdrawn
but still used in absence of alternative)
Specification for steel pipe fittings, screwed and socket
welding for the petroleum industry
Code of practice for the selection and application of
bellows expansion joints for use in pressure systems.
Metallic bellows expansion joints
Pipe threads where pressure tight joint are made on the
threads
Steel threaded pipe fittings
Butt-welding pipe fittings
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DOC NO AATC000860
Document No.
BS EN 12513
BS2853
Description / Title
Founding. Abrasion resistant cast irons
The design and testing of Steel Overhead Runway Beams
Page 40 of 44
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DOC NO AATC000860
APPENDIX B TRANSITION DISTANCE FOR CONVEYOR BELTS
Figure 35 - Solid woven belt transition distance
Figure 36 - Steel cord belt transition distance
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DOC NO AATC000860
APPENDIX C STANDARD DRAWINGS

Drawing Number
Drawing Title
0000-0000-MED-0080
High seam conveyor layout
0000-0000-MED-0081
Low seam conveyor layout
0000-0000-MED-0082
High seam transfer section
0000-0000-MED-0083
High seam drive section
0000-0000-MED-0084
High seam turnout module section
0000-0000-MED-0085
High seam take-up trolley section
0000-0000-MED-0086
High seam winch bay section
0000-0000-MED-0087
High seam graded section
0000-0000-MED-0088
High seam tractor bridge section
0000-0000-MED-0089
High seam magnet section
0000-0000-MED-0090
High seam tail section
0000-0000-MED-0091
Low seam transfer section
0000-0000-MED-0092
Low seam drive section
0000-0000-MED-0093
Low seam turnout module section
0000-0000-MED-0094
Low seam take-up trolley section
0000-0000-MED-0095
Low seam winch bay section
0000-0000-MED-0096
Low seam tail end section
0000-0000-MED-0097
Underground block plan
0000-0000-MED-0098
Underground civil layout
0000-0000-MED-0099
Underground lighting layout
0000-0000-MED-0100
Underground sub-station layout
0000-0000-MED-0101
Substation and sump area civil layout
0000-0000-MED-0102
Lighting and cable rack layout
0000-0000-MED-0103
High seam 90 hood & spoon layout
0000-0000-MED-0104
High seam 90 dead box transfer
0000-0000-MED-0106
High seam inline ski-jump transfer
0000-0000-MED-0107
High seam angled dead box transfer
0000-0000-MED-0108
High seam reverse angled dead box transfer
0000-0000-MED-0109
Low seam 90 dead box transfer
0000-0000-MED-0110
Low seam 90 spiral transfer
0000-0000-MED-0112
Crawl beam anchor detail
0000-0000-MED-0113
Standard trolley arrangement
0000-0000-MED-0114
Services on section conveyor
0000-0000-MED-0115
Services on trunk and shaft conveyor
P3249-01
1050 BW adjustable structure c/w 1200BW v-return S25
P3249-02
P3249-03
P3249-04
P3249-05
ACCWS-998
Standard 8m belt sky
Note: Refer to tables below for specific dimension related to standard drawings
Page 42 of 44
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DOC NO AATC000860
Legend
A
B
C
D
E
F
G
H
I
J
K
LW
LN
M
N
O
P
Q
R
RS
S
Explanation
Roof Height - If E<2.1m then A should increase. A(New)=(C+D+F)
Haulage Width - If M<2m then B should increase. B(New)=(N+P+2*Q+L+R+2m) OR
B(New)=(H+2*J+2*K+L+2m). Whichever is greater.
Dimension based on a flooded belt with a 400mm slab on top
Workable height from walkway or floor level to carry strand for maintenance and inspection
Average distance between carry and return idler
Minimum workable height >2.1m
Distance to centre on drive pulley (dependent on power pack size)
Minimum walkway clearance between equipment and sidewall
Minimum clearance underneath structure for cleaning purposes
Size is dependent on installed power pack size (refer to table 3 - dimension Y)
Workable size from centre of Plummer block to end of Bikon coupling
Wide bearing centres as per AA_SPEC_371001 Conv Pulleys and Shafts
Narrow bearing centres as per AA_SPEC_371001 Conv Pulleys and Shafts
Travelling side >2m. M=B-(H+2*J+2*K+L).
Minimum walkway clearance between equipment and sidewall
O=G-0.5*Drive Pulley + 0.5*LTU Pulley . O is also the entry to the winch drum
Minimum walkway width on non-travelling side
Workable distance from main steelwork to walkway
Minimum walkway width on travelling side
Rail centres of LTU carriage (can be the same as LN)
Travelling side >2m. S=B-(N+P+2*Q+R+L).
Page 43 of 44
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DOC NO AATC000860
Legend
Explanation
T
U
V
W
X
Y
Z
TA
AS
BS
DA
AA
AB
Dribble Chute Angle

Receiving belts haulage width
Workable distance from floor to receiving belt (1.2m)
Floor to return strand for tractor road access
Gearbox height (based on averages)
Gearbox to Bikon (based on averages)
Output shaft to base of gearbox (based on averages)
Tripper Drive pulley centres (dependant on power pack size and wrap angles)
Access side or travelling way of a conveyor
Blind side or non-travelling way of a conveyor
Distance dependant on drive configuration and drive pulley wrap angles
Jib base length (dependant on jib height and system tensions)
Underpass bridge length (>3m)
Underpass / tractor bridge height (>2.1m for walkways & >2.8m for tractor clearance) these
height are underside of guards
Distance from jib to drive (generally less than one split length away to ensure that drive is
situated in centre of split )
Drive length (dependant on drive configuration and structural design
Turnout module length generally height and system tension dependant
Rail bay length can vary between 3m & 4.5m
Minimum height to be guarded at belt inclination (>500mm)
Magnet Structure height dependant on tripper height, magnet type, magnet weight
Roof clearance above magnet structure generally 500mm for assembly purposes
Distance between pulley and magnet belt (specified by magnet suppliers)
Dimensions must be determined by designer.
AC
AD
AE
AF
AG
AH
MA
MB
MC
*
Page 44 of 44
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Underground Conveyor Design Guide

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Underground Conveyor Design Guide

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THERMAL COAL

UNDERGROUND CONVEYOR DESIGN GUIDE

AATC Head Opencast

UNDERGROUND CONVEYOR DESIGN GUIDE

UNDERGROUND MINING SYSTEM

BUNKER FEEDERS/ UNDERGROUND SILOS

MATERIAL DESIGN PARAMETER

Section Conveyor Drive

Trunk Conveyor Drive

Section Belt Tail Section

Trunk Belt Anchor Point

Shaft Bottom Layout

Section Conveyor Stool and Stringers

Trunk Conveyor Stool and Stringers

Belt Skys (Tractor Road Bridge)

Walk under Protection

Section Conveyor Take-Up Structures

Trunk Conveyor Take-Up Structures

Civil Design Considerations

UNDERGROUND CONVEYOR DESIGN GUIDE

Chutes Design Considerations

Belt Scrapers and Nip Angles

POWER PACK INSTALLATIONS

Drive Type Selection

OVER BELT MAGNETS

SAFETY AND ENVIRONMENTAL

Conveyor Isolation and Protection

Brakes and flywheels on Conveyors

Fabrication, Construction and Installation

APPENDIX A STANDARDS AND SPECIFICATIONS

APPENDIX B TRANSITION DISTANCE FOR CONVEYOR BELTS

APPENDIX C STANDARD DRAWINGS

UNDERGROUND CONVEYOR DESIGN GUIDE

Anglo American Thermal Coal

Conveyor Equipment Manufacturers Association

Conveyor Manufacturers Association

AATC Discipline Engineer assigned to the project

Flexible Conveyor Train

Motor Control Centre

Process Flow Diagram

South African National Standard

Variable Speed Drive

UNDERGROUND CONVEYOR DESIGN GUIDE

UNDERGROUND MINING SYSTEM

Figure 1 Typical underground mine layout (Refer drawing 0000-0000-MED-0097)

Normative reference specifications are listed in Appendix A.

UNDERGROUND CONVEYOR DESIGN GUIDE

High Production and

Solid woven (Fire

0.8 mm PVC, 3 mm top and 2 mm bottom nitrile cover when required

35, 127 mm, Series 35, 127 mm, Series

*Recommended pulleys sizes for head, drive and tripper pulleys:

UNDERGROUND CONVEYOR DESIGN GUIDE

Conveyor design capacity to be validated by a simulation study.

*Head, drive and tripper

630 mm, 800 mm, 900 mm, 1000 mm

UNDERGROUND CONVEYOR DESIGN GUIDE

*Head, drive and tripper

Conveyor design capacity to be validated by a simulation study.

BUNKER FEEDERS/ UNDERGROUND SILOS

UNDERGROUND CONVEYOR DESIGN GUIDE

MATERIAL DESIGN PARAMETER

*Material surcharge angle