IS : 4776 (Part I) - 1977

(Reaffirmed 1999)
Edition 2.1
UDC 621.867.218 (1990-04)

Indian Standard
SPECIFICATION FOR
TROUGHED BELT CONVEYORS
Conveyors, Vertical Hoists and Bucket Elevators Sectional Committee, EDC 61; Belt Conveyors Subcommittee, EDC 61 : 1 [Ref : Doc : EDC 61 (2283)]

PART I TROUGHED BELT CONVEYORS FOR SURFACE INSTALLATION

( First Revision )
(Incorporating Amendment No. 1)

1. Scope — This standard (Part I) covers the requirements for troughed belt conveyors using rubber
and canvas belts conforming to IS : 1891-1968 ‘Specification for rubber conveyor and elevator belting
(issued in 4 parts)’, for handling loose bulk materials within the range of belt widths from 300 mm to
2 000 mm. If other types of conveyor belting are used, requirements in the standard which relate to
belt tensions, and take-up allowances may not be applicable.

1.1 This standard is not applicable to conveyors handling material which does not behave as a solid.

1.2 Guidance on the information to be supplied by the purchaser with enquiry or order and
information to be supplied by the manufacturer, is given in Appendix A.

2. Terminology — For the purpose of this standard, the terms and definitions as given in IS : 4240-
1967 ‘Glossary of conveyor terms and definitions’ shall apply.

3. Dimensions and Capacities

3.1 Size — The size of the belt conveyor shall be the width b of the belt which the conveyor is
designed to carry. It shall be one of the following:

300, 400, 500, 650, 800, 1 000, 1 200, 1 400, 1 600, 1 800 or 2 000 mm.

3.2 A typical belt conveyor arrangement is illustrated in Fig. 1.

3.3 Length — The length of the conveyor is the total length from the axis of the head pulley to the
axis of the tail pulley with all adjustable or telescopic sections adjusted to their shortest length
measured along the path of the conveyor.

3.4 Calculated Conveyor Capacity — The conveyor capacity shall be calculated on the basis of
nominal cross-sectional area of load stream ( see Appendix B ) with due regard to the belt troughing
angle, surcharge angle, density, nature and size of the material being handled, together with the
pitch of the idler sets used on the conveyor installation. The design load shall also take account of
any impact conditions when conveying material containing heavy constituent pieces.

4. Material — The materials used in the construction of troughed belt conveyors shall comply with
the requirements specified in the appropriate Indian Standards.

5. Take-Up Device — A take-up device shall be provided for all belt conveyors. The type of take-up
device shall be mutually agreed to between the purchaser and the supplier. Typical arrangements of
take-up devices are shown in Fig. 2 to 5.

5.1 The allowance for take-up movement based on the centre to centre lengths of conveyor shall be as
shown in Table 1.

Adopted 25 October 1977 © BIS 2002 Price Group 5

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN , 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
 IS : 4776 (Part I) - 1977
FIG. 1 TYPICAL TROUGHED BELT CONVEYOR
2

FIG. 3 TYPICAL GRAVITY WEIGHT OPERATED

TAKE-UP AT INTERMEDIATE POINT OF
FIG. 2 TYPICAL LOOP TAKE-UP DEVICE CONVEYOR
 FIG. 4 TYPICAL SCREW OPERATED TAKE-UP AT TAIL END OF CONVEYOR
3

IS : 4776 (Part I) - 1977

FIG. 5 TYPICAL GRAVITY WEIGHT OPERATED TAKE-UP AT TAIL END OF CONVEYOR
IS : 4776 (Part I) - 1977

TABLE 1 ALLOWANCE FOR BELT ELONGATION TENSIONING AND TAKE-UP

( Clause 5.1 )
Type of Take-up Mechanical Joints Vulcanized Joints
















































100 Percent 75 Percent or Less 100 Percent 75 Percent
Rated Tension Rated Tension Rated Tension Rated Tension

Screw or winch 1.5 percent 1 percent 2 percent 1.5 percent

Automatic 2 percent 1.5 percent 2.5 percent 2 percent
+ 600 mm + 600 mm
Note — The values specified above are only minimum and as far as possible higher values may be employed.

6. Pulleys — The pulleys shall conform to the requirements laid down in IS : 8531-1977
‘Specification for pulleys for belt conveyors’.
7. Idlers — The idlers shall conform to IS : 8598-1977 ‘Specification for idlers and idler sets for
belt conveyors’.
7.1 Pitch of Idler Sets — The pitch of idler sets along the length of the conveyor depends upon a
number of factors, such as tension within the belting, load being carried and transverse stiffness
characteristics of the belt. The pitch should be arranged to ensure adequate support of the load
between idler sets with the sag of the belting not exceeding a maximum of 2 percent of the distance
between idler sets.
7.1.1 In normal circumstances, conveyors arranged with the pitch as indicated in Table 2 may be
found to be suitable.
7.1.2 At loading points, where considerable impact may occur, carrying idlers may be spaced more
closely, and to lessen any impact damage to the belt special types of cushion idlers or other
suitable devices shall be used.
7.1.3 For side idler inclinations greater than 30° it may be necessary to decrease the pitch,
depending upon belt loading conditions and on the nature of the belt in use. In such cases
reference should be made to the conveyor manufacturer.
7.1.4 A set of self-aligning idlers shall be provided at a distance of 15 m on the carrying run and at
30 m on the return run. In case of short conveyors at least one set of self-aligning idlers shall be
provided on the carrying and return run.

TABLE 2 RECOMMENDED PITCH OF IDLER SETS

All dimensions in millimetres.

Belt Width Carrying Idler Sets Density of Material, kg/m3 Return Idler Sets
400 to 1 200 1 201 to 2 800
Recommended Pitch

300
400
1 500 1 000 3 000
500
650

800
1 000 1 000 3 000
1 000

1 200
1 400
1 600 1 000 750 3 000
1 800
2 000

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 IS : 4776 (Part I) - 1977

8. Skirt Plates — Skirt plates are fitted to feed chutes/stringers to guide the material into the
centre of the belt and to prevent spillage. The width between them shall be not more than
two-thirds of the belt width.
9. Trippers
9.1 Travelling trippers may be:
a) hand operated trough gearing, chain or friction;
b) driven by the belt and have hand control of direction of motion;
c) driven by the belt and have automatic control of direction of operation;
d) propelled by independent motor; and
e) propelled by fixed haulage winch.
9.1.1 All operating levers and handles, as well as the lubricating points, shall be within easy and
safe reach of the operators.
9.1.2 Adequate means for locking the tripper in a stationary position shall be provided. If required
by the purchaser, provision shall be made so that the locking device cannot be operated while the
propelling mechanism is in operation, and vice-versa.
9.2 While designing the angle of trippers, it is recommended that the following points may be
taken into consideration.
9.2.1 At least two-thirds of the inclined length of the belt of the tripper rests on the idlers under
loaded conditions.
9.2.2 The inclination of the tripper top shall not be greater than 75 percent of the maximum
conveying angle of the material.
10. Protection of Belt — The stationary parts of the conveyor (idler support brackets,
intermediate section, structural parts, etc), situated close to belt edge shall have streamlined
forms to protect the belt from wear.
11. Electrical Requirements
11.1 Motors — The motors shall be three-phase squirrel cage induction motors complying with
IS : 325-1970 ‘Specification for three-phase induction motors ( third revision )’, operating on 415 V
unless otherwise specified.
11.1.1 Rating — The motors shall have a continuous rating.
11.1.2 Torque — The minimum starting torque shall be twice the full load torque. However, in
case fluid or similar other couplings are employed, a suitable compensation may be made in the
above minimum torque.
11.1.3 Power — The power required for acceleration shall not exceed 100 percent required to
overcome friction in the idlers of the loaded conveyors in the case of level conveyor.
11.2 Control Gear — The controller used in starting and controlling the electric motor may be
reversing or non-reversing.
11.2.1 Rating
a) Voltage rating — The voltage rating of the controller shall be the same as that of the motor
with which it is used.
b) Power rating ( kilowatt rating ) — The kilowatt rating of an electric controller shall not be
less than that of the motor which it controls.
c) Continuous rating — Electric controllers shall have continuous rating.
11.3 Protection for the Motor Circuit — Controllers shall be provided with a means for protecting
the motor which it controls against the circuits, overload, under-voltage and earth leakage.
11.3.1 Protection for the control circuit — All semi-magnetic and full magnetic electric controls
shall be provided with fuses for protection of control circuits.

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IS : 4776 (Part I) - 1977

11.3.2 Emergency stop switch — Suitable means shall be provided for stopping the conveyor in an
emergency at any point throughout its length.
11.4 Load Control Switches — Load control switches or the equivalent shall be used for main belt
conveyors to prevent overloading of the main belt by the feeder belt. The switch automatically
shuts down the feeder belt when the main belt becomes overloaded. The switch then automatically
starts the feeder belt when the load on the main belt becomes normal.
11.5 Belt Slip Protection — A belt-slip protection device is an assembly which causes the power to
be disconnected if the belt slips excessively on the drive pulley.
Note — This is commonly a speed-responsive switch which is driven by the belt and electrically connected to the
conveyor starter. During the starting drive, this switch is held inoperative until the belt has reached a predetermined
speed. Thereafter, if the conveyor belt speed drops below a pre-determined set speed, power to the motor drive is cut-off.

12. Cleaning — Means appropriate to the material conveyed shall be provided for cleaning up of
the belts. The device shall be operative in line and shall be automatic in design so that cleaning
operation is continuous and effective without special attendant requirements. Provisions for
cleaning up pulleys and return belt shall be provided, if required by the purchaser.
13. Lubrication — Provision shall be made, where applicable, for the lubrication of bearings,
including ball and roller bearings. Where fitted, all lubricating nipples shall be readily accessible
from ground level or from a gangway or platform, without removing the guards and shall be
preferably on one side of the conveyor, if specified by the purchaser.
14. Statutory Requirements — The purchaser shall at the time of enquiry disclose to the
manufacturer any additional statutory requirements which the conveyors may be subjected to,
when in use and which are intended to ensure its safe working. The conveyor shall be so
constructed as to comply with these requirements.
Note — A list of the statutory provisions affecting troughed belt conveyors to be used in India is given in Appendix C.

15. Safety Requirements — All safety requirements as specified in IS : 7155-1974 ‘Code of

practice for conveyor safety’ shall be followed in the selection, design and operation of conveyors.
15.1 Wherever the conveyor forms part of the system, the following safety devices shall be
provided:
a) Belt sway switches,
b) Pull cord switches,
c) Overload protection switches,
d) Chute blocade switches, and
e) Overspeed switches.
However the switches at (d) and (e) above shall be provided as required and/or if agreed to
between the purchaser and the supplier.
16. Tools and Accessories — Tools and accessories for belt conveyors shall be provided only
when required by the purchaser and shall be mutually agreed upon between the supplier and the
purchaser.
17. Marking — The belt conveyor shall be marked with the following information on the
name-plate provided on the conveyor at suitable prominent place(s):
a) Manufacturer’s name and identification mark,
b) Purchaser’s equipment code No.,
c) Type and width,
d) Capacity and speed, and
e) Any other information specifically required by the purchaser.
17.1 ISI Certification Marking — Details available with the Indian Standards Institution.

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 IS : 4776 (Part I) - 1977

APPENDIX A
( Clause 1.2 )
SPECIFICATION SHEET BELT CONVEYOR

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IS : 4776 (Part I) - 1977

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 IS : 4776 (Part I) - 1977

APPENDIX B
( Clause 3.4 )
METHOD OF DETERMINING NOMINAL CROSS-SECTIONAL AREA OF LOAD
STREAM
B-1. The method given in this appendix should be used in calculating the nominal cross-sectional
area of load stream ( see Fig. 6 ) for troughed belt conveyors complying with the requirements of
this standard.
The method ignores any transit radii between those parts of the belt in contact with the centre
idler and those in contact with the inclined side idlers, as having a negligible effect on the results.

FIG. 6 NOMINAL CROSS-SECTION OF LOAD STREAM

B-2. Calculations — The notation given below refer to Fig. 6:

S = 0.5 ( b – W ) – ( 0.05 b + 25 )
Where b and W are expressed in mm.
Then area of trapezium = 2S sin × W
----- + S sin × cos
2
= S sin ( W + S cos )
0.5 W + S cos β
R = ---------------------------------------------
sin α
where W and S are in mm.
Nominal cross-sectional area of load stream ( Z ) in m2 (considering it as the sum of the areas
of the segment and the trapezium).
2π
= 10–6 [ S sin ( W + S cos ) + 0.5 R2 ( ---------- α – sin 2 α ) ]
180
where S, W and R are expressed in mm.
B-3. Surcharge Angle — The values of the surcharge angle α in relation to material
characteristics may be obtained from the following table:

Material Characteristics Surcharge Angle, α

Degree
Fluid material and grain 0 to 5
Fine, dry, free-flowing materials 10
Average flowing materials 20
Non-flowing materials 25
Mixed lumps and fines 30

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IS : 4776 (Part I) - 1977
B-3.1 Values of some of the terms containing the surcharge angle α and troughing angle may
then be obtained from the following table:
Angle 5° 10° 20° 25° 30° 35° 45° 55°
Sin α 0.087 2 0.173 6 0.342 0 0.422 6 0.500 0 — — —
2 α – sin α 0.007 0 0.007 0 0.065 3 0.106 6 0.181 2 — — —
Sin — — 0.342 0 0.422 6 0.500 0 0.573 6 0.707 1 0.819 2
Cos — — 0.939 7 0.906 3 0.866 0 0.819 2 0.707 1 0.573 6

The nominal full cross-sectional capacity of the belt (m3/h) = Z × 360 0 V

where V = belt speed (m/s).
B-3.2 Where belts run other than horizontally, the nominal cross-sectional area of load stream (or
nominal cross-sectional capacity of the belt) should be reduced by multiplying by the appropriate
factor from the following table:
Plain Surface Belts Inclination Reduction
Inclined at Angle Factor
Degree
0 to 10 1.0
Above 10 to 15 0.95
Above 15 to 20 0.90
Above 20 0.85
Note 1 — The maximum angle of inclination of the conveyor should be appropriate to the installation and the
characteristics of materials being conveyed.
Note 2 — The above reduction factors are also applicable to declined belts, except where regenerative running
conditions exist. In such cases carrying capacities may be further reduced, and should be subject to agreement between
the manufacturer and the purchaser.

APPENDIX C
( Clause 14 )
LIST OF STATUTORY PROVISIONS AFFECTING CONVEYORS
TO BE OPERATED IN INDIA
C-1. Indian Electricity Act, 1910 (9 of 1910).
C-2. Electricity (Supply) Act, 1948 (54 of 1948).
C-3. Factories Act, 1948 (63 of 1946).
C-4. Coal Mines (Conservation and Safety) Act, 1952 (12 of 1952).
C-5. Mines Act, 1952 (35 of 1952).
C-6. Mines and Minerals (Regulation and Development) Act, 1957 (67 of 1957).
C-7. Coal Bearing Areas (Acquisition and Development) Act, 1957 (20 of 1957).
C-8. Indian Ports Act, 1908 (15 of 1908).
C-9. Indian Duck Safety Act, . . . . . . . . .
C-10. Indian Explosives Act, . . . . . . . . .

EXPLANATORY NOTE
This standard (Part I) was first issued in 1968. While revising the standard the requirements
pertaining to idlers and idlers sets and pulleys have been deleted and reference has been made to
the following standards:
IS : 8531-1977 Specification for pulleys for belt conveyors
IS : 8598-1977 Specification for idlers and idler sets for belt conveyors
This standard is being issued in the following two parts:
Part I Troughed belt conveyors for surface installations
Part II Troughed belt conveyors for underground installations
While preparing this standard assistance has been derived from BS 2890 : 1973 ‘Specification for
troughed belt conveyors’ issued by the British Standards Institution.
This edition 2.1 incorporates Amendment No. 1 (April 1990). Side bar indicates modification of the
text as the result of incorporation of the amendment.
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