Panzerbelt®

Cable
Protection
System
Cavotec is a leading Panzerbelt® is a system that efficiently and cost
cleantech company effectively protects power cables from damage
that designs and and problems caused by cross-traffic in ports and
delivers connection terminals.
and electrification
solutions to enable The first Panzerbelt® system entered
service in 1976. Today, the system is in
Key benefits:
Replaces steel trench covers
the decarbonization operation at more than 550 installations • Originally designed to replace
around the world, in ports, container antiquated hinged steel trench cover
of ports and industrial terminals, shipyards, steel mills and other plates
heavy industry sites. More than 280,000 • No limitation on crane travel speeds
applications. metres of Panzerbelt® have been • Smooth, quiet operation
installed to date. • Low maintenance
• Cleaner channels, reduced
Panzerbelt® withstands all cross-traffic obstructions
from vehicles typically used in ports Designed for container yard traffic
without permanent • Panzerbelt®: standard belt suitable
deformation. It prevents spillages of all for waterside locations, or occasional
kinds from entering the cable channel traffic
and provides an exceptional degree of • Super Panzerbelt®: reinforced belt
cable protection without the need of suitable for landside locations with
maintenance. heavy traffic crossing
• Corrosion Resistant: stainless steel
channel construction, AISI 304 or AISI
316
Total operational safety
• Cable Protection: cable protected from
mechanical damage, debris, spillage,
sunlight, personnel contact with live
cable
• Dock Surface: elimination of above
ground cable or tray, no personnel trip
hazard, improved surface for vehicle
traffic
• Proven System: more than 550
installations worldwide, more than
280km of belt installed

02
System description

Panzerbelt® is a cable protection system Panzerbelt® System Components

incorporating a continuous semi-flexible 1. Panzerbelt®: supplied in 50m rolls 9. Support Bracket: 2 per 2m section,
belt, fabricated from rubber with inlaid 2. Panzerbelt® Joint Plate: 1 per belt for installation
steel reinforcement, which lies over a roll, preinstalled 10. Self-tapping Screws: 6 per 2m
channel cast in the quay. 3. Joint Plate Rivets: 5 per joint section, for installation
4. Fixing Strip: supplied in 2m sections 11. Copper Earthing Strip: 2 per 2m
The belt is riveted to the quay surface 5. Fixing Strip Rivets: 26 per 2m section
along one edge, while the other section 12. M8 Hardware: 4 sets per 2m section,
remains free to be raised by a cable 6. Panzerbelt® Channel: supplied in 2m earthing strip
guide and belt-lifting device fitted to sections 13. M8 Hardware: 4 sets per 2m section,
the crane. Steel reinforcement has 7. Cable Stand (anti-freeze): supplied in channel joint
been incorporated to retain directional 2m sections 14. Plastic Plug: 4 per 2m section, drill jig
strength and flexibility of the belt. 8. Expanded Poly-Styrene Filler: 1 per 15. Drill Jig: 1 per system
2m section, for installation

3 4

2 15

10 5

14
1

9
6

11 2

12 13

8 7

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Technical The belt

characteristics The most significant feature of the costs. It is weather and corrosion
Panzerbelt® System is the belt. Its resistant, and is particularly suitable for
manufacture, defined after several years dockside environments.
of testing and practical experience, allows
it to perform conflicting duties; it must Panzerbelt® is available in two versions:
have a high transversal rigidity to support Standard Panzerbelt® for light traffic
all types of vehicles passing over, but it applications and Super Panzerbelt® which
must also possess sufficient longitudinal offers extra reinforcement to withstand
flexibility to allow the belt to be lifted into passage of heavy vehicles.
the vertical position.
NOTE: Panzerbelt® is not intended to
The belt resists mechanical and abrasive withstand passage of tracked vehicles.
wear thereby minimising maintenance

Guarding against imitations

The Panzerbelt® System is covered by several registration certificates. Still, imitations

have appeared on the market.

The wealth of technology and experience The double layer of steel cord makes the
put into the Panzerbelt® system cannot belt rigid in the transversal direction, and
be copied. Our belt consists of 13 layers flexible in the longitudinal direction. This is
of different materials, including a double fundamental for trouble-free operation of
layer of steel and textile cord, vulcanized the system.
together at very high temperatures and
pressure.

Panzerbelt® original system Belt imitation

04
Panzerbelt® specifications

Panzerbelt® Super Panzerbelt®

Applications Light vehicle traffic Heavy vehicle traffic
Travel perpendicular to belt Travel at angle to belt, steering over belt
Water side of crane rail Land side of crane rail
Materials* 80% SBR - Styrene Butadiene Rubber 75% SBR - Styrene Butadiene Rubber
15% Steel Cord 15% Steel Cord
5% Nylon Synthetic Fiber 10% Nylon Synthetic Fiber
Transverse Reinforcing Two layers brass coated steel cord Two layers brass coated steel cord
(Weft) Breaking load: 640kN/m each layer Breaking load: 640kN/m each layer
Two layers RFL dipped nylon fabric
Breaking load: 55kN/m each layer
Longitudinal Reinforcing Two layers RFL dipped nylon yarn Two layers RFL dipped nylon yarn
Type dimension A (mm)
(Warp) Weight (kg/m)
Breaking load: 50kN/m each layer Breaking load: 50kN/m each layer
PB 300 295 ≈ 6.0 Two layers RFL dipped nylon fabric
PB 400 395 ≈ 7.5 Breaking load: 160kN/m each layer
PB 500 495 ≈ 9.5
Maximum Wheel Load 8.00N/mm2 at max. channel width 100mm 12.00N/mm2 at channel width 100mm
PB 600 595 ≈ 11.5
7.50N/mm2 at max. channel width 160mm
Belt
15 Thickness
30.5 80.5 16mm 17mm
Ambient
15
Temperature -30°C / +80°C
Opening Angle 90° maximum
A
Force to open 90° 40kg maximum
Estimated Lifetime > 250,000 open/close cycles
Type dimension A (mm) Weight (kg/m)
Restrictions Panzerbelt® is not designed to withstand passage of tracked vehicles
SPB 300 295 ≈ 6.5
* SPB 400material formulations
Other 395 ≈ request
available on 8.0 for low temperature or special applications
SPB 500 495 ≈ 10.0
SPB 600 595 ≈ 12.0

15 30.5 80.5

15

Minimum Horizontal Curve Radius Weight

Nominal Size Dimension 'A' Open side external Open side internal Panzerbelt® Super Panzerbelt®
300 295mm 45m 35m 6.1kg/m 6.4kg/m
400 395mm 45m 35m 8.2kg/m 8.6kg/m
500 495mm 80m 70m 10.3kg/m 10.8kg/m
600 595mm 115m 105m 12.7kg/m 13.0kg/m

The belt joint

Belt sections are supplied with splice joints pre-installed at one end ready to join to the next belt roll. Splice joints are attached
using the same rivets used to fix the belt to the channel. Cavotec also offers a vulcanizing procedure to splice belt sections
together on request.

05
 The standard channel

The Panzerbelt® channel is typically The integral anchoring profile provides

supplied in stainless steel and provides a secure retension of the belt and channel
form for the creation to the concrete.
of a cable duct in the quay. The resulting
cable channel is smooth and free from The standard channel comes in two
sharp edges to reduce wear and damage meters lengths with accessories for fast
to crane cables. and simple installation on site.

The upper surface of the channel is

recessed to locate the Panzerbelt® cover
at grade level, thus ensuring protection of
its edges and providing a level surface for
vehicle and pedestrian traffic.

DEPTH
(mm) 227.5 327.5 427.5 527.5 627.5

Note: Customised channels

CODES 402 403 404 405 406
available on request.

Panzerbelt® channel options

Dual slot channel E-RTG channel

• Store cables in side by side stack • Wide funnel to collect cable
• Reduced depth of installation • Reduced load capacity
• Embedded central slot divider • E-RTG road crossing with hold-open
• 160 mm maximum overall slot width

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Accessories To meet a wide variety of specific requirements, the Panzerbelt® cable protection
system can be supplied with options such as:

1. Stainless steel turnover anchor (single or double)

2. Junction boxes for connecting the fixed cable to the mobile one
3. Fixed Panzerbelt opening device
4. Belt lifting device for cable guides
5. Vault covers or prefabricated pit assemblies

1 2

3 4

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Simple and fast Installation procedure

installation • Position reinforcing bar and concrete • Final concrete pour to grade level
forms • Install Panzerbelt, stretch, drill and rivet
• Suspend channel and position in place • Detailed installation instructions
• Align and brace channel in final position provided with system
• First concrete pour to lock channel base

Panzerbelt® retrofit or formed concrete channel

Our engineers work closely with The diagram and images below show
customers on a wide variety of a typical retrofit application where
applications to develop Panzerbelt® a customer decided to implement
solutions that meet specific requirements. Panzerbelt® without its channel in an
existing slot.

Pre-existing slot used for the Panzerbelt® installation. Completed retrofit, (1,500m in length).

08
After-sales Services is a key element of our value proposition to
service offer a total life cycle solutions for our customers. We
help them maximise the availability of their assets,
reduce operating costs and extend equipment
lifespan.

With 75 service experts in more than 20 For Panzerbelt® Cable Protection System
countries, Cavotec supports customers we offer a range of services:
with a range of service offerings, • Pre-installation check
including: • Site supervision
• inspection, training and preventive • Final inspection of new installations
maintenance • Inspection of existing Panzerbelt®
• spare parts systems
• repair and replacement • Panzerbelt® cover installation or
• equipment renovation and upgrades replacement
• Retrofit solutions or extension to
Furthermore, four service level existing installations
agreements have been developed to
support the maintenance of the 24,000
Cavotec units currently in service
worldwide:
• Cavotec Care
• Cavotec Care Enhanced
• Cavotec Care Enhanced Plus
• Total Cavotec Care

09
References* The first Panzerbelt® system entered
service in 1976. Today, the system is in
terminals, shipyards, steel mills and other
heavy industry sites. More than 280,000
operation at more than 550 installations metres of Panzerbelt® have been
around the world, in ports, container installed to date.

Country No, Installed Country No, Installed

installations Length (m) installations Length (m)
Argentina 2 364 Malaysia 22 7,119
Australia 1 433 Malta 1 1,050
Bahrain 1 1,200 Martinique 2 908
Brazil 13 6,091 Mexico 11 3,519
Canada 4 2,494 Morocco 1 1,610
Chile 3 1,786 Nigeria 1 330
China 8 4,007 Norway 8 1,635
Costa Rica 3 1,155 Oman 3 2,580
Croatia 3 612 Peru 3 1,762
Cyprus 2 1,085 Philippines 1 300
Denmark 4 852 Portugal 2 420
Djibouti 2 750 Qatar 4 3,553
Ecuador 1 694 Russia 3 4,010
Egypt 4 4,708 Sierra Leone 1 265
Finland 1 302 Singapore 24 11,506
France 25 12,247 Slovenia 1 450
Germany 24 8,460 South Africa 6 4,915
Greece 16 13,147 South Korea 6 5,240
Guinea 1 300 Spain 2 824
Holland 6 3,583 Sweden 10 2,082
India 1 400 Syria 1 225
Indonesia 5 1,272 Tanzania 2 1,640
Iran 1 400 Turkey 6 2,871
Israel 4 1,455 Turkmenistan 2 380
Italy 110 61,049 UAE 31 26,559
Ivory Coast 1 425 UK 44 15,706
Jamaica 10 4,453 Ukraine 3 1,560
Japan 8 2,326 USA 80 36,666
Korea 6 2,445 Yemen 1 680
Lebanon 1 580
Libya 1 110
Lithuania 2 476

*As of December 2019

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11
Have Cavotec
contact you!
To discuss your specific requirements
for making your operations safer, more
efficient and more sustainable.

Simply book a call at

www.cavotec.com/contact-us

Disclaimer: specifications are subject to change

without notice.

Issued November 2021.