Ceiling-mounted and floor-mounted belt conveyor lines

Ceiling-mounted belt conveyors turn floor loading into roof loading and need slab-load approval, anti-vibration hangers and frequent levelling checks, giving clear floors for clean rooms or forklift traffic but raising installation and maintenance cost 15–25 %. Floor-mounted lines anchor to 500 kg/m² concrete, allow heavier loads, simpler levelling and ground-level servicing, but occupy floor space and leave bolt scars when relocated. Choose suspended only if roof capacity ≥2.5 kN/m², clearance ≥2.2 m and frequent under-traffic is required; otherwise floor type is cheaper and sturdier.

1. Key design differences

ItemCeiling-suspended (top-hung)Floor-mounted
Civil data requiredRoof-slab load report (≥2.5 kN/m² is common); pre-embedded steel beams or special hanger points for spans >6 mOnly ground uniform load check; ordinary industrial floor (500 kg/m²) is enough for light/medium duty
Centre-line controlUse laser plumb to transfer roof marks to floor, keep ±2 mmDirect chalk line on floor; ±1 mm is easy
Take-up locationUsually gravity take-up + tail pulley hung under the line; reserve 0.8–1.2 m drop for weight travelScrew, carriage or gravity take-up possible; space flexible, not limited by roof height
Anti-vibrationDamped hanger rods or spring isolators mandatory to keep start-up shock away from slab (especially >6 m/min)Only needed if line stands on steel mezzanine; concrete floor can take direct anchor bolts

2. Structure & load

ItemCeiling-suspendedFloor-mounted
Main frameTwin channel or aluminium truss; ∅12–16 mm wire rope or threaded rod every 1.5–2 m; continuous beam for spans >4 m to reduce sag40×40, 40×80 aluminium profile or 50×50 square legs, post spacing 1–1.5 m
Rated loadSingle hanger ≤200 kg typical; heavier loads need external floor-mounted drive platformSingle leg 500–1 000 kg common; swap to 80×80 steel legs for heavy duty
Deflection limitL/500 under full load (L = hanger spacing) to avoid belt wanderL/1 000 for steel legs, easier target

3. Erection

ItemCeiling-suspendedFloor-mounted
Setting-out sequence1. mark centre on slab → 2. install hanger plates → 3. level reference wire → 4. assemble truss on floor → 5. lift & level whole bay1. mark floor centre → 2. build first frame section → 3. add sections → 4. level complete line
Levelling methodDouble-nut + washers on hanger rods; check every bay with level, height diff. ≤2 mmFoot plates or jack-bolts; ≤1 mm/m, quick
Drive mountingSide-mount on slab or post to isolate vibration; independent floor bracket if motor >2.2 kWDirect on head frame, rigid fixing OK
Clearance≥0.5 m walkway under line; ≥2.2 m if forklifts cross0.4–0.6 m service space around frame for belt swap/clean-out

4. Operation & maintenance

ItemCeiling-suspendedFloor-mounted
Belt wanderVery sensitive to unequal hanger length or slab vibration; re-check hanger forces every two weeksGood rigidity, low wander; routine visual check enough
Cleaning/lubeNeed mobile platform to reach idlers & grease; +30 % labourAll reachable from floor, large service window
Extension/re-locationUnhook and lower entire line, fast; new plant must re-check roof loadMust cut anchor bolts, floor holes left; slightly more work

5. Quick-selection guide

ApplicationRecommended mounting
1. Food / electronic clean-room, floor wash-down requiredCeiling + stainless shroud
2. Temporary line, rental workshop, 2–3 year moveCeiling with quick couplers
3. Heavy load (>50 kg/m), high incline (>15°), high power (>3 kW)Floor
4. Retrofit of old building with pre-cast hollow core slabFloor
5. Frequent forklift / AGV traffic under lineCeiling (clear ≥2.2 m)

Conclusion

  1. First check roof load—if insufficient, go floor-mounted.
  2. “Hanging” is not just saving floor space; it transfers load to the roof and adds extra steps for vibration control, levelling and maintenance access.
  3. For the same belt width & speed, ceiling suspension costs 15–25 % more, but gives clear floor and flexible layout—ideal for clean rooms, high-changeover lines or mixed traffic areas.

Score the four factors—civil condition, load, budget and maintenance resource—and the choice between “hang” or “stand” becomes straightforward.

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