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Flexsteel® Steel Cable Belt

ContiTech Flexsteel® belts are custom designed to meet the specific needs of the given application, providing superior protection against the abuse of conveying virtually any material.

See the difference with the Flexsteel® Steel Cable Belt

Flexsteel® Belts’ steel cord provides superior impact resistance, with the number and size being selected to meet the desired operating tension and application needs. The insulation gum is specifically designed to encapsulate each steel cord filament to reduce internal friction while providing enhanced adhesion to the cover rubbers. Top and bottom covers provide maximum protection to the steel cord. The cover compounds are specifically designed to meet the demands of the application and are available in a wide variety of rubber types and gauges.

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Flexsteel® Belts
ContiTech Flexsteel® belts are custom designed to meet the specific needs of the given
application, providing superior protection against the abuse of conveying virtually
any material.

Flexsteel® Belts’ steel cord provides superior impact resistance,
with the number and size being selected to meet the desired
operating tension and application needs. The insulation gum is
specifically designed to encapsulate each steel cord filament to
reduce internal friction while providing enhanced adhesion to
the cover rubbers. Top and bottom covers provide maximum
protection to the steel cord. The cover compounds are
specifically designed to meet the demands of the application
and are available in a wide variety of rubber types and gauges.

Flexsteel® Belts
Since we introduced the world’s first steel reinforced belt to
the material handling industry in 1942, we have continued
to advance the technology to satisfy the most demanding
and abusive conveyor applications.
Using state-of-the-art technology, we ensure superior product
design and maximum performance for our customers.
Shipping from six production plants on five continents,
Flexsteel® remains our premium global product.
Our worldwide engineering group continues to design
Flexsteel® specifications that will provide a lower cost-per-ton
of material conveyed for each customer’s unique system

Markets Applications Cover Compounds
› Aggregate
› Cement
› Coal
› Hard rock
› Power generation
› Steel production
› Mainlines
› Overland belts
› Pit belts
› Ship loaders
› Slope belts
› Any high abuse applications
› 6740A
› FR-2G
› FRAR-2G
› FRORS-2G
› Easyrider™
› FRAS-C
› Global X®
› Solar-Shield®
› Stacker®
› Style BLE
› Style B II
› Survivor®
› Survivor® Plus
› Other compounds available on request
See the process diagram for Aggregate, Hard Rock Mining, Sand and Gravel markets on page 6 for alternative belt recommendations.
Get a lower cost-per-ton conveyed. Tension Range: ST500 to over ST10000

Flexsteel® Belts
A Technically Superior Product
Generations of our engineers have been involved for
over 70 years in the design and application of Flexsteel®
conveyor belting. This cumulative experience translates into
state-of-the-art technology, assuring superior product design
and maximum performance for our customers.
Superior strength, durability, ease
of installation
ContiTech's Flexsteel® conveyor belting has provided maximum
protection against pounding and abuse in some of the world's
largest and most demanding applications. Flexsteel® belting is
the only choice when extremely high tensions are present,
having proven itself on copper and oil sands system operations
at 6000 PIW (ST7000) tension.
Flexsteel® is also the preferred belt on long overlands and short
Stacker systems where minimum belt elongation is a critical
design consideration. Flexsteel®’s steel cord reinforcement
elongates a maximum of .25% at rated tension, allowing for
acceptable take-up travel design on long overlands, as well as
short Stacker/Reclaimer systems.
We have the capability to manufacture Flexsteel® belts in long
lengths up to 168 in. (4.2m) roll diameters, or 50 short ton
(45.4 M.T.) rolls at some production locations. This allows for
the minimum number of splices or joints in a conveyor system,
which facilitates faster installation while providing a more
reliable system. Specialized oblong packaging is available to
further maximize belt lengths.
Additional time can be saved during installation by using
another Flexsteel® innovation: Preform™ Splice kits. Preform™ is
a pre-grooved form that simplifies splicing by allowing you to
“sandwhich” the cables coming from either side between the
formed rubber. Not only is the process of splicing made easier,
but the belt itself is made stronger.
You can depend on Flexsteel® steel cord belts to be precisely
engineered to meet rigorous manufacturing standards. Rely on
Flexsteel® for strength, durability and ease of installation.
There are three component parts to
Flexsteel® belting, each one critical to
belt performance:
Zinc galvanized steel cord
Flexsteel® belts are designed by selecting cord construction
to provide the best specification for a particular application.
The cords, made up of many wire filaments, are constructed
to provide high flexibility, low elongation and permit efficient
and high strength splice designs. The galvanized zinc coating
produces a bonding agent between the cord and insulation
gum and provides an important barrier against corrosion.
Insulation gum (core rubber)
Extensive rubber compounding technology has enabled
Flexsteel® engineers to develop a superior insulation gum
bonding rubber, which penetrates and adheres to the steel
cords. The result is excellent adhesions, corrosion resistance
and splice efficiencies.
Outer rubber covers
The advanced compounds in Flexsteel®’s top and bottom
covers are designed to protect the steel cord strength member
against the abusive environmental conditions prevalent in most
conveying applications. Compounds are available to withstand
abrasion, jagged cutting and gouging, high impact, sub-zero
temperatures, moderate heat, hardening effects of ozone
attack and fire propagation. Special service compounds are
available for unique applications, such as the oil sands in
Canada, which require a compound that withstands both low
temperatures and oil.

Flexsteel® Belts
Features & Benefits
High Tension Capabilities
Flexsteel® belts handle the most demanding applications. We continue to lead the industry in
designing the strongest belts to meet the growing demand for long overland systems.
Fewer Transfer Points
Flexsteel®’s high-tension capabilities permit extremely long centers, exceptionally high lifts and
multiple horizontal curves. This allows the designer to reduce the number of transfer points to
minimize a major source of maintenance headaches and downtime.
Limited Take-up Travel
Flexsteel® belts elongate a maximum of 0.25% at rated tension. This allows lower cost take-up
systems on many applications and makes Flexsteel® the preferred choice for long overland and
short stacker/reclaiming systems, where minimum elongation is critical.
Life-long Splices
Our proven splicing methods, validated on our Two-Pulley Splice Tester, result in dynamic splice
efficiencies in excess of the 50% rating defined in DIN 22110 Part 3. With proper technique,
splices on Flexsteel® belts should last the life of the belt. And when your belt is expected to last
20 years, that is a long time.
See Preform™ Patented Splice Technology on page 48.
High Impact Resistance
Our advanced cover compounds and our insulation gum’s superior adhesion combine to provide
the impact, tear and abuse resistance your applications demand.

Exceptional Belt Training
Flexsteel® belts are built in a “uniplane” construction, where cords are laid in precisely the same plane
with tension carefully controlled and equalized under cure. Belts run straight and true because cords
are laid with alternating left and right hand twist. Flexsteel®’s superior troughing characteristics help
ensure that the belt is in constant contact with idlers, which further enhances its ability to
run straight.
Superior Troughing Characteristics
Because Flexsteel® belts are not interwoven in the transverse direction, they offer superior
troughability. Even the highest strength Flexsteel® belts on steep angle idlers will trough perfectly,
leading to easy belt training and full load capacity.
Lower Cost-Per-Ton
Fewer conveyors and splices, shorter take-ups and reduced belt inventory add up to significant
cost savings right up front. Longer belt life, life-long splices, excellent belt training and reduced
downtime save you even more down the road. Overland conveyors are typically more efficient
than trucks or rail. It all adds up to the a lower cost-per-ton of material conveyed, which can make
a major improvement in your bottom line.

Industry-leading Belt Monitoring System
If your operation demands belt rip and transverse tear detection, cord or splice damage detection, look
to ContiTech for periodic assessments or 24/7 real-time monitoring of your ContiTech belt systems.
Packaging the Way You Want It
Packaging options include keeper bars, HEX steel reels and oblong reels. All are designed to
protect your investment and minimize the number of belt splices to lower installation costs,
facilitate field installation and reduce downtime and shipping costs.

Easyrider™ Pulley Covers
There has been significant technical
progress in the transport of bulk materials
in the last several years.
The next step to improved conveyor efficiency is the reduction
of power required to operate these high performance systems.
Just as some tires provide lower rolling resistance depending
upon their construction and compounds, a conveyor belt can
also be designed to provide lower resistance as it rolls over the
support idlers.
The power required to operate a typical conveyor belt has
been studied, both theoretically and dynamically. As the belt
passes over an idler, the pulley cover rubber passes through
a compression/rebound cycle that absorbs power. It has been
determined that on long center horizontal conveyors, the
rolling resistance power loss due to the indentation effect
can reach 61% of the total system power.
Using specialized pulley cover compounds from our Easyrider™
family of low rolling resistance compounds will reduce power
consumption. Our LRR Easyrider™ compound will reduce
energy consumption by up to 20% and our SLRR Easyrider™
compound will reduce energy consumption by up to 32%.
This savings is realized year after year, resulting in an overall
reduction to operating costs.
As an example, if your energy costs are $1 million per year,
a 32% savings available with Easyrider™ represents a savings
of $320,000 compared to other compounds. Over ten years,
this can add up to savings of $3.2 million or more depending
on your operation.

Preform™ Patented Splice Technology
Improves splice strength and saves time.

There have been significant technical advancements in steel
cord belt splicing in the past several years. Our patented
Preform™ splices provide improved splice efficiency, along with
reduced splice time and improved performance. This means
more dollars in your pocket.
Conventional splice methods involve the use of cements and
rubber noodles. Cement drying time extends the overall
splicing time, while providing the opportunity for increased
contamination. The alternative laying of cord and noodle,
further extends splice time, as constant chalk line checking
and adjustment to the noodle width is necessary to maintain
cord alignment. Cord misalignment and contamination are
critical factors in the resultant splice performance.

Preform™ Panel
This illustration shows how the top and bottom multi-groove
panels encase each cord, eliminating the need for noodles to
ensure cord alignment and uniformly accurate spacing.
Preform™ Splice Method
Preform™ splices utilize preformed, multi-grooved top and
bottom cover panels, eliminating the need for cements and
noodles. Cement drying times are eliminated, reducing the
possibility of splice contamination from dust infiltration. Cord
laying time is significantly reduced and the correct cord
spacing and alignment is virtually guaranteed. The result is
a stronger splice, with improved performance and life.
Improved Performance
Testing on the 2-Pulley Dynamic splice tester at our Technical
Center in Marysville, Ohio, shows the results of two identical
belts, one spliced using Preform™ and one spliced using
conventional splicing methods. This one test shows the
Preform™ splice to withstand 33% more load cycles, or a
theoretical 33% longer service life, than the conventional splice.
Static pull splice strength tests conducted at an independent
laboratory showed the Preform™ splice to be at least 10%
stronger than a conventional splice.
Savings
Preform™ splices have been made successfully in many
countries around the world. Savings of 16% to 25% were based
on actual field measurements, comparing one splice technique
versus the other, on the same belt, at the same time. Reduced
splicing time means more uptime and increased productivity.
24 hours to
splice using the
old method
18 hours to
splice using
Preform™
24
22
20
18
16
14
12
10
8
6
4
2
0
Hours
Less Downtime
Preform™ Splices: 25% faster
Conventional
Preform™

Belt Tension Rating
Minimum Ultimate
Tension Operating Tension
Cable Diameter
(Nominal)
Cable Pitch
(Approximate) Belt Modulus
Imperial PIW PIW in. in. PIW
ST800 4568 685 0.142 0.688 329,000
ST1000 5710 856 0.142 0.547 411,000
ST1250 7138 1070 0.173 0.639 514,000
ST1600 9137 1370 0.173 0.498 658,000
ST2000 11,421 1712 0.173 0.398 822,000
ST2500 14,276 2140 0.205 0.428 1,027,000
ST3150 17,988 2697 0.260 0.492 1,294,000
ST3500 19,987 2997 0.315 0.655 1,438,000
ST4000 22,842 3425 0.362 0.753 1,644,000
ST4500 25,697 3853 0.394 0.806 1,849,000
ST5000 28,552 4281 0.433 0.820 2,055,000
ST5400 30,836 4623 0.433 0.764 2,219,000
ST6000 34,263 5137 0.488 0.850 2,466,000
ST6500 37,118 5565 0.488 0.790 2,671,000
ST7000 39,973 5993 0.488 0.738 2,877,000
ST7500 42,828 6421
Contact ContiTech
3,082,000
ST8000 45683 6849 3,288,000
ST8500 48,539 7277 3,493,000
ST9000 51,394 7705 3,699,000
ST9500 54,249 8133 3,904,000
ST10000 57,104 8561 4,109,000
Metric kN/m kN/m mm mm kN/m
ST800 800 120 3.6 17.5 58,000
ST1000 1000 150 3.6 13.9 72,000
ST1250 1250 187 4.4 16.2 90,000
ST1600 1600 240 4.4 12.7 115000
ST2000 2000 300 4.4 10.2 144,000
ST2500 2500 375 5.2 10.9 180,000
ST3150 3150 472 6.6 12.5 227,000
ST3500 3500 525 8.0 16.6 252,000
ST4000 4000 600 9.2 19.1 288,000
ST4500 4500 675 10.0 20.5 324,000
ST5000 5000 750 11.0 20.8 360,000
ST5400 5400 810 11.0 19.4 389,000
ST6000 6000 900 12.4 21.6 432,000
ST6500 6500 975 12.4 20.1 468,000
ST7000 7000 1049 12.4 18.8 504,000
ST7500 7500 1124
Contact ContiTech
540,000
ST8000 8000 1199 576,000
ST8500 8500 1274 612,000
ST9000 9000 1349 648,000
ST9500 9500 1424 684,000
ST10000 10,000 1499 720,000
Tension ratings are available in addition to those shown above. Other cable diameters may be substituted according to individual requirements. Operating tensions are based on a 6.67:1
safety factor. Cable pitch based on 48 in. (1220mm) wide belts.

Flexsteel® Belt Thickness
Imperial
Belt Tension Rating PIW 600-1000 1001-1926 1927-2251 2252-2825 2826-3200
Cable Diameter in. 0.15 0.18 0.21 0.26 0.32
Belt Tension Rating PIW 3201-3500 3501-4200 4201-4650 4651-6420
Cable Diameter in. 0.37 0.40 0.44 0.49
Metric
Belt Tension Rating kN/m ST701-ST1169 ST1170-ST2250 ST2251-ST2629 ST2630-ST3300 ST3301-ST3738
Cable Diameter mm 3.6 4.4 5.2 6.6 8.0
Belt Tension Rating kN/m ST3739-ST4089 ST4090-ST4906 ST4907-ST5432 ST5433-ST7499
Cable Diameter mm 9.2 10.0 11.0 12.4
Approximate belt thickness = cable diameter + cover gauges.
Flexsteel® Belt Weight
Imperial
Belt Tension Rating PIW 685 856 1070 1370 1712
Carcass Weight lb./sq. ft. 1.4 1.5 2.1 2.3 2.6
Belt Tension Rating PIW 2140 2697 2997 3425 3853
Carcass Weight lb./sq. ft. 2.9 4.2 4.4 5.0 5.5
Belt Tension Rating PIW 4281 4623 5137 5565 5993
Carcass Weight lb./sq. ft. 6.3 6.7 7.5 7.8 8.2
Metric
Belt Tension Rating kN/m ST800 ST1000 ST1250 ST1600 ST2000
Carcass Weight kg/sq. m 6.8 7.4 10.3 11.3 12.6
Belt Tension Rating kN/m ST2500 ST3150 ST3500 ST4000 ST4500
Carcass Weight kg/sq. m 14.2 20.4 21.5 24.6 27.0
Belt Tension Rating kN/m ST5000 ST5400 ST6000 ST6500 ST7000
Carcass Weight kg/sq. m 31.0 32.5 36.4 38.4 40.3
Approximate belt weight = carcass weight + cover weight. Minimum pulley cover requirements for belts with Sensor Guard® 3/16 in. (4.8mm). Contact your Sales Representative for
minimum pulley cover that applies to your application. Minimum cover gauge is dependent on the belt rating. Average cover weight per 1/32 in. (1mm) is .19 lb./sq. ft. (1.18 kg/sq. m).
Contact your sales representative for specific weight information.

Recommended Minimum Pulley Diameters
Percent of Rated Tension
Belt Tension Rating >100% - 125% 75 - 100% 50 - 75% <50% Snubs
Imperial (PIW)
600 - 1000 36 30 24 16 16
1001 - 1926 42 36 30 20 18
1927 - 2251 48 42 30 24 24
2252 - 2825 54 48 36 30 30
2826 - 3200 60 54 42 36 36
3201 - 3500 72 60 54 42 42
3501 - 4200 78 72 54 42 42
4201 - 4650 84 72 54 48 48
4651 - 6420 90 78 66 54 54
6421 - 6800 96 84 66 54 54
6801 - 8561 120 102 78 60 60
Metric (kN/m)
ST701-ST1169 1000 800 630 400 400
ST1170-ST2250 1000 1000 630 500 500
ST2251-ST2629 1250 1000 800 630 500
ST2630-ST3300 1250 1250 1000 800 630
ST3301-ST3738 1600 1400 1000 800 800
ST3739-ST4088 1800 1600 1250 1000 1000
ST4089-ST4906 2000 1800 1400 1000 1000
ST4907-ST5432 2000 1800 1400 1250 1250
ST5433-ST7499 2400 2000 1600 1250 1250
ST7500-ST7943 2400 2200 1600 1400 1400
ST7944-ST10000 3000 2500 2000 1400 1400
Snubs are defined as having 6 in. (152.4mm) or less belt contact and tension less than 50% of belt rating. Pulley sizes for Flexsteel® belts are determined by face pressure on the pulley
and/or the pulley-to-cable diameter ratio. All pulleys must be flat as crowned pulleys will cause excessive center tension in the high modulus steel cable product.
Flexsteel® Belts
Recommended Minimum Transition Distance at Half & Full Trough Depth
Minimum Transition Distance ( W = Belt Width ) by Idler Angle
Half Trough Full Trough
Percent of Rated Tension 20 Deg 35 Deg 45 Deg 20 Deg 35 Deg 45 Deg
More than 90% 2.0W 3.4W 4.0W 4.0W 6.8W 8.0W
60% to 90% 1.6W 2.6W 3.2W 3.2W 5.2W 6.4W
Less than 60% 1.0W 1.8W 2.2W 2.0W 3.6W 4.4W
Snubs are defined as having 6 in. (152.4mm) or less belt contact and tension less than 50% of belt rating. Pulley sizes for Flexsteel® belts are determined by face pressure on the pulley
and/or the pulley-to-cable diameter ratio. All pulleys must be flat as crowned pulleys will cause excessive center tension in the high modulus steel cable product.