India's first Elevated, Triangulated Gallery Overland Conveyor System

Overland Conveyor System

India's first Elevated, Triangulated Gallery Overland Conveyor System

In 2010 the Adani Group broke ground on a new solid cargo handing port with the installation of a unique conveyor system that moves up to 6000 t/h to a rail loading silo approx. 4.75 kilometres from the port. These conveyors are supported by lightweight triangular galleries that do not include walkways and are maintained with a motorised trolley.
(ed. WoMaMarcel - 17/7/2014)
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Conveyor Maintenance

Walkways substantially increase the weight of conveyor galleries. To eliminate this additional weight, CDI designed and provided detail drawings for a triangular maintenance trolley that allows maintenance personnel access to the conveyor (Fig. 6). In the past CDI had provided only GA drawings of the trolley. The Dahej trolley was the first trolley for which CDI created a complete set of electrical and mechanical drawings. These drawings were given to Elecon so that they could manufacturer the trolleys on their plant in Gujarat.

Dust Control

Coal dust generation was a major concern at Dahej, particularly where the conveyor passes through Lakhigam Village. Instead of enclosing the entire gallery with cladding, the belt trough-stringer-hoodcover were designed to form a single aerodynamic section that shields the coal from wind (Fig. 7). The design was validated using computational flow dynamics (Fig. 8). Installing side cladding on the gallery would have made idler inspection from the trolley very difficult. The low profile hood cover prevents personnel from viewing the top side of the belt. Alignment of the conveyor can be visualized from the underside of the belt. Heat detection systems are critical as it is not possible to see a fire on the belt outside of the transfer towers.

To further reduce dust, a Dry Fog Dust Suppression (DFDS) system was installed at each conveyor discharge point to control dust generated in the chutes.

System Erection

Since the conveyor system passes through both residential and industrial areas, minimizing the inconvenience and disruptions to the local community was an important consideration. PMC created a strategic plan for each and every gallery, mapping the approach through the village to ensure fast safe erection of the galleries.

Once the land issues were resolved construction proceeded rapidly. As land was acquired foundations for the conveyor support columns were poured. After completing the foundations, the bents and 36 m long galleries were moved out of the port on 24 m long trailers. In total, 86 triangular galleries travelled 2 to 4 km along the main village road, before reaching the conveyor where they were quickly installed using cranes. Final gallery positioning was completed with the assistance of a surveyor to maintain the +/1 mm conveyor centreline accuracy.


In India, acquiring land is challenging and conveyor systems often must allow local populations to freely pass through the conveyor corridor. Free movement is best facilitated by elevating the conveyor system, but this can become cost prohibitive. A triangular gallery with a motorised maintenance trolley is a practical structure for economically supporting elevated conveyors.

In addition to the light weight structure, high speed conveying and horizontal curves offers further reduce capital investment costs.

This paper outlines the engineering and construction challenges faced when constructing these conveyors. The authors hope the Dahej conveyor design can offer a benchmark for modern overland conveyor design


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  3. Staples, P.: Effects of Support Structures on Belt Conveyor Systems- A Case for the Triangular Gantry. Beltcon 11, Johannesburg 2001.
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