The Panzerbelt® Cable Protection System

Manufactured by Cavotec Specimas

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Cavotec SpecimasPanzerbelt® System

In the following pageswe illustrate the Panzerbelt® CableProtection System manufactured byCavotec Specimas, sold and servicedby the Cavotec Sales Companies andby a network of Cavotec GroupDistributors.

Our aim isto be local everywhere

Cavotec SpecimasOur fieldsof activity are

Mining,tunnelling

Steel Mills

Forestry

Ports,Terminals

Robots,Automation

Offshore

Based in Italy, Cavotec Specimas isthe Cavotec production centre ofmotorised cable reels, slipringassemblies and Panzerbelt cableprotection systems, for ports, marine,offshore and tunnelling operations.The company started in 1963 with thedevelopment and manufacture of aninnovative cable reeling system whichsoon captured the interest oftechnicians in major ports throughoutEurope. The good customerrelationship which was established,encouraged the company to broadenits range of products in the field ofpower equipment.One of the early successfuldevelopments was the Panzerbeltsystem illustrated in the followingpages. Today, more than 250installations of Panzerbelt system arein operation at ports and shipyardsaround the world.It is a trouble-free, reliable andsmooth operation which adds years tothe life of the expensive cables.Cavotec Specimas has today acquiredthe reputation of being in the forefrontof its sector and the most innovativecable reel manufacturer in the world.

The Cavotec Group

Constructions

Cavotec is the name of a group ofcompanies specialized in power supplytechnology for cranes and otherindustrial equipment. It is formed by6 manufacturing companies located inAustralia, France, Germany, Italy,Sweden and USA, and by 18 Cavotecsales companies which, together witha network of Distributors, serve morethan 30 countries in five continents.Each manufacturing company, nomatter where it is located, aims atbeing a market leader in its field byproviding innovative and reliableproducts to Group customers.Although they manufacture differentproducts in different countries, theyare globally supported andcoordinated by the Cavotec Group intheir product development andmarketing activities.Each sales company, and eachdistributor, has a policy aiming atbetter serving its local market withthe full support of the Cavotec Group.

Great emphasis is put in providing thehighest quality not only in the selectedproducts, but also in service andbacking to their customers.Our philosophy in fact is to be localeverywhere.

The cover picture shows a double Panzerbelt®

installation at Contship's Medcenter terminal,at Gioia Tauro, Italy. A view of the Cavotec Specimas manufacturing plant at Nova Milanese, Milano, Italy.

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The Panzerbelt® Cable Protection System.

"Panzerbelt®" is a patented systemdeveloped by Specimas in the mid-70s,with the aim of giving an efficient andeconomic protection to power cablesagainst damages and problems causedby the increasing cross traffic in portsand terminals.

The more than 250 installations atwork today (2002) around the world,since the first Panzerbelt® was put inoperation back in 1976 in the Port ofLeghorn, Italy, prove that the systemis the right solution.

Panzerbelt® withstands cross traffic ofall vehicles normally used in portswithout permanent deformation.It prevents spillage of any nature fromentering into the channel. It gives thehighest degree of cable protectionwithout the need of maintenance.

In the following pages we give adetailed description of the Panzerbelt®

System.Here we show some images of theconventional cable protection systems— flush steel plate covers — and amaintenance-free Panzerbelt®

installation.

Everglades Terminal, Florida, USA

Today: Panzerbelt®

Yesterday: hinged metal plates

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Panzerbelt® is the Cavotec Specimassolution to a number of problemsconcerning protection of the electricalsupply to mobile equipment inenvironments such as ports, shipyardsand steel mills which have an intensetraffic of haulage vehicles and heavyload transport.The Panzerbelt® System is easy toinstall and guarantees long term,trouble-free operation with no need ofmaintenance.

The background.The traditional method of feedingelectrical power to quayside cranesthrough contact rails has nowvirtually been superseded by cablesystems.However it is still necessary to provideprotection for the cable from quaytraffic and safety regulations in manyports require some form of housing.The simplest and most economicmethod is to provide an open duct,althought this is a hazard topedestrians and can easily becomeclogged by debris, possibily damagingthe cable.Another solution is to provide a raisedcable support, but this cannot beadopted where traffic crosses thecrane’s path and therefore has limitedapplication.A more sophisticated solution is tocover the duct with hinged metalplates, as frequently used in contactrail installations. This systemhowever, suffers from manydrawbacks since maintenancerequirements are considerable.Moreover, the complex design of theplate lifting mechanism slows transitspeeds and can cause costly downtime.

Panzerbelt®.A description of the system.

The solution.Panzerbelt® is a cable protectionsystem incorporating a continuoussemi-flexible belt, fabricated fromrubber with inlaid steel reinforcement,which lies over a channel cast in thequay. The belt is riveted to the quaysurface along one edge, while theother remains free to be raised by acable guide and belt lifting devicefitted to the crane.Steel reinforcement has beendeveloped to retain flexibility of thebelt in all directions, excepttransversely to the channel axis, sothat the cable once in the channel, istotally protected from vehiclescrossing the track and from objectsfalling into the cable duct. It is alsopossible to convert a hinged platesystem both for conductor bars orcable reel supply to this more flexiblecovering system.

Stainless steel rivets

Pre-drilled fixing strip

Panzerbelt® steel reinforced rubber cover

Steel channel profile

A Panzerbelt® installation at Kawasaki ContainerTerminal, Tokyo, Japan.

The main components of the Panzerbelt® System.

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Two versions:Standard Panzerbelt®

Super Panzerbelt®

As a result of development, trialinstallations, and practical experiencein close cooperation with itscustomers, Cavotec Specimas can nowoffer two versions of the Panzerbelt®

System: Standard Panzerbelt® andSuper Panzerbelt® .

Standard Panzerbelt® is designed toallow traffic of most vehicles used inharbours, including container carrierswith small solid wheels such as Mafiwagons.

Super Panzerbelt® offers an extraadvantage as it allows heavy vehiclesand fork-lift trucks not only to passover the belt, but also to have theirwheels turning on top of the belt.This is a typical application for landside installation with heavy traffic.

A number of reasons in favour of Panzerbelt®.Panzerbelt®— a continuous flexible covering system for cablechannels and conductor bars trenches — gives numerousadvantages to the user.

The 10 most important reasons are:❍ Total operational safety❍ Low installation cost❍ Full cable protection❍ Maintenance free❍ No load restrictions❍ Channel free from spillage❍ Operates under any climatic conditions❍ No crane speed limitations❍ No alignment problems❍ Easily adaptable to existing systems

Exologan Terminal, Buenos Aires, Argentina.

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15 30,5 80,5

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Technical characteristics of the Panzerbelt® System.

Standard Panzerbelt® type PB

Materials: 80% SBR-Styrene Butadiene Rubber*15% Steel cord5% Nylon

Reinforcing: Warp:RFL dipped nylon yarnBreaking load 12 kN

Weft:Brass coated steel cord Breaking load 720 kN/m

Super Panzerbelt® type SPB (USA and Europe Patent)

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

Reinforcing Warp:RFL dipped nylon yarnBreaking load 12 kNTwo layers specially composed of synthetical fibresPolyestere yarn – Breaking load 20 kNWeft:Brass coated steel cord Breaking load 720 kN/mPolyamide yarn – Breaking load 20 kN

General characteristics of belt.

Ambient temperature: - 30°C...+ 80°COpening angle: 90° maximumEstimated lifetime: > 250.000 cycles (open/close)Horizontal bending radius with hinge profile externally: min. 30m

with hinge profile internally: min. 70mMaximum load: The maximum load applied on a Panzerbelt® System

with a 100 mm wide slot should not exceed 400 N/cm2.

Elongation: 2‰ with a load of 3000 N.Approx. length of rolls: 50m.

Type dimension A (mm) Weight (kg/m) Type dimension A (mm) Weight (kg/m)

SPB 300 295 ≈ 6.5SPB 400 395 ≈ 8.0

The belt.

The most significant feature of the Panzerbelt® System isthe belt.Its manufacture, defined after several years of testing andpractical experience, allows it to perform conflicting duties;as it must have a high transversal rigidity to support alltypes of vehicles passing over, but it must also possess

sufficient longitudinal flexibility to allow the belt to belifted into the vertical position. In addition it is alsoresistant to mechanical and abrasive wear thus minimisingmaintenance costs. It is weather and corrosion resistant-particularly in view of normal marine environmentconditions.

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

PB 300 295 ≈ 6.0PB 400 395 ≈ 7.5PB 600 595 ≈ 11.5

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The channel.

The Panzerbelt® channel, made ofstainless steel sheet, according tocustomer requirements, servesprimarly as a formwork for thecreation of a duct in the quay.Secondly it is shaped to provide arecess for the belt thus ensuringprotection of its edges. It also carriesthe additional profile that ensures afirm fixing of the belt to the concrete.The standard channel comes in twometers lengths with accessories forfast and simple installation on site.

Standard channels (for belts PB 400 and SPB 400)

NOTE: Customized channel available on request.

627,5227,5 327,5 427,5 527,5

402 403 404 405 406

DEPHT(mm)

CODES

NOTE: Customized channels available on request

The belt joint.Belt sections are supplied withgalvanized steel joints already fixedat one end.The same rivets - available for fixingthe belt - are used to connect the jointto the next belt section.

The channel interlock front view.

The special channel.For the US market a special channelwith interlocks and pre-drilledchannel fixing holes is available.

The channel interlock side view.

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Panzerbelt® : simple and fast installation.

The supply of a Panzerbelt® Systemconsists of the following components:

■ The Panzerbelt® both Standardand Super reinforced belt, in rollsof approx. 50m, with a joint at oneend.

■ Stainless steel channel AISI 304,1,5 mm thick, in different sizes,2 meter long sections.

■ Hot dip galvanised 30x80mmfixing strips, with 13 pre-drilledholes per meter, in 2 meter longsections.

■ Stainless steel or nickel copperrivets, 13 per meter.

■ Earthing copper strips with screwsand nuts.

■ Anti-filling and alignment systemwith expanded polystyrene.

■ Alignment brackets for channelsections.

Customized components such aschannels, fixing rivets, etc areavailable on request.

The installation of the Panzerbelt®

System is a simple and fast operation.The main steps are illustrated here.To insure correct installation Panzerbelt®

should be put under tension by firstfixing one end, pulling initially with aforce of 3000 N± 500N, releasing to 750N± 250N, then fixing at the otherextremity. Repeat for every 50m length.

1 Section through typical quayside with crane railbeam cast.Depth A to be equal to depth of channel + 30 cm.

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Positioning of a retaining wall and suitablereinforcement. Initial concrete casting fixing thesteel reinforcements (dim. X = 10 cm approx.).

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

4 Positioning of the channel section.Adjacent sections are connected using thepolystyrene block and the end brackets.

5 Final alignment and levelling of sections withrespect to crane rail.Welding of sections to steel reinforcements.

6 Final concrete casting.Removal of installation, including polystyreneblocks.

7 Positioning of belt and fixing through the pre-drilledsteel strip using rivets.

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Typical Panzerbelt® channel installation.Hupac of Switzerland, Busto Terminal.PB

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The belt lifting device.

Thanks to the characteristics of theflexible rubber cover, the belt-liftingdevice is a simple and lightconstruction.The device is made of stainless steelwith rollers in nylon charged withmolybdenum and is easily adaptableto existing cable guides or pick-upsystems.

Belt lifting devicewith nylon roller

Open beltClosed belt

Cable guidedevice

Cable

Accessories.

According to the end users' technicalspecifications, the Panzerbelt® systemcan be supplied with optionals like:

1 Stainless steel turnover anchor,single or double

2 Junction boxes for connectingthe fixed cable to the mobile one

3 Fixed Panzerbelt® opening device

4 Electrical connectors, mediumvoltage with optical fibre

5 Panzerbelt® lifting device

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2 3 4

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Drawing and pictures show a typicalretrofit application where thecustomer – Jebel Ali Port, Dubai –decided to use the Panzerbelt®

without its channel in an existing slot.Our engineering staff are prepared toexamine any application and proposealternative solutions utilizing thePanzerbelt® System.

Retrofit.

Panzerbelt® retrofit.

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

installation.

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

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Panzerbelt® – a unique system.

The Panzerbelt® System is covered byseveral patents and registrationcertificates. Still, as it usuallyhappens with any innovative andsuccessful product, imitations haverecently appeared on the market.Here we can only say that the wealthof technology and experience put inthe Panzerbelt® System cannot easilybe copied. Take for example the belt,the most important component of thePanzerbelt® cable 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 cord makesthe belt rigid in the transversaldirection, and flexible in thelongitudinal direction. This is offundamental importance for thetrouble-free operation of the system.The pictures below show an originalPanzerbelt® installation followed bythe installation of a belt imitation.

OriginalPanzerbelt®

Panzerbelt®

original systemBeltimitation

Belt imitation

The picture proves the difference between the originalPanzerbelt® and a belt imitation which shows earlysigns of severe belt deterioration.

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Cable Reels to Panzerbelt®.

Typical complete system supplied byCavotec, composed of "Pull & Store" cablereel, flexible cable and Panzerbelt®.

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Motorised cable reels are mainlydivided in applications for Horizontaland Vertical Reeling, and a distinctionis made for Intermittent Duty orContinuous Duty applications.For Intermittent Duty applicationsCavotec Specimas normally uses theHydrodynamic System, which isparticularly suitable for theseapplications due to its simplicity andhigh reliability. Compact design, eventorque output in reeling and unreelingmode, standard motor and lowmaintenance are some of the featuresof this system. More than 50.000 unitshave been produced by CavotecSpecimas in almost 40 years.

The Panzerbelt system described inthis catalogue is a vital component ofthe cable management programdeveloped by Specimas since 1963.Cable Reels manufactured by CavotecSpecimas are today at work in anumber of ports, terminals, mines,tunnels and industries all overthe world. The range of CavotecSpecimas motorised cable reels hasbeen enlarged to cover almost anyapplication and requirement.Here we give some basic informationabout the Cavotec Specimas cablereels. A specific publication on thecable reels technology is available onrequest.

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Halmstad, Sweden, Cavotec Specimas Panzerbelt® and reel working at minus 35°C

Evergreen Terminal, Taranto, Italy - Fantuzzi Crane

Cavotec Specimas cable reels with "pull and store" andPanzerbelt ® in operation at Everglades Terminal, USA.

Cavotec Specimas cable reels in operation onFantuzzi, Ansaldo Reggiane container cranes at thePort of Voltri, VTE, Italy.

Cavotec Specimas Panzerbelt ® in operation inSouthampton, United Kingdom.

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For Continuous Duty applicationsCavotec Specimas uses the new family ofT-series gear-boxes, which can be usedwith several drive systems of whichthe frequency inverter -CDC- is themost popular. In order to optimisecosts and technique, Cavotec Specimasuses different drive systems for differentapplications and sizes.

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253 Panzerbelt® installations around the world.

Innovation is a basic assetof Cavotec Specimasmanufacturing.The Panzerbelt® Systemfully proves such acharacteristic. It is in facta unique and exclusivesystem of cable protectionwhich guarantees longterm trouble-freeoperation.The 253 existinginstallations in portsaround the world, having atotal length over 300 km,carried out during theyears are still in operation,in hot enviroments as wellas in extremely cold ones,like the minus 35°C in aScandinavian port.Here is the list of countrieswhere Panzerbelt® is at work.

Country N° of installationsArgentina 1Australia 1Brazil 3Cyprus 1Costa Rica 2Denmark 2Djibouti 2Dubai 3Egypt 1England 24Filippine 1France 12Germany 17Greece 4Holland 2Italy 71India 2Indonesia 3Israel 1Ivory Coast 1Yemen 1Japan 1Jamaica 2Korea 2Lituania 1Malaysia 12Malta 1Martinique 2Mexico 6Norway 6Oman 2Portugal 2Singapore 10Slovenia 1South Africa 4South Korea 5Spain 1Sweden 6Tanzania 2Turkey 2Ukraine 2U.S.A. 28

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Los Angeles, USA

Freeport, Malta

Hamburg, Germany Brani, Singapore

Southampton, UKDurban, South Africa

Salalah, Oman Pasir Panjang, Singapore Hamburg, Germany

Kawasaki, Tokyo, Japan Algeciras, SpainOakland, USA

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Power supply and crane technology

Cavotec GroupManufacturing Companies

Cavotec GroupSales Companies and Distributors

Cavotec GroupHeadquarters

The NetherlandsCavotec Group Holdings N.V.Postbus 213NL-2950 AE Alblasserdamphone: int. 31-78-693 0794fax: int. 31-78-693 1212

U.K.Cavotec International LtdStirling Way, Market DeepingLincolnshire PE6 8ASphone: int. 44-1778.346 769fax: int. 44-1778.341 850

For more information consultour home page on the Internet:www.cavotec.comE-commerce sites:www.cavotecshop.comwww.flexiblecables.com

AustraliaCavotec MetoolCardiff (Newcastle)Perth

FranceCavotec RMSCergy Pontoise (Paris)

GermanyCavotec AlfoOverath (Köln)

ItalyCavotec SpecimasNova Milanese (Milan)

SwedenCavotec ConnectorsDalby (Malmö)

U.S.A./CanadaCavotec Inc.Statesville, NC

ArgentinaCavotec Latin AmericaBuenos Aires

AustraliaCavotec MetoolCardiff (Newcastle),Brisbane, Sydney, Perth,Melbourne

BeNeLuxCavotec BeneluxAlblasserdam (Rotterdam)The Netherlands

BrasilMarlin GantrexRio de Janeiro

ChileGantrexSantiago

ChinaCavotec ChinaShanghai

DenmarkCavotec DanmarkOdense

EgyptAse, Cairo

FinlandCavotec FinlandEspoo (Helsinki)

FranceCavotec RMSCergy Pontoise (Paris)

GermanyCavotec AlfoEschborn (Frankfurt)

Hong KongCavotec Hong KongShatin

IndonesiaCavotec IndonesiaJakarta Utara

ItalyCavotec ItaliaNova Milanese (Milan)

JapanNippon IcanTokyo

KoreaCavotec KoreaUlsan

NorwayCavotec NorgeDrammen

Saudi ArabiaAKTEDammam

SingaporeCavotec SingaporeSingapore

South AfricaGantrexGermiston

SwedenCavotec SverigeStockholm

TaiwanEhrung IndustrialTaipei Hsein

U.A.E.Cavotec Middle EastDubai,Abu Dhabi,Bahrain

U.K. & IrelandCavotec UKMarket Deeping

U.S.A. & CanadaCavotec Inc.Statesville, NC

Cavotec Partners

Brevetti StendaltoMonza, Italy

De JongLeerdam, The Netherlands

Micro-controlStjørdal, Norway

Pirelli CaviMilan, Italy

Apr2002