MULTIPLE-PLY

CONVEYOR BELT
SPLICING MANUAL AT FIELD

DRB Conveyor Development Team

1
1. Splicing Prepare

(1) Safety Requirements

- All operators must be site inducted.
- This must include the Site Emergency Response Plan, Site Energy Isolation procedures
and area specific hazards and controls.
- All operators will be competent in the requirements of this procedure and in the use
of the equipment required.
- Any personnel dogging or rigging must be ticketed.
- All loads must have a lanyard attached.
- All site specific safety requirements.
- In accordance with all National and State Work Cover requirements

(2) Selection of splicing place

- Place near sources of electricity
- Level surface for easy and safe splicing work
- Convenient place for carrying vulcanizing press
- Dry and little dust area

(3) Splicing Tool & Equipment (Attach a file #1)

- Knife, Stitcher, Hand Roller, Pencil for marking line

- Hooked Ply Lifter, Scratch Brush
- Brush for cleaning, Rule, Brush for applying rubber cement
- Calipers, Thermometer, Scissors, Pliers, Wrench, Screw Driver
- Electric Grinder, Peeler, Hand Operated Winch
2. Splicing Materials
- Storage Condition / How to judge if materials are usable?

To prevent scorch and deformation of splicing materials, which must be stored away
from long periods of time and be sure to pay attention for following factors.

(1) Store in a cool and dry place

- Temperature Range : 10～20℃
- Humidity range : Below 60%
- Under 10℃, Materials become too hard to be used.
(2) Keep away from Direct sunlight.
(3) Don’t get materials in contact with Oil, Moisture and Foreign materials which could
harm the splicing material.
(4) Keep the validity period.
- Validity(Storage) period : 6 months
※ If it were not optimum condition storage periods shall be decreasing.

► How to judge if materials are unusable?

Tie gum and cover rubber can not be bonded
(1) After they are melted and the rubber cement is spread on them, if they shrink
quickly back to its original size from 1cm wide rubber after being stretched by hand
to 5 or 6 times its normal length.
(2) Rubber cement is not usable after it changes from a liquid to semi-solid(like jelly).
3. Splicing Procedure
- Selection of Place for Splicing

In putting belt into place, following circumstance should be considered.

(1) Place near the source of Electricity.
(2) Level surface for Easy and Safe splicing work.
(3) Convenient place for carrying vulcanizing press.
(4) Dry and Non-dust area.
3. Splicing Procedure
- Splicing Dimensions

(1) Step Length

Carcass Construction – Total Tensile Strength Step Length (mm)

160/2 250/3 315/4 400/5 100
200/2 250/2 315/3 400/3 400/4 500/4 500/5 600/5 630/5 150
315/2 500/3 630/4 800/5 200
400/2 600/3 630/3 800/4 1000/5 250
500/2 800/3 1000/4 1250/5 300
600/2 800/3 1100/4 1250/4 350
800/2 1000/3 1600/4 1800/5 400

(2) Splicing Length(mm)

► L = 0.3B + S (P-1) + 2K ► For Example

EP630/4 1200W, 6+4
* L : Splicing Length (mm) * B : Belt Width (mm) Splicing Length
* S : Step Length(mm) * P : Number of ply = (0.3*1200)+200(4-1)+2*K
* K : Band Length
= 1010mm
3. Splicing Procedure
- Splicing Dimensions

(3) Cross Section of Belt

Belt Travel
Top
cover

Bottom
cover

Belt Travel
3. Splicing Procedure
- Splicing Method

(1) Mark out the center line of the belt.

- By measuring the middle point of the belt width at a number of stations
and join these together.
(2) Mark the step length(S) and angle(0.3B) with a Glass pencil at Belt Edge of one
belt according to the splicing dimension of splicing procedure.

Center Line
3. Splicing Procedure
- Splicing Method

(3) Cut the end of both belts along the splicing angle line(0.3B) with knife holding
perpendicular to the belt.
(4) With knife, mark first cover band part and cut along line RQ.
* Note : Cut Cover rubber part only. Do not cut Fabric part.
(5) Cut off PO up to top ply, EF up to 2nd ply, GH up to 3rd ply, IJ up to 4th ply Vertically
* Note : Cut off up to appointed ply.
3. Splicing Procedure
- Splicing Method

(6) After cutting the cover rubber, Clamp the cover rubber with a peeler and Peel it off.
(7) Peel in step shape like type of splicing by using peeler.
(8) Follow the same procedures to complete the preparation of the other side.
3. Splicing Procedure
- Splicing Method

(9) After peeling off, give buffing thoroughly to the sections of the
① Top & Bottom cover, ② Edge rubber and ③ Fabric step “c”.
* When using rotating wire brush on “c” part, be careful not to damage fabric ply.

Buffing Rubber Part

Buffing Step “C” part

3. Splicing Procedure
- Splicing Method

(10) After buffing, clean all exposed areas of the belt using a brush to remove the buff
powder. Then, apply a small amount of “Trichloroethylene” to a rag and remove stain
of the surfaces of the belt.
* Before spreading the rubber cement, overlap the belt and check again to correct
the belt center line
3. Splicing Procedure
- Splicing Method

(11) Spread the rubber cement evenly on the entire surface to be spliced, and let it dry.
Spread the rubber cement on the other surface to be spliced in the same method.
(12) Dry the cement satisfactory till it does not stick to fingers when touched.
3. Splicing Procedure
- Splicing Method

(13) Applying a Tie gum (300mm widthx0.6mm thickness x required length) on entire
splicing surface of one end roll it down with a hand roll.
(14) After applying, with hand roller, force coating rubber in good contact with cemented
surface, use awl to puncture any trapped air bubbles.
3. Splicing Procedure
- Splicing Method

(15) Applying Filling gums at the End of each step.

(16) Remove air pockets with hand rollers and cutter knives.
3. Splicing Procedure
- Splicing Method

(17) Overlapping Top cover rubber part and Bottom cover rubber part.
3. Splicing Procedure
- Splicing Method

(18) Doing the Fill-in Area-1

- Spread the Rubber Cement on the Fill-in area.
- After the cement is dry, apply a sheet of Tie gum and roll it down with a hand roll.
- Apply the Rubber Cement on the surface of 30mm width Breaker strip(Reinforced
Fabric).
- After the rubber cement is dry, apply the Breaker strip(Reinforced Fabric) on the
sheet of tie gum and roll it down with a hand roll.

Cover
gum Tie gum

Breaker strip
(Reinforced Fabric)
3. Splicing Procedure
- Splicing Method

(19) Doing the Fill-in Area-2

- Trim off excess Cover Rubber stock all around to make the thickness equal to the belt
thickness.
- For the Bottom Cover Fill-in, the procedure is the same as Top Cover Rubber.
- Using awls, make many holes in uncured cover stock in order to let trapped air of
steam escape during vulcanization.
- When laps are firmly fitted together, the belt is ready for curing.
3. Splicing Procedure
- Splicing Method

(20) Vulcanizing-1
- Place the Un-cured belt on the platen
* Belt edge part should be placed on the platen at least 100mm inside the edge of
platen.
3. Splicing Procedure
- Splicing Method

(20) Vulcanizing-2
► Vulcanizing time and temperature differs depending on the belt thickness.
Usually, for 10mm belt at 145~150℃ for 25 minutes, and add minute for increasing
every 1mm thickness.
► Required time for vulcanizing is measured from the time when platen temperature
reaches fixed temperature. Splicing part of belt should be vulcanized in one press
► Vulcanizing time is calculated from the moment when the thermometer with the lowest
reading reaches the minimum vulcanizing temperature.
► Belt quality is greatly affected by the vulcanizing temperature. Temperatures higher
than those recommended have a deleterious effect on belt quality. Thus the
temperature of the vulcanizer should be checked constantly.
3. Splicing Procedure
- Splicing Method

(21) Cooling
► The vulcanizer should only be dismantled after the temperature has fallen below
100℃.

Temp(℃)
155~160

145~150 HRB
Normal ORN
HRP Temperature of
FR HRS
100 Dismantle
vulcanizer
• Vulcanizing Time : T4–T0
•Vulcanizing Time : T1-T0 • Time of rejected heater : T4
•Time of rejected heater : T1 • Dismantle Vulcanizer : T5
•Dismantle Vulcanizer : T2
0
T0 T1 T2 T3 T4 T5 T6

(22 ) Finishing
► Trim strip flush with belt edge thoroughly.
► Make smooth splicing part of cover rubber with sanding machine or sandpaper.
3. Splicing Procedure
- Splicing Method

(23) Chcking alignment

► Mark the center line at four points, 1/2/3/4 project line from 1 and 2 and from 3 and 4.
► Then draw a straight line between points 1 and 4.
► Measure the shift distance “h” between the two lines at the center point. The shift
distance indicates the non straightness of the spliced portion.

Standard h = less than 0.1%

h (mm)
distance from 1 to 4 (mm)
3. Splicing Procedure
- Measurement of the position of the take-up

► After dismantling the working table and belt clamps, apply the tension to the
conveyor belt by determining the position of take-up with the weight.
► Measure the length of sketch and record the values.

(a) Spare Length _________m

(b) Sufficient Length to Absorb

Elastic Elongation _________m
3. Splicing Procedure
- Splicing Check-Sheet

Check List Data

Specification of conveyor belt : EP630/4P 1000x4Px6.5x2.5 , 100M
Date of Splicing Jan. 13, 2009
Validity of splicing materials Till Oct. 13, 2009
Direction of splicing (belt travel direction) OK
Step length (mm) 200 mm
Damage of fabric NO
Place the uncured belt on the platen with belt edge (mm) 150 mm
Time (min.) 20 min.
Temperature (℃) 145 ℃
Vulcanizing
Pressure (kgf/cm2) 10 kgf/cm2
Edge iron thickness (mm) 14 mm
Shift distance (h) ratio (%) 0.05 %

Take-up pulley Spare length (a) 1.0 m

position Sufficient length to absorb elongation (b) 5.0 m
Attach a file #1