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Heavy-Duty Conveyor Types for Manufacturing and Process Plants

In this article, a heavy-duty conveyor is a fixed-path conveyor that carries heavy unit loads, such as castings, coils, billets, pallets of parts, or assemblies, between process steps in a manufacturing or process plant. UTEC Industrial designs, engineers, machines, fabricates, and installs custom material handling systems for aerospace and heavy industry from its Spokane Valley, WA facility, integrating Allen-Bradley PLC and motion control with in-house CNC machining, heat treating, and stress relief. The article sets out what public sources say about five conveyor types (chain, roller, slat, walking-beam, and indexing), how federal rules and the ASME B20 conveyor standard reach a plant conveyor, which hazards each type presents, and which sensing and controls it needs. The conveyor is taught here along the build chain, design → engineering → parts machining → fabrication → assembly → weld fatigue → stress relief → drives → controls → tuning → monitoring.

What does the B20 conveyor standard cover, and what does it leave out?​

ASME's B20 committee charter covers the design, construction, installation, maintenance, inspection, and operation of conveyors and conveying systems in relation to accident hazards. It names power conveyors, gravity conveyors, pneumatic tubes, skip hoists, vertical reciprocating conveyors, and power unloading scoops as conveyors covered by the B20 standard. It states that the B20 standard does not apply to industrial powered trucks, tiering machines, cranes, derricks, hoists, power and hand shovels, bucket drag lines, moving stairways, dumbwaiters, manlifts, and platform elevators to carry passengers or the elevator operator.

The latest edition on ASME's product page (October 2026) is ASME B20.1-2024, Safety Standard for Conveyors and Related Equipment. That page states that it applies to the design, construction, installation, maintenance, inspection, and operation of conveyors and conveying systems in relation to hazards, and that the conveyors may be of the bulk material, package, or unit handling types where the installation is designed for permanent, temporary, or portable operation. The page says the Standard shall apply, with the exceptions it notes, to all conveyor installations, and that it specifically excludes any conveyor designed for, installed for, or used primarily for the movement of human beings. It does, however, apply to certain conveying devices that incorporate within their supporting structure work stations or operator's stations specifically designed for authorized operating personnel.

The charter is the committee's remit, not the standard's scope clause, so this article reads coverage from the publisher's scope text. What B20.1-2024 itself requires, clause by clause, is read from the standard (ASME B20 committee page, 2026; ASME B20.1-2024).

When does a chain conveyor suit a heavy unit load?​

Kay's course notes describe the chain conveyor as a unit-load, in-floor or on-floor type with no accumulation, which "uses one or more endless chains on which loads are carried directly". The notes add that a parallel chain configuration is used as a chain pallet conveyor or as a pop-up device for sortation, and that a vertical chain conveyor is used for continuous high-frequency vertical transfers, with material on horizontal platforms attached to the chain. As engineering reasoning, "no accumulation" means loads cannot queue on a running chain conveyor, so a line that must hold loads either stops the chain or passes the load to an accumulating section.

CEMA's Conveyor Chain and Sprocket Section separates the chain families by use. It states that roller chains are primarily used for the transmission of power, while engineering class chains are most often used for the movement of materials, with "some exceptions". It notes that roller chains use a universal code in which number 80 equals a 1-inch pitch, and that there is no standard numbering system for engineering class chains; each manufacturer uses its own. ASME publishes the welded-steel mill and drag chain families, which the ASME B29 chain article sets out, in B29.200-2001 (R2021), and the steel bushed rollerless and steel roller type conveyor chains in B29.12M-1997 (S2025) and B29.15M-1997 (S2025). Selecting chain for wet, abrasive, or hot duty is covered in the conveyor chain selection article (Kay 2012, §5, item 4, p. 27; CEMA Conveyor Chain Fact Sheet 2007-02, 2007; ASME B29.200-2001 R2021; ASME B29.12M-1997 S2025; ASME B29.15M-1997 S2025).

How do gravity and chain-driven live roller conveyors differ?​

Kay groups roller conveyors as unit-load, on-floor types that can accumulate loads. The notes give four points that apply to roller conveyors in general:

  • Riding surface. Materials must have a rigid riding surface.
  • Roller count. A minimum of three rollers must support the smallest loads at all times.
  • Curves. Tapered rollers on curves are used to maintain load orientation.
  • Pallet width. A parallel roller configuration used as a pallet conveyor is, in Kay's words, more flexible than a chain pallet conveyor because rollers can accommodate a greater variation of pallet widths.

The two drive arrangements then differ. Kay lists the gravity roller conveyor as an alternative to the wheel conveyor "for heavy-duty applications", with a slope for gravity movement that depends on load weight. The live, or powered, roller conveyor is "belt or chain driven", can use a force-sensitive transmission to disengage rollers for accumulation, and provides limited incline capability. As engineering reasoning, the slope dependence on load weight means a gravity line set for the heaviest part may run a light part too slowly, and a line set for a light part may let a heavy part arrive too fast. Urethane-covered rollers, and what a durometer hardness callout on their treads does and does not state, are covered in the polyurethane tread hardness article.

ANSI/CEMA 404-2003, reaffirmed in 2020, is described by its publisher as the fourth standard in CEMA's unit handling series, which "establishes recommended design and application engineering practice for chain driven live roller conveyors". As this article understands it, that practice covers roller centers, the drive-chain arrangement, guarding, and capacity; this article states none of its values (Kay 2012, §5, item 3, pp. 26–27; ANSI/CEMA 404-2003 R2020).

What is a slat conveyor used for, and how is its chain sized?​

Kay describes the slat conveyor as using "discretely spaced slats connected to a chain". The unit being transported retains its position, as on a belt conveyor, and the orientation and placement of the load are controlled; Kay lists it as "used for heavy loads or loads that might damage a belt". Like the chain conveyor, it is listed with no accumulation.

Renold's 2010 designer guide works a two-strand slat conveyor as its selection example, for Renold chain:

  • Inputs. 36 m head-to-tail centres, boxed products 650 × 800 mm at 36 kg each, a maximum load of 50 boxes (1,800 kg), slats at 15 kg/m, 152.4 mm pitch chain preferred, clean and well-lubricated conditions, a chain speed of 0.45 m/s, and 8-tooth sprockets.
  • Preliminary selection. A preliminary chain pull of 5,907 N times a factor of safety of 8, divided by 2 per chain, gives a minimum breaking load of 23,628 N per chain, and a 33,000 N breaking-load chain is chosen.
  • Final check. With the actual chain mass the chain pull is 5,005 N, and the factor of safety becomes 33,000 × 2 ÷ 5,005 = 13.19. Roller bearing pressure is 0.23 N/mm², which the guide compares with an allowable maximum of 1.2 N/mm² for sintered steel rollers.
  • Drive. The power at the headshaft is 2.25 kW, which the guide notes is the power to keep the conveyor moving, not the motor size; the headshaft turns 21.6 rpm and carries 996 N·m.

The equal split between two strands is the example's arithmetic, not a stated rule for every multi-strand conveyor. ANSI/CEMA 405-2003, reaffirmed in 2020, is described by its publisher as proposing "certain minimum standards for use in the design and application of unit handling slat conveyors", with formulas and tables. As this article understands it, those formulas address chain pull and slat spacing; this article states none of them (Kay 2012, §5, item 5, p. 27; Renold REN16/ENG/10.10, p. 36; ANSI/CEMA 405-2003 R2020).

What is a walking-beam conveyor, and how much do public sources say about it?​

The only public, non-patent source this article uses for walking beams describes them inside furnaces. The US Department of Energy's process-heating sourcebook classifies furnaces by their material handling system. Its Table 2 lists walking beam furnaces as "primarily used for large loads, such as reheating of steel slabs, billets, ingots, etc.", with metals (steel) as the primary industry. Its text says the load is "walked" through the furnace by using special beams, and that the furnaces are usually direct-fired with several top- and bottom-fired zones. The sourcebook does not describe the beam motion itself.

Kay's Table 7, which lists 19 conveyor types, does not include a walking-beam conveyor. ANSI/CEMA 102-2022, Conveyor Terms & Definitions, is CEMA's vocabulary standard, and as this article understands it, it defines chain, slat, chain-driven live roller, and indexing conveyors; whether it defines a walking-beam conveyor is not known from public sources.

As engineering reasoning, not a statement in these sources, a walking-beam conveyor is described here as a set of moving beams that lift the load off fixed rails or saddles, advance it one step, set it down, and return beneath it. On that description, the failure modes are a load set down off its saddles when lift and advance are not sequenced, a load that shifts on the beams under acceleration, and pinch and shear points between the moving and fixed members (U.S. DOE 2015, Table 2 and pp. 15–16; Kay 2012, Table 7, p. 25; ANSI/CEMA 102-2022).

Where do indexing conveyors fit among the conveyor types?​

Kay separates two indexing arrangements. A rotary index table is used for the synchronous transfer of small parts from station to station in a single workcenter; the circular table rotates in discrete intermittent steps, and since each part moves between stations at the same time, it is difficult to put buffers between stations. Kay calls this different from "conveyors used as in-line indexing machines, where linear transfers can take place between multiple workcenters separated by long distances".

The in-line indexing conveyor, and what it takes to stop a delicate assembly at a station repeatably, is the subject of the indexing conveyor article. It covers precision chain, S-curve index moves, rotary-axis programming traps, and station confirmation, and none of that is repeated here (Kay 2012, §4, Table 6 item 5, pp. 21–22).

When is a conveyor the right machine, and when is it a transfer car or crane?​

The CICMHE equipment-selection guide reproduces Dunning's comparison of three equipment families. Conveyors are for moving uniform loads continuously over fixed paths where the primary function is transporting. Cranes and hoists are for moving varying loads intermittently to any point within a fixed area, and industrial trucks for moving mixed or uniform loads intermittently over various paths with suitable surfaces where the primary function is maneuvering. Kay gives the same conditions in his own words: conveyors are used when material is to be moved frequently between specific points, over a fixed path, and when there is a sufficient flow volume to justify the fixed conveyor investment.

A custom machine can sit between the families. In a 2004 letter about an automatic transfer device for processing and moving product, OSHA replied that it "cannot fully make that determination without an on-site inspection", but that the equipment "would most likely be considered a conveyor rather than a crane", so the overhead and gantry crane standard may not apply. The letter adds that, since the equipment is custom designed and manufactured, there may be circumstances where 29 CFR 1910.179 would be applicable, and that Subpart D (walking-working surfaces), Subpart O (machine guarding), and Subpart S (electrical) may still apply regardless. OSHA's letters state that they cannot create additional employer obligations. The trade-off between a conveyor, a rail-guided car, and a floor vehicle for very heavy loads is covered in the transfer car comparison (Peters 1998, CICMHE equipment selection guide, General Considerations table; Kay 2012, §5, p. 25; OSHA Standard Interpretation, January 16, 2004).

Which federal rules reach a plant conveyor, and which B20.1 edition do they name?​

OSHA's 1984 letter on vertical reciprocating conveyors also describes how other conveyors are regulated. OSHA wrote that it regulates vertical reciprocating conveyors used in general industry under various standards relative to specific types of applications, that "all other applications of conveyors are regulated under 29 CFR 1910.212", and that "OSHA relies on the recommendations of the ANSI B20.1-1976 for the acceptable safeguarding of employees exposed to conveyors".

Where federal rules do name the conveyor standard, they name the 1957 edition:

  • The incorporation list. 29 CFR 1910.6(e)(17) lists ANSI B20.1-57, Safety Code for Conveyors, Cableways, and Related Equipment, as approved for incorporation in 1910.218(j)(3); 1910.261(a)(3)(x), (b)(1), (c)(15)(iv), (f)(4), and (j)(2); and 1910.265(c)(18)(i).
  • Forge facilities. Under 1910.218(j)(3), conveyor power transmission equipment in forge facilities shall be guarded in accordance with ANSI B20.1-1957. The paragraph names power transmission equipment only.
  • Pulp and paper mills. Under 1910.261(c)(15)(iii), all conveyors for pulpwood shall have the inrunning nips between chain and sprockets guarded, and turning drums shall be guarded.
  • Sawmills. The sawmill conveyor rule, 1910.265(c)(18), is covered in the sawmill conveyor and deck safety article.

Under 1910.6(a)(1)(i), only the mandatory provisions of a standard incorporated by reference, those containing the word "shall" or other mandatory language, are adopted. The list names the 1957 edition, not B20.1-2024, the latest edition, and under 1910.6(a)(1), to enforce any edition other than the one specified, OSHA must publish a document in the Federal Register and the material must be available to the public. ASME's continuous-maintenance list, updated May 7, 2025, gives 2027 as the anticipated date of the next complete edition, an anticipated date rather than a commitment (OSHA Standard Interpretation, July 30, 1984; OSHA 29 CFR 1910.6, §1910.6 paragraphs a.1, a.1.i, and e.17; OSHA 29 CFR 1910.218, §1910.218 paragraph j.3; OSHA 29 CFR 1910.261-2016, §1910.261 paragraph c.15.iii; ASME 2025, continuous maintenance list).

What hazards does each conveyor type present?​

OSHA's advisory booklet on amputations states that conveyor-related injuries "typically involve" an employee's hands or fingers becoming caught in nip points or shear points, and that they may occur when cleaning and maintaining a conveyor, especially while it is still operating, and when reaching into an in-going nip point to remove debris or free jammed material. One of its case histories describes an employee who turned off a conveyor, removed the guard of a chain-and-sprocket drive, and began work without locking out the system; when someone started the conveyor, the employee's fingers were amputated. For the types in this article the booklet gives:

  • Chain conveyors. Nip points occur where a chain contacts a sprocket, for example where it runs around a sprocket, where it is supported by a sprocket, or where a shoe above the chain keeps it from lifting off. They also occur at drives, terminals, take-ups, and idlers, and automatic take-ups may also have shear points. The booklet notes that moving chains sometimes cannot be enclosed without impairing the conveyor's function, and that in some cases barrier guards may be installed around the moving parts, or nip and shear points may be eliminated by placing a guard at the nip or shear point.
  • Roller conveyors. Powered roller conveyors can snag and pull hands, hair, and clothing into the area between the rollers and the stationary components. In-going nip points generally exist between the drive chain and sprockets, between belt and carrier rollers, and at terminals, drives, take-ups, idlers, and snub rollers.
  • Slat conveyors. The booklet's slat-conveyor figure marks an in-running nip point at the slats, with fixed guards.

The federal rules behind the booklet are general. 29 CFR 1910.212(a)(1) requires one or more methods of machine guarding to protect the operator and other employees in the machine area from hazards such as ingoing nip points and rotating parts, and 1910.219(f)(3) requires all sprocket wheels and chains to be enclosed unless they are more than 7 ft above the floor or platform; the paragraph does not apply to manually operated sprockets. The booklet's own disclaimer says it is not a standard or regulation. In a 2002 interpretation on the 1996 edition, asked whether belt-conveyor rollers over a walkway, read by the inquirer as nip points under paragraph 5.9.3, must be guarded, ASME replied that 5.9.3, in the General Safety Standards section, is prefaced by "In general" and tempered by "unless other means to assure safety are provided. See Section 6 for specific conveyors." As this article understands B20.1-2024, its Section 6 likewise carries provisions for specific conveyor types, including chain, slat, and roller conveyors, that address guarding of the nip and shear points each type creates (ASME B20 Standards Committee 2024, Interp. 20-18 on B20.1-1996; OSHA 3170, 2007, pp. 26–29; OSHA 29 CFR 1910.212-1974, §1910.212 paragraph a.1; OSHA 29 CFR 1910.219, §1910.219 paragraph f.3; ASME B20.1-2024).

What sensing and controls does a heavy conveyor need?​

CEMA's e-stop guide, which states that it is advisory only and is to be used in conjunction with the applicable current B20.1 standard, gives guidelines common to all conveyors. It says that e-stop stopping behavior is defined by NFPA 79, and that for most conveyors a Category 0 emergency stop immediately removes power to the conveyor actuators, resulting in an uncontrolled stop. It adds that when an uncontrolled stop is more hazardous than a controlled stop, the e-stop shall trigger a Category 1 stop, in which power is not removed until the stop is complete. When the stop cycle completes, the e-stop circuit shall ensure that no torque-generating energy can continue to act upon a motor, and shall also prevent unintentional initiation of hazardous motion. In its bulk-conveyor section, the guide warns that uncontrolled stops can create additional hazards on some conveyors, such as downhill regenerative conveyors.

The drive and controller supply the means:

  • Torque removal. The Kinetix 5700 user manual states that 2198-xxxx-ERS3 and ERS4 drives are equipped for hardwired and integrated safe torque-off (p. 241). It also states that disabling the power transistor output does not provide physical isolation of the electrical output that is required for some applications (p. 250).
  • Controller tasks. In the Logix 5000 design considerations manual, controller tasks can be configured as continuous, periodic, or event (Ch. 5, p. 39), and a periodic task performs a function at a specific time interval (p. 41).
  • Safety-related controls. ISO 13849-1:2023 specifies a methodology and provides related requirements, recommendations and guidance for the design and integration of safety-related parts of control systems that perform safety functions, for high demand and continuous modes of operation; it does not apply to low demand mode of operation.
  • Electrical equipment. IEC 60204-1:2016+AMD1:2021 applies to the application of electrical, electronic, and programmable electronic equipment and systems to machines not portable by hand while working.

The sensing layer below is this article's engineering practice, not a requirement of these sources. A heavy chain or slat line carries a motion or zero-speed sensor on a tail shaft to detect a broken or derailed chain while the drive still turns, load-present sensors at each transfer and stop, drive current trended against load to show a jam or a dragging bearing, and, on a walking-beam or indexing line, position feedback on each axis checked against a station sensor before the next step. UTEC Industrial, a Rockwell Automation Recognized System Integrator, builds UL 508A control panels and integrates Allen-Bradley ControlLogix and CompactLogix controllers with VFD and servo drives for this kind of conveyor logic (CEMA SBP-002, 2016, §3.1 and §5.1; Rockwell Automation 2198-UM002E-EN-P, 2018, pp. 241 and 250; Rockwell Automation 1756-RM094N-EN-P-2025, Ch. 5 pp. 39 and 41; ISO 13849-1:2023; IEC 60204-1:2016+AMD1:2021).

Where does a heavy conveyor sit in the design-to-monitoring chain?​

Each step of the chain bears on how evenly the strands carry the load:

  • Design and engineering. As engineering reasoning, the conveyor type, strand count, chain family, and drive arrangement are fixed from the load, its riding surface, and the rate, before the frame is drawn.
  • Parts machining. Renold's guide says that where chains have been matched, the drive sprockets should be bored and keywayed as a set in relation to a tooth, as in a normal conveyor drive, and it recommends that a machine-cut tooth form also be used to ensure equal load sharing.
  • Chain supply and assembly. CEMA's matched-strands report says it is best practice to use matched strands when pairs or groups of chain run in parallel, and that this is particularly important where through rods, scraper flights, or other carrying attachments rigidly connect multiple strands. It warns that unmatched strands may result in unequal loading, which can cause uneven wear resulting in racking problems.
  • Fabrication, weld fatigue, and stress relief. As engineering reasoning, a welded frame that moves after machining moves the sprocket and rail lines with it. Stress relief ahead of final machining is covered in the stress-relief article for machine bases and frames.
  • Monitoring. CEMA's chain fact sheet says chain and sprockets should be inspected after three months' service and at six-month intervals thereafter.

UTEC Industrial machines to tolerances as tight as ±0.001 in and performs automated vibratory stress relief and CMM inspection on the frames and parts it builds, which is where shaft and sprocket alignment can be set and checked (Renold REN16/ENG/10.10, p. 32; CEMA Technical Report 2016-01, 2016, p. 1; CEMA Conveyor Chain Fact Sheet 2007-03, 2007).

What should a heavy-duty conveyor specification state?​

UTEC Industrial has built heavy-duty conveyor systems for Kaiser Aluminum for aluminum production loads. As engineering practice, a request for a heavy-duty conveyor gives the builder what each source above needs:

  • The load. Mass, footprint, riding surface, center of gravity, and temperature at pickup, so the type can be chosen against Kay's riding-surface and three-roller conditions.
  • The flow. Rate, accumulation needed or not, station positions, and whether loads must hold their orientation, which Kay lists for the slat conveyor.
  • The chain. The ASME B29 family where one applies, strand count, and whether matched and tagged strands are required, which CEMA's report recommends identifying when ordering.
  • The rules. The governing OSHA sections for the site, the B20.1 edition the contract invokes (2024, not the 1957 edition the federal rules name), and the risk assessment that guarding decisions rest on.
  • Guarding and stops. Drive enclosure under 1910.219(f)(3), guarding of chain-and-sprocket nips, and the stop category and placement of e-stops.
  • Controls and proof. Torque-off method, sensing at each transfer, and the acceptance tests that show stop behavior with the heaviest load.

The rule items trace to the federal text and B20.1's publisher scope; the chain and type items trace to the CEMA, Renold, and Kay documents as dated sources, not as current general practice (Kay 2012, §5; CEMA Technical Report 2016-01, 2016, p. 2; OSHA 29 CFR 1910.219, §1910.219 paragraph f.3; ASME B20.1-2024).

Related Articles

References​

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