Where Are Belt Scales Installed? Typical Locations, Layouts, and Site Considerations

Knowing where to install a belt scale is as important as choosing the right model. Placement determines the accuracy, reliability and safety of measurements. This guide describes common locations for belt scales, the site considerations that influence placement, and practical examples and pitfalls to avoid for a successful installation.

Common installation locations

• Primary infeed conveyors - Placing a belt scale on the main conveyor that feeds the plant gives a reliable measure of total plant throughput. This location is common in mining, aggregates and processing plants.
• Discharge points and loading stations - Scales at truck-loading or ship-loading conveyors record shipments for invoicing and custody transfer. These are often chosen when material leaves the site.
• Transfer points and chutes - Installation directly downstream of a transfer point can capture flow from a specific upstream source, useful for allocation and process control.
• Silo or bin feed lines - Scales on conveyor lines serving silos provide inventory movement records and help reconcile silo levels.
• Process loop points - For control purposes, belt scales can be placed at strategic points in the process (e.g., before a crusher, conveying between grinding stages) to enable local flow control and balance.
• Temporary or portable surveying locations - Portable belt scales are used during commissioning or plant surveys to validate fixed installations or assess production rates at different points.

Site and layout considerations

• Straight belt runs - Scales require a stable belt segment typically with a straight run of specified length before and after the weighing idlers. Curved sections or side-loading reduce accuracy.
• Belt speed and pulleys - Mounting a speed sensor near a drive or idler with consistent rotation ensures reliable speed input. Avoid placing scales on sections affected by frequent speed changes or starting/stopping events.
• Material loading pattern - Ideally, the material load should be uniform and centered on the belt at the scale location. Highly variable or off-centered loading requires multi-idler scales or improved chute design.
• Support and foundation - A rigid, vibration-free support for the weighbridge increases repeatability. Soft or unstable foundations introduce noise and errors.
• Dust, moisture and environmental protection - Enclosures and IP-rated components are important where dust or weather could impact sensors. Consider local ventilation and dust suppression to reduce buildup on idlers and load cells.
• Access for maintenance and calibration - Choose a location with safe access for technicians to inspect idlers, clean sensors and replace parts. Avoid cramped spaces that impede routine checks.
• Safety and guarding - Ensure that installed scales meet machine guarding and lockout/tagout requirements. Loading and unloading zones must be safe for personnel.
• Electrical and communication routing - Plan cable runs for load cell and speed sensor signals to the integrator, minimizing exposure to EMI, heat and mechanical damage.

Examples of practical placements

• At a quarry, the belt scale is mounted on the conveyor leaving the crusher because this captures the crushed output entering the next stage and provides a single point for production reporting.
• On a port ship loader, the belt scale is placed just upstream of the chute feeding the ship to record the tons loaded for each vessel and to provide receipts for customers.
• In a grain terminal, scales are stationed at truck offload conveyors and at outbound rail loading conveyors to reconcile inbound and outbound tonnage.

Placement mistakes to avoid

• Installing over a belt splice or near a take-up where the belt tension fluctuates significantly; this causes unstable readings.
• Placing the scale where material does not fully cover the belt (light loading) or where material is consistently off-centered.
• Ignoring vibration sources such as nearby heavy machinery or poorly supported conveyor frames.
• Choosing a location without sufficient straight belt run length before and after the scale.

Commissioning checks for a good installation

1. Verify straight run and belt tracking at the scale location.
2. Perform static and dynamic calibration checks and validate against known loads.
3. Confirm speed sensor reliability across the expected operating range.
4. Check for consistent loading and absence of spillage or side-loading at the scale zone.
5. Establish a maintenance access plan and schedules for inspection, cleaning and recalibration.

Choosing the right place for a belt scale balances operational needs with physical constraints. When placed on a stable, straight conveyor run where loading is uniform and maintenance access is good, a belt scale provides accurate, reliable flow data that supports production control, inventory and billing. Poor placement, on the other hand, reduces accuracy and increases maintenance burden. Engaging operations, maintenance and process engineers during siting helps ensure the best long-term results.