Beruflich Dokumente
Kultur Dokumente
Procedure
(Splicing Manual)
Incorporating
A part of
Apex
Steel Cord Belting
Contents
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Scope
These instructions refer to the materials and techniques involved in splicing Apex Steel Cord
conveyor belt. To maximise performance at the high tensions under which steel cord belting
operates, the procedures in this specification must be strictly adhered to. Fenner Dunlop cannot
be held responsible for any modification or shortcut in the operation of this procedure.1
Note: All recommendations for the use of any product or products described herein and all other data or information
set forth in this document, whether concerning such products or otherwise, are furnished without any guarantee,
warranty, representation or inducement of any kind, whether express or implied, including, but not limited to,
implied warranties of merchantability and fitness for a particular purpose, and Fenner Dunlop expressly
disclaims liability under any theory including, without limitation, contract or negligence, misrepresentation or
breach of any obligation relating to the recommendation, data or information set forth herein. Readers and
customers are encouraged to conduct their own tests. Before using any product, read its label and all related
instructions.
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SM 226 rev 0
Vulcanised Splicing Procedure Steel Cord Belt (Splicing Manual)
National Service Manager
Page 1 of 18
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National Service Manager
Page 2 of 18
The work area should be adequately ventilated as the process emits vapours
during the cleaning and cementing operations. In the event that a person should
experience any respiratory irritation, move them into fresh air. If the symptoms
persist, follow procedures as described on the MSDS and obtain medical
attention.
b)
c)
d)
Empty and/or unused tins are not to be left behind and should be disposed of in
an approved method.
e)
Most solutions and solvents are flammable and the splice station should be clear
of any ignition source. Smoking should specifically be prohibited at or near the
splice station.
1.4 Make sure the conveyor belt is properly tagged out, de-energised and secured prior
to initiating any work on the system. Ensure that all Fenner Dunlop and site Safe
Work Procedures are adhered to.
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Vulcanised Splicing Procedure Steel Cord Belt (Splicing Manual)
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2. Materials
2.1 Fenner Dunlop supplies complete splicing materials, in custom-made kit form, each
kit being sufficient to effect one splice. The following information is required to provide
the correct components and quantities:
ST Rating
Belt Width
Cover gauges and grade designation
Number of cords, pitch and diameter
Presence of Breakers and type
All splicing materials have a limited shelf life. Splice material past their expiry date should
not be used. Each component of the splice kit is marked with its expiration date and they
need to be checked prior to commencing splicing.
If a kit is stored at extremely low temperatures it must be allowed to stand at an acceptable
air temperature for at least 24 hours before use without exposing to direct sun light.
Splice kits should be kept in a cold room below 10oC. Splice kits stored at ambient
temperature have a shorter shelf life.
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Table-1
Cover
Rubber/
Grade
A
A-Plus
MZ-AR
M
M-Plus
XCG
LRR
Bonder /
bonding
gum
1535
Orange
3535
S*
1530
White
3533
Plastic
Colour
Cover
Plastic
Colour
Rubber
Cement
Cleaning Solvent
Class
S19
Toluene or X3B
(Light
Hydrocarbon)
S17
Toluene
3526
1525
Yellow
Blue
3525
Dark
Green
Light
Green
*Grade S materials above are approved for above ground use only. If splice is to be carried
out underground or in a hazardous environment, contact Fenner Dunlop for advice.
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Vulcanised Splicing Procedure Steel Cord Belt (Splicing Manual)
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0.4 W
CL
A
Bias A ngle
Q :R :S :D/ d 14 -1
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Diagram 1
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Vulcanised Splicing Procedure Steel Cord Belt (Splicing Manual)
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4.0
Vulcanisation Requirements
4.1 The first step in making a quality splice is preparing the work area so that it is
efficient, bright, clean and adequately protected. Outside installations should be
protected by a shelter against adverse weather conditions. Inside installations should
be cleaned of excessive dust (especially overhead), have good lighting and protected
against dripping water.
4.2 The temperature should be 16C minimum. The humidity should be 75% maximum. If
humidity is over 70%, the surface temperature and dew point must be carefully
monitored during the laying up of the splice.
4.3 The edges of the platen must be parallel to the direction of the belt run travel.
4.4 A splicing table extending at least 2m from each end of the bottom platen and 25mm
wider than the belt should be constructed. In addition, a separate table of sufficient
size should be constructed on which to prepare the rubber splice components. The
splicing table must be level or 5mm lower than the platen surface.
4.5 The vulcaniser must be large enough to cure the splice in one heat with a minimum
175mm overlap onto the original belt cover at each end of the splice and 200mm
wider than the belt width. For multi platen vulcanisers a common plate to cover entire
surface with a minimum overlap of 100mm on the end should be used.
4.6 The vulcaniser must be capable of a curing pressure of 1000 to 1400kPa (150
200psi). Consult splice diagram provided for the specific belt.
4.7 The curing temperature must be accurately controlled over the whole platen area to
+/-8C during heat-up and +/-5C when at the required curing temperature. For this
reason, vulcanisers with thermostats must be carefully checked for function and
monitored continuously with thermocouples to ensure they are operating properly.
The thermocouples should be strategically placed over the surface of both top and
bottom platens. Over cured and/or under cured splices do not provide the sufficient
splice quality. Refer to splice diagram for curing times.
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5.0
Belt Preparation
5.1 The belt should be centrally located on the troughing idlers on each side of the splice
area. This allows final adjustments to be made easily for splice alignment. The two
belt ends are then overlapped on the bottom platen of the vulcaniser and aligned
visually.
5.2 Mark centre points on each belt end (three or four times) at 1 to 2m intervals that are
then joined using a chalk line. Do not use belt edge as a reference. The centre lines
are used to make final alignment.
Now clamp the belt to the work surface to prevent movement.
Do not nail belt. Nails can damage the cords and the nail holes may allow moisture
to come in contact with cords causing corrosion and premature failure.
5.3 Marking the Splice Bias Lines
5.3.1 On the belt edges, mark the splice bias lines on both ends. Match the bias
angle to the vulcaniser angle and mark a bias line on the top end parallel to the
end of the platen and at least 175mm in from the end.
5.3.2 Measure a distance equal to the splice length from the ends of the bias line
toward the belt and mark a second bias line parallel to the first line. Make sure
this line is at least 175mm in from the other end of the platen.
5.3.3 Fold back the top end, use edge mark to draw the bias line on the bottom end.
Make sure that the belt ends are still in alignment.
5.4 Stripping the Covers
5.4.1 Starting with the upper belt end make a vertical cut down to the cords
approximately 50mm past the cut off end. (This allows extra room to cut cords
to the length at a later stage.)
5.4.2 A second cut at 30 - 45 skive angle is then made along the other bias line
making sure not to damage the cords.
5.4.3 Next remove the rubber edges along the length of the splice on the outer
cords.
5.4.4 After removal of edge rubber, make at least 2mm deep insertion along the top
of cords from the bottom of skive through to the cut off end.
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5.4.5 Start stripping the top cover at the leading point of skived cut by pulling with
pincers and cutting under the cover just above the cord. Try to leave thin layer
of rubber on the cord.
5.4.6 When there is sufficient rubber free, attach a stripping jaw and put the cover
under tension to facilitate cutting. Control the tension in the cover so that the
rubber between the cords is not distributed.
5.4.7 Freeing the cords can be achieved by either hooking or piano wires. It is
recommended for belts with cord diameter over 5.5mm the piano wire method
is used.
Hook knife method
From bottom of the skive, cut rubber between cords parallel to skive.
Fold belt end back, cut skive and remove approximately 200mm window.
Cut 20 to 25mm window between cords from end of skive.
Insert folded piano wire around every cord.
Fold belt end back to the table and proceed to pull piano wires by using
pulling plate.
Clean excess rubber off from cords to ensure uniform shape prior to cutting
cords to length. Refer to Diagram 2.
Cut cords to length using approved cord cutters as per splice diagram.
Cut off waste belt and fold belt end back.
Repeat process for other end.
5.4.8 Buff the skive with a rotary wire brush taking great care not to expose any
cords or burn rubber. And extend buffing back onto the top and bottom cover
surface and edge of the cover approximately 100mm.
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2
3
Take great care not to get solvent into the ends of the cords as blisters may result during curing.
Excessive chalk on the back cover could affect adhesion.
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6.3.5 Stitch and roll the cover joints firmly then lightly hammer the entire splice
surface.
6.3.6 Mark the belt edges on the splice with a chalk line approximately 5mm wider
and trim excess rubber using a straight edge.
6.3.7 Install Splice Identification Brand
Tighten edge bar sash clamps, check that the edge bars are not tilted and then
apply platen pressure of 400kPa (60psi).
6.4.9
After the pressure has reached 400kPa (60psi), check the edge bars and sash
clamps, and tighten again if necessary.
To prevent air entrapment the practice of holding and rolling must be used, i.e., gradually lowering the cover panel into
place while rolling.
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6.4.11 When one of the thermocouples reaches 110oC, increase pressure to 850kPa
(125psi) and shut down control box.
6.4.12 After 5 minutes switch control boxes back on and Increase platen pressure to
950kPa (140psi).
6.4.13 When temperature reaches 120C, increase platen pressure to 1100kPa
(160psi) and hold until the temperature rises to the curing temperature
specified in splice diagram.
6.4.14 After the temperature reaches the curing temperature specified in the splice
diagram, if necessary increase the platen pressure to the curing pressure
specified in splice diagram and maintain this pressure.
6.4.15 Cure the splice for the recommended time specified in splice diagram.
6.4.16 In order to assure uniform temperature the vulcaniser must be protected from
drafts during the cure.
6.4.17 Temperature and pressure must be monitored every 5 minutes during curing
process.
6.4.18 When the cure is complete, water cool to 60C and hold for 15 min before
releasing the pressure.
6.4.19 Dismantle the vulcaniser and trim the splice.
6.4.20 Buff over flow rubber from skives only after surface has cooled.
6.4.21 It is recommended to check dimension of splice (thickness, width and length),
straightness and durometer on top and bottom cover to ensure proper cure.
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Page 14 of 18
Appendix I
Using foreign splicing materials with Apex Belts
In some circumstances, it can be necessary to carry out a splice on an Apex belt,
using materials other than Fenner Dunlop materials as are listed in the Fenner Dunlop
Vulcanised Splicing Procedure.
For standard grades, such as M, N, A, XCG etc., where Fenner Dunlop 1525 Bonder
and S19 Solution are specified, there is a reasonable expectation that similar basic
"chemistry" would be employed and consequently a reasonable expectation of
adequate compatibility when the splicing materials are used correctly, as intended by
the manufacturer.
With "special" grades, such as Fire Resistant, there is a likelihood of incompatibility
and the correct materials must be used.
Where materials other than Fenner Dunlop are being used there are two important
considerations:
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Status
Title/Signature
National Service Manager
Date
P RUSCOE
01/05/2010
R DAY
01/05/2010
Authorised by:
Technical Manager
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Page 18 of 18