Panzerbelt Cable Protection...

Panzerbelt Cable Protection System

Manufactured by Cavotec Specimascom

06177-Panzerbelt 8-01-2008 10:08 Pagina 3

2 • Panzerbelt Cable Protection System

Who we areCavotec is a multinational group ofcompanies serving the followingindustries: mining and tunnelling, portsand maritime, steel and aluminium,energy and offshore, airports, generalindustry and automation. In the early1960’s our main focus was the designand production of motorised cable reelsprimarily for manufacturers of towercranes, harbour cranes and miningequipment. Today, Cavotec is connectingmobile equipment around the world inmany diverse applications.

Where we areThe Cavotec Group consists of 7manufacturing “Centres of Excellence”located in France, Germany, Italy,Norway and Sweden and by 5 localmanufacturing units located in Australia,China, Germany and the USA. For thedistribution of products and providingsupport to customers Cavotec has 27sales companies which, together with anetwork of distributors, serve more than30 countries in five continents. The ultimate objective is to be perceivedas “local everywhere”.

How we workOur aim is to work closely with ourcustomers in order to build long-termpartnerships. To achieve this aim wehave created a working environmentthat attracts the best people, encouragesthem to stay and brings out their bestqualities. By producing totally reliablesystems and backing them with efficientservice, we strive to create true customersatisfaction.

Panzerbelt Cable Protection System

Panzerbelt Cable Protection SystemBased in Italy, Cavotec Specimas is the Cavotec production centre of motorised cable reels, slipring assemblies and Panzerbelt cableprotection systems for use in ports, marine, offshore and tunnelling operations.

One of the early successful developments was the Panzerbelt system illustrated in the following pages. Today, more than 390 instal-lations of the Panzerbelt system are in operation at ports and shipyards around the world, reliably adding years to the life of expen-sive cables.


Panzerbelt Cable Protection System • 3

Cavotec Group Organisation

As shown here, the Cavotec Group isorganised to support its customersaround the world through itsmanufacturing units and sales companies.

Each Cavotec manufacturing company,no matter where it is located, aims atbeing a market leader in its field byproviding innovative and reliableproducts to Group customers.

Each Cavotec sales company, in the 27countries where they operate, aims atbetter serving its local market followingthe Group philosophy “to be localeverywhere”.

Manufacturing network

Centres of Excellence

FranceCavotec RMSSpring Driven Reels

GermanyCavotec AlfoSpring Driven ReelsSlipring Columns

Cavotec FladungAircraft Support SystemsSecurity Systems

ItalyCavotec SpecimasMotorized Cable ReelsPanzerbelt Cable ProtectionSlipring Columns

NorwayCavotec Micro-controlRadio Remote Controls

SwedenCavotec ConnectorsElectrical Plugs & Sockets

New ZealandCavotec MoorMasterAutomated Mooring Systems

Local Manufacturing

AustraliaCavotec AustraliaMotorised Cable Reels

ChinaCavotec ChinaProduct Assembly

GermanyCavotec Micro-controlRadio Remote Controls

SwedenCavotec SwedenProduct Assembly

USACavotec USAProduct Assembly

Group Partners

BelgiumGantryCrane Rail Systems

ItalyBrevetti StendaltoCable ChainsPrysmianFlexible CablesTratos CaviFlexible Cables

Sales network

Cavotec Sales Companies

Cavotec Abu Dhabi

Cavotec Australia

Cavotec Belgium*

Cavotec BeNeLux

Cavotec Brazil*

Cavotec Canada

Cavotec Chile

Cavotec China

Cavotec Denmark

Cavotec Finland

Cavotec France

Cavotec Germany

Cavotec Hong Kong

Cavotec India

Cavotec Italy

Cavotec Korea

Cavotec Latin America

Cavotec Mexico

Cavotec Middle East

Cavotec Norway

Cavotec Russia*

Cavotec Singapore

Cavotec South Africa

Cavotec Sweden

Cavotec Turkey*

Cavotec UK & Ireland

Cavotec USA

* Branch Office



Panzerbelt - a unique system

Yesterday: hinged metal plates

Today: Panzerbelt Cable Protection System.

"Panzerbelt" is a patented systemdeveloped by Cavotec Specimas in themid-70s, with the aim of providingefficient and economic protection topower cables against damage andproblems caused by the increasing crosstraffic in ports and terminals.

The more than 390 installations at workaround the world today, since the firstPanzerbelt was put in operation back in1976 in the Port of Leghorn, Italy, provethat the system is the right solution.Panzerbelt withstands cross traffic of allvehicles normally used in ports withoutpermanent deformation. It preventsspillage of any nature from entering intothe channel and provides the highestdegree of cable protection without theneed of maintenance.


The Panzerbelt System is covered byseveral patents and registrationcertificates. Still, as usually happens withany innovative and successful product,imitations have appeared on the market.We can only say that the wealth oftechnology and experience put in thePanzerbelt System cannot be copied.

Take for example the belt, the mostimportant component of the Panzerbeltcable protection system.

It consists of 13 layers of differentmaterials, including a double layer ofsteel and textile cord, vulcanizedtogether at very high temperature andpressure. The double layer of steel cordmakes the belt rigid in the transversaldirection, and flexible in the longitudinaldirection. This is of fundamentalimportance for trouble-free operation ofthe system.


Guarding against imitations

Panzerbelt original system

Belt imitation



A description of the system

Panzerbelt is a cable protection systemincorporating a continuous semi-flexiblebelt, fabricated from rubber with inlaidsteel reinforcement, which lies over achannel cast in the quay.

The belt is riveted to the quay surfacealong one edge, while the other remainsfree to be raised by a cable guide andbelt lifting device fitted to the crane.Steel reinforcement has beenincorporated to retain flexibility of thebelt in all directions, except transverselyto the channel axis, so that the cableinside the channel is totally protectedfrom vehicles crossing the track and fromobjects falling into the cable duct.

It is possible to convert a hinged platesystem both for conductor bars or cablereel supply to this more flexible coveringsystem. As a result of development, trialinstallations, and practical experience inclose cooperation with its customers,Cavotec Specimas can now offer twoversions, Standard Panzerbelt and theSuper Panzerbelt which offers extrareinforcement in the fixing area for theheavy vehicles passage.

The main advantages of Panzerbelt

Panzerbelt – a continuous flexible covering system for cable channelsand conductor bars trenches – gives numerous advantages to the user.

The 10 most important of these are:

• Total operational safety• Low installation cost• Full cable protection• Maintenance free• No load restrictions

• Channel free from spillage• Operates in any climate• No crane speed limitations• No alignment problems• Easily adaptable to existing systems

1

2

3

4

The main components of the Panzerbelt System:1. stainless steel rivets2. pre-drilled fixing strip3. Panzerbelt steel reinforced rubber cover4. steel channel profile


Standard Panzerbelt type PB

Materials: 80% SBR-Styrene Butadiene Rubber*15% Steel cord

5% Nylon

Reinforcing: Warp: • Two layers of RFL dipped nylon yarn - breaking load 50 kN/m

Weft: • Brass coated steel cord - breaking load 640 kN/m

Super Panzerbelt type SPB (USA and Europe Patent)

Materials: 75% SBR-Styrene Butadiene Rubber15% Steel cord10% Nylon

Reinforcing: Warp: • Two layers of RFL dipped nylon yarn- breaking load 50 kN/m• Two layers of RFL dipped nylon fabric - breaking load 160 kN/m

Weft: • Brass coated steel cord - breaking load 640 kN/m• Two layers of RFL dipped nylon fabric- breaking load 55 kN/m

The most significant feature of thePanzerbelt System is the belt. Itsmanufacture, defined after several yearsof testing and practical experience,allows it to perform conflicting duties; itmust have a high transversal rigidity tosupport all types of vehicles passingover, but it must also possess sufficientlongitudinal flexibility to allow the beltto be lifted into the vertical position.

The belt resists mechanical and abrasivewear thereby minimising maintenancecosts. It is weather and corrosionresistant, and is particularly suitable fordockside environments.

General characteristics of the belt


Technical characteristics

Type dimension A (mm) Weight (kg/m)PB 300 295 ≈ 6.0PB 400 395 ≈ 7.5PB 500 495 ≈ 9.5PB 600 595 ≈ 11.5

Type dimension A (mm) Weight (kg/m)SPB 300 295 ≈ 6.5SPB 400 395 ≈ 8.0

Ambient temperature: - 30°C up to + 80°C

Opening angle: 90° max

Estimated lifetime: > 250,000 cycles (open/close)

Horizontal bending radius: 35m (minimum) with hinge profile external45m (minimum) with hinge profile internal

Maximum load: The maximum load applied on a Panzerbelt System with a 100 mmwide slot should not exceed 400 N/cm2

Maximum breaking load at joint: 1750 kg for standard Panzerbelt2650 kg for SuperPanzerbelt

Elongation: 2% with a load of 3000 N

Approx. length of rolls: 50 m

Max force to open the belt at 90°: 40 kg

A

15

15 30.5 80.5

A

15

15 30.5 80.5

* Other types of rubber and reinforcement layers are available for special working enviroments.


The standard channel

The Panzerbelt channel is made ofstainless steel sheet and serves primarilyas a framework for the creation of aduct in the quay.

Secondly it is shaped to provide a recessfor the belt thus ensuring protection ofits edges. It also carries the additionalprofile that ensures firm fixing of thebelt to the concrete. The standardchannel comes in two meters lengthswith accessories for fast and simpleinstallation on site.

The belt joint

Belt sections are supplied with galvanizedsteel joints already fixed at one end.The rivets used to connect the joints tothe belt sections are the same as thoseused to fix the belts to the channel.


Note: Customized channels available on request.

Channel - lateral view

227.5 327.5 427.5 527.5

402 403 404 405 406

DEPTH(mm)

CODES

627.5



Simple and fast installation

A complete Panzerbelt System consistsof the following components:

• Either Standard or Super reinforcedbelt in rolls of approx. 50m, withjoints at their ends.

• Stainless steel channel AISI 304 orAISI 316, 1.5mm thick, 2 metre longsections.

• Hot dip galvanised 30x8mm fixingstrips, with 13 pre-drilled holes permetre, in 2 meter long sections.

• Stainless steel or nickel copper rivets,13 per metre.

• Earthing copper strips with screwsand nuts.

• Anti-filling and alignment systemwith expanded polystyrene.

• Alignment brackets for channelsections.

Customised components such aschannels, fixing rivets, etc are availableon request.

hannel installation. nd, Busto Terminal.

1.Positioning of a retaining wall and suitable reinforcement. Initial concrete casting fixing thesteel reinforcements.

4.Final alignment and levelling of sections withrespect to crane rail. Welding of sections tosteel reinforcements.

5.Final concrete casting. Removal of installationaids, including polystyrene blocks.

6.Positioning of belt and fixing through the pre-drilled steel strip using rivets.

2.Preparation of a channel section ready forinstallation. (Cross-members not supplied).

3.Positioning of the channel section. Adjacentsections are connected using the polystyreneblocks and the end brackets.



Panzerbelt retrofit

The drawing and pictures show a typicalretrofit application where the customer– Jebel Ali Port, Dubai – decided to usethe Panzerbelt without its channel in anexisting slot.

Our engineering staff is prepared toexamine any application and proposealternative solutions utilising thePanzerbelt System to provide theultimate solution to any specificrequirement.

Jebel Ali Port - Dubai.The pre-existing slot used for the Panzerbelt installation.

Jebel Ali Port - Dubai.The finished retrofit installation 1500 m long.



Every different job requires a customisedapproach which might need someadditional equipment. To meet anyspecific requirements, the Panzerbeltcable protection system can be suppliedwith optionals such as:

1 Stainless steel turnover anchor (singleor double)

2 Junction boxes for connecting the fixed cable to the mobile one

3 Fixed Panzerbelt opening device

4 The belt lifting device. Thanks to thethe characteristics of the flexiblerubber cover, the belt-lifting devicehas a simple and light construction.The device is made of stainless steelwith rollers in nylon charged withmolybdenum and is easily adaptableto existing cable guides or pick-upsystems.

Accessories

Cable

Cable guide device

Belt lifting devicewith nylon rollers

Closed belt

Open belt

1 2

3 4



Panzerbelt installations around the world

The Panzerbelt system is in use allaround the world ensuring that ports areable to function smoothly and efficiently.The number of installations is testamentto the quality and reliability of thePanzerbelt system.

Country N° of installationsArgentina 1

Australia 1

Bahrain 1

Brazil 5

Canada 2

China 4

Costa Rica 3

Croatia 2

Cyprus 1

Denmark 4

Djibouti 2

Egypt 2

France 17

Germany 19

Greece 6

Holland 4

India 1

Indonesia 5

Israel 2

Italy 84

Ivory Coast 1

Jamaica 7

Japan 8

Lebanon 1

Country N° of installationsLibya 2

Lithuania 1

Malaysia 23

Malta 1

Martinique 1

Mexico 10

Morocco 1

Norway 7

Oman 2

Philippines 1

Portugal 2

Singapore 21

Slovenia 1

South Africa 5

South Korea 12

Spain 1

Sweden 8

Tanzania 2

Turkey 4

Ukraine 3

United Arab Emirates 12

United Kingdom 29

USA 51

Yemen 1

TOTAL 384


For more information please visit our website www.cavotec.comor contact us directly at [email protected]

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Cavotec (Swiss) SAVia Serafino Balestra 27CH-6900 Lugano, Switzerland

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