Splice Steel

1

Splicing Manual

Splicing ofSteel Cable Conveyor Belts

North

American

Edition

2

I. Range of Application 3

II. Products for SplicingSteel Cable Belts 4

III. Tools and Equipment 4

IV. General Conditions for SplicingSteel Cable Belts 51. Work place 52. Conveyor belt 53. Equipment and tools 54. Splicing products 55. Ambient conditions 56. Documentation 57. Precautions 5

V. Construction and Dimensionsof Steel Cable Belt Splices 61. Splicing methods 62. Construction 63. Determination of splice and step length 8

VI. Splicing of Steel Cable Belt 101. Preparations for splicing 102. Preparing the belt edges 113. Assembly of cover pads 164. Preparing and placing the bottom cover pad 165. Matching and laying the cables 186. Placing the top cover pad 227. Curing the splice 238. Completing the splice 24

VII. Questionnaire forREMA TIP TOP Splicing Kits 25

VIII. REMA TIP TOP Splicing Record Sheet 26

PageContents

3

This manual describes the splicing of steel cableconveyor belts (DIN 22131) with rubber covers made ofthe following polymers:

- Natural rubber NR*- Styrene butadiene rubber SBR*- Isoprene rubber IR*- Butadiene rubber BR*- or a mixture of above polymers, e.g NR/SBR*

In case of doubt, consult the supplier of the conveyorbelt about the rubber grade.

For splicing steel cable belts with a breaker pleasecontact your REMA TIP TOP distributor.

Splicing can be done in the workshop or on site.

* Abbreviations according to DIN ISO

I . Range of Application

4

I I . Products for SplicingSteel Cable Belts

STB COVER STOCK 43" & 53" wide byRef. No. 528 8889 - 538 0529 36 ft & 1/16" to 3/8"

STZ TIE GUM RUBBER 43" & 53" wide byRef. No. 538 8889 - 538 0938 36 ft & .060 to .125

STZ NOODLE STRIPS .080 to .120 gaugeRef. No. 538 0952 by .200 to .275 width

STL-RF CEMENT (NON-FLAMMABLE)Ref. No. 538 8882 - LRF - QT quartRef. No. 538 8882 - LRF - GAL gallonRef. No. 538 8882 - LRF - 5GAL 5 - gallonRef. No. 538 8882 - LRF - 200L 55 - gallon

STL-RF4 CEMENT (FLAMMABLE)Ref. No. 538 8882 - RF4 - QT quartRef. No. 538 8882 - RF4 - GAL gallonRef. No. 538 8882 - RF4 - 5GAL 5 - gallonRef. No. 538 8882 - RF4 - 200L 55 - gallon

REMA CLEAN #13 SOLVENT (NON-FLAMMABLE)Ref. No. 595 9020 1000549 quartRef. No. 595 9046 1000559 gallonRef. No. 595 tri 1000569 55 - gallon

REMA CLEAN #50 SOLVENT (FLAMMABLE)Ref. No. SOL FLAME QT quartRef. No. SOL FLAME GAL gallonRef. No. SOL FLAME 5GAL 5 - gallonRef. No. SOL FLAME 55GAL 55 - gallon

BROWN COATED RELEASE PAPERRef. No. 538 1030 76100 76" wide x 100' long

PRESSURE COMPENSATION CLOTHRef. No. 538 1009 41 49" wide x 41' long

STZ NOODLE EXTRUDER GUNRef. No. 517 5174

REMA TIP TOP Splicing Kits for other steel cablebelt cover grades are available on request!Please see section VII on page 25.

Splicing shelter / tentPolyethylene film (PE film)Cover clothScrew clampsMeasuring tapeRuler (in./mm)Metal ruleFlat angleMarking crayon (white)Rubber markerPlumb line6" knifeOff-set knifeWhetstoneScissorsPincersVise grip No. 2Vise grip No. 3Chain or cables winchesCable cuttersAngle grinderHand brushCement brushesStitchers & RollersHammerCable drumSafety gogglesWork glovesBuffing motor with flexible shaftRotating wire brushesGrooved wire brushesRTT Belt stripping systemVulcanizing press incl. edge bars and clampsThermometersRubber CutThickness GaugeSTZ Extruder gun

For detailed information about equipment,measuring instruments and tools please referto: REMA TIP TOP Industrial Programme.

I I I . Tools and Equipment

5

IV. General Conditions for SplicingSteel Cable Belts

´1. Work place

In order to ensure quality and durability of asplice, a clean and sheltered work place aswell as correct use and application of thesplicing products are essential.The exposed surfaces of stripped cables,bevel cuts and cover pads must be keptabsolutely clean.

2. Conveyor beltOnly clean and dry conveyor belts can bespliced reliably.Dirty or contaminated belts must be cleaned.Water-soluble contaminations should be scrapedoff and then washed away with water and dried.Oil and grease should be removed with CleaningSolvent.

3. Equipment and toolsTools and equipment must be in perfect workingorder. Measuring instruments have to becalibrated.

4. Splicing productsREMA TIP TOP Splicing products are suitablefor cable belts with RMA grade I & II rubbercovers. Splicing products have to be stored ina dry and dark place at a temperature of max.25oC (77oF) in accordance with DIN 7716.Check expiration dates and dispose of outdatedand contaminated products.

5. Ambient conditionsAny influence of humidity, e.g. formation ofcondensation water (temperature falling belowdew point) must be absolutely avoided.Precondition products to ambient temperatureif necessary.Erect a splicing shelter/tent for protectionagainst sun, dust, wind, rain etc.

6. DocumentationDuring the splicing operation all irregularitesand special conditions have to be recorded.The record sheet must be signed by thesupervisor at the end of each shift.

7. PrecautionsObserve safety precautions on the cans.

Note:Our recommendations result from field testsand years of experience. However, in view ofthe different materials and work conditionsbeyond our control, we recommend to makecorresponding tests locally in any case.We cannot assume any kind of liability resultingfrom these recommendations.

6

The loadability of both the rectangular and the rhombicshaped splice is similar. Usually a rectangular splice ispreferred, because it can be done more easily.

The following description refers to a rectangular splice.

2. Construction

Cable diameter d and cable pitch t as well as theminimum breaking strength of a cable and the dynamiccable tear-out strength in the splice area dictate lengthand geometrical construction of a splice.

The geometrical construction is determined by- number of steps- length of steps- length of transitions- cyclic cable laying sequence (incl. cut cables)- cable pitch in the splice area (noodle thickness).

The construction is also influenced by- distance between butted cables- stepping of cable ends- cable laying corrections and laying cycle modifications.

Rhombic shapeRectangular shape

Fig. 1

The gap between butted cables has to be min.3 times and max. 4 times the cable diameter d.

The cable ends should be staggered in order to re-duce the flexing load, when the belt runs over thepulleys.This mainly applies to belts with thin top covers.

Cables on the belt edges should not be cut.They should be layed in full length in oppositerunning direction of the belt.

Deviations of the cable laying scheme should bemoved to the belt center area, because the edgezones are exposed to a higher load.

V. Construction and Dimensions ofSteel Cable Belt Splices

1. Splicing methodsSplices on steel cable belts in accordance withDIN 22131 can be 1-step or multi-step splices inrhombic (belt width x .4) or rectangular shape.

7

lv = Length of splice

lq = Deflecting zones of cables

lp = Staggering of cable ends

lst = Minimum step length

ls = Distance between butted cables (3 to 4 x d)

d = Steel cable diameter

If a steel cable belt is equipped with a breaker, a breakershould be applied in the splice area corresponding tothe belt construction.Between breaker and transition zones where the topcovers are bevelled, there should be a gap of approx. 2In.

Transitionzone

Transitionzone

Fig. 2

20O - 30O

20O - 30O

Fig. 3

Belt Splice

Transition zone 2 inch

Top cover padBreakerSteel cableBottom cover pad

8

Other splicing methodsThe cable laying schemes as well as the step lengths,deflecting zone lengths and the splice lengthsindicated may be modified if necessary; e.g. whensplicing different belt types (mixed splice, belts endswith differnt amount of cables). Such modificationsrequire the approval of the plant operator.

3. Determination of splice and step length

The splice length lv includes:- Deflection zones of cables lq- Staggering of cable ends lp- Minimum step length lst- Distance of butted cables ls

Belt type Number Min. step length Splice length Thickness x Width (DIN) of steps lst lv Inchs

St 1000 1 24" 32" .080 x .235

St 1250 1 24" 32" .080 x .275

St 1600 1 24" 32" .080 x .275

St 2000 2 16" 46" .100 x .275

St 2500 2 20" 54" .100 x .390

St 3150 2 26" 66" .080 x .390

St 3500 3 26" 98" .100 x .430

St 4000 3 30" 110" .100 x .430

St 4500 3 32" 116" .080 x .470

St 5000 4 36" 170" .100 x .510

St 5400 4 40" 186" .100 x .510

Step lengths and splice lengths STZ Noodle Rubber

9

6" 6"

2"2" 2"

2-step splice(sectional view) Fig. 5

GurtlaufrichtungRunning direction of belt


Gurtlaufrichtung

2" 2" 2" 2"

8" 8"

Running direction of belt

Gurtlaufrichtung


10" 10"

2"2"2"2"2"



2" 2"

4" 4"


10

Fig. 9

8"3"Fig. 8

1.3 Aligning the belt ends

Place and align belt ends on lower part of pressand work tables, ensuring that both endsare overlapping on the press by at least thesplice length lv plus 4".Secure belt ends in this positon with clamps.

VI. Splicing of Steel Cable Belt

The heating platens must be flush with the surfaces ofthe work tables in order to avoid tensions at the belt ends.

The heating platens must be at least 8" longer than thesplice on either side and at least 3" wider than the belt oneach side (edge bars must be fully covered by the heatingplatens).

1. Preparations for splicing

1.1 Prepare tools, equipment and splicing materials.

1.2 Erect a splicing shelter, install a work table andthe vulcanizing press:The entire work area has to be adequately protectedby the shelter from environmental influences.

The work area consists of the lower part of the press(traverses and heating platens) and approx. 10 - 12ft. long wooden work tables at either end of the press.

11

Fig. 10

Fig. 11

Fig. 12

Fig. 13 Reference line

Placing the rulers

Belt center line

2. Preparing the Belt Ends

2.1 On both belt ends establish and mark- the belt center line- the perpendicular reference lines and- the belt cover transition lines.

Establish and mark center line of belt by measuringacross width of belt at three points in length of each beltend at a distance of approx. 6". At least two centermarkings on each belt end must be outside the splicearea.

The establishment of the center line is easiest done withtwo rulers (Fig. 10).The three center markings on each belt end are thenconnected by means of a chalk line which representsthe belt center line. This center line ensures exactalignment of the belt ends, which is indispensable forstraight belt running.The center line outside the splice area must be durableenough to remain evident throughout the entire splicingoperation!

Destroyed or missing rubber edges must be considered.The width of the rubber edge is established by measuringthe width of the carcass at suitable areas of the belt ends.

Establish a perpendicular reference line across bothbelt ends outside the splice area.On narrow belts this can be done by placing a metalsquare onto the center line.

On wide belts it is recommended to establish thereference lines as follows (Figs 11 to 13):Outside the splice area select a point A on the centerline. Mark points B and C on the center line equidistantto point A (AB=AC) (Fig. 11).

Now describe a circle with the same radius around pointsB and C by means of a plumb line and a pen. The pointsof intersection of both circles must still be on the belt.These intersections are points D and E (Fig. 12).

A line drawn between these two points will beperdendicular to the belt edges and forms the referenceline, which should pass point A for additional control (Fig.13)

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2.2 Cut off the rubber edges along the outer steel cablesfrom belt transition lines to belt ends with a long knife(Fig. 15).

Center line

Center line

Fig. 16

Reference lineReference line

Belt endBelt end Transition line Center line Transition line

4"

a = Distance between reference lines (must be equal on both sides)

Fig.14

2.3 Bevel cut through top cover down to the steel cablesalong the belt transition line using a Don Carlos knifeheld at an angle of approx. 30o (Fig. 16).

4"

Fig. 15 Transition line

Transition line

4"

The reference lines are now marked by cutting smallnotches into the belt edges.

The notch marks of the reference lines on both edges ofthe belt ends are now the reference points from whichthe splice length lv is measured and marked (Fig. 14).

For exact measuring, another 4" are added to the splicelength on either side and marked.

The marks now established for the splice length areconnected on the belt with a chalk line or with a ruleand a pen.

These lines are the belt transition lines for the bevelcuts on carrying and running side of the belt.

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ca. 1/2"

Transition line

Transition line

Center line

During this operation the rubber cover is under tensionand has to be secured with a rope in order to protect thework men in case the vise grip slips off. When cutting offthe rubber cover hold the knife at such an angle that thesteel cables remain covered with rubber.

The exposed carcass must be protected from contami-nation and placed onto a clean surface (e.g. PE film).

After having removed the rubber covers on both sides ofthe belt, cut out the rubber between the steel cables witha 6" knife to within 1/2" of the bevelled transition zone(Fig. 18).

The stripped cables should still be covered with rubber(cubed cable rubber). On cables which are stronglytwisted the corners should be trimmed off also (Fig. 19).

Cables with a diameter of 8 mm and more:Before cutting out the rubber between the cables notchthe rubber between the cables at an angle of approx.45o, resulting in a hexagonal rubber (Fig. 20).

Stripped cables should be handled with clean gloves onlyand placed onto a clean surface (PE sheet).

Fig. 19

Fig. 20

Fig. 18

Fig. 17

Center line

2.4 Removing top and bottom cover andstripping of steel cables

a) Conventional manual procedure

Cut the rubber covers on the carrying and running sideinto parallel strips with a Don Carlos knife (15" - 30" wideaccording to belt width) in length direction of the belt.

Lift the rubber cover with pincers at one corner of a stripin the area of the belt transition line and cut it free withthe Don Carlos knife just above the steel cables, untilthe cover can be gripped with a REMA TIP TOP ViseGrip.By means of the vise grip, a winch and continuous cutting(just above the steel cables) the complete rubber coveris removed (Fig. 17).

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Fig. 21 REMASTRIP-Cutting unit Pulling cable Pulling unit

6" - 8"

2.5 Buffing the rubber embedded cables (Fig. 22)

Carefully buff the rubber embedded cables with a groovedREMA wire brush. Avoid overheating, shiny spots andscorching of the rubber. Buffing will automatically breakthe edges of cubed cable rubber. Non-adhering or looserubber has to be removed. A minimum of bare metal shouldbe exposed. A small amount of such exposure can betolerated. The strength of a splice depends on the levelof cable adhesion to the original rubber embedding it.The new STZ rubber bonds to the original cable rubber.The splice strength depends on the shear adhesion of arubber to rubber bond, rather than a rubber to metal bond.Damaged, corroded or bare cables have to be buffeduntil they are bright. An excessively damaged cable hasto be removed. In case of several damaged or corrodedcables the operator should be informed immediately, whowill have to decide whether the splicing job should becontinued or a new belt installed. The number andcondition of such cables and partially bare cables shouldbe noted in the splicing record.

Fig. 22

b) Stripping the steel cables with theREMA TIP TOP Cable Stripping System

With the REMA TIP TOP Cable Stripping System thecables are stripped in one single, time-saving operation,without prior removal of the top and bottom cover.

This mechanical stripping system requires the followingadditional preparations:

- Approx. 6" - 8" from the transition line drawan additional, parallel line on top cover side andbottom cover side of the belt ends.

- Cut the rubber cover along this line straight downto the cables.

- Remove the rubber cover between transition lineand the vertical cut in the conventional, manual way.

Now install the REMA TIP TOP Cable Stripping Systemaccording to instructions and start stripping the cablesfrom the left side of the belt in direction belt end.

Please make sure to use cutting blades correspondingto the cable diameter.

After stripping, the result should be a nearly round cable,with .010 of rubber embedded on the cable.

Stripped cables should be handled with clean gloves onlyand placed onto a clean surface (PE film).

15

approx 1/2" - 3/4"

PE protection film

STL-RF / STL-RF4 Cement

center line

approx 1/2" - 3/4"

Fig. 23

2.6 Buffing the transition zonesOn the top cover and bottom cover side of both belt endsthe rubber surfaces of the transition zones and another1" - 2" on either side of them must be thoroughly buffedwith a rotating wire brush. Overheating, shiny spots andscorching of the rubber should be avoided.

2.7 Removing the buffing dustThe buffing dust has to be thoroughly removed with aclean hand brush. Place belt ends back onto the worktables and arrange the cables on a clean surface (PEfilm).

2.8 Applying heating solutionApply two thin and even coats of REMATIP TOP STL-RF or STL-RF4 cement to the transitionzones and the cables (Fig. 23).Allow the first coat to dry completely before applying thesecond coat.

2.9 Aligning the belt endsAlign lower part of the vulcanizing press (traverses andheating platens). In case of low ambient temperaturepreheat the heating platens to max. 100oF (40oC).Establish number of cables of each belt end and markthe carcass center.

Align the belt ends under consideration of splice length lv,the belt center line and the carcass center line on eachbelt end and mark correct alignment with a chalk line.Now the center lines on both belt ends must form onestraight line. The distance of the reference lines on bothbelt edges must be equidistant (a = a - see Fig. 14 onpage 12). Secure both belt ends with clamps.

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Fig. 24

Cloth

3. Assembly of cover pads

Pressure Cloth

Pressure Clothstrips

Brown ReleasePaper

Brown Release Paper

4. Preparing and placing the bottom cover pad

4.1 If necessary place thin metal strips over the joints onlower heating platens. Place strips of 10" - 12" widePressure Compensation Cloth over the transition zonesand the splice edge zones in such a manner, that theycan be folded up later in order to cover the complete rubberedge. Then cover the complete heating area with BrownSilicone Coated Release paper (Fig. 24).

4.2 Remove the green protection film from the coverstock side of the cover pad. Place the cover pad ontothe covered heating platens and align. The red protectionfilm (STZ rubber side) is now on top.In case of several partial cover pads also coat thebevelled edges with STL-RF / STL-RF4 Cement and allowto dry until they are still slightly tacky. Then join the coatededges without trapping air and stitch together .

The assembly of top cover pad and bottom coverpad is usually done in the workshop. They consistof .080 thick STZ tie gum rubber and STB cover stock.

Required minimum thickness of cover pads:- Thickness of belt cover plus .040.

Dimensions of the cover pads:- Belt width plus 6"- Splice length plus 10"

For large splice lengths and wide belts the coverpads may be made up in two or more parts.

The tie gum rubber side is covered with a red protectionfilm; the cover stock side is covered with agreen protection film.

For splices with breaker the STZ tie rubber is.120 thick. The breaker is placed between STBcover stock and STZ tie gum rubber and should notextend into the rubber edge zones and leave2" between breaker edge and both transitionzones. In this case the minimum cover pad thicknessis: Thickness of belt cover plus .080.Type and construction of the breaker required shouldbe coordinated with the operator or the belt manufacturer.

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Fig. 25

3/8" STB.080 STZ

Fig. 26

Fig. 27

Cover pad

4.4 The transition zone of the other belt end is matchedand placed in the same way (Fig. 26).

Again check the correct alignment of the belt center linesand also the splice length lv and adjust/correct if required(Fig. 27).

4.3 In the area of the transition zone remove the redprotection film by approx. 4". Place one belt end onto thecover pad and mark first splice edge. Fold belt end backagain and bevel cut the cover pad at an angle of approx.30o corresponding to the bevel cut angle of the transitionzone.Before handling the belt ends bundle the steel cablesand wrap them into PE film.

Now apply a thin and even coat of STL Cement to thebevelled edge of the cover pad.If the coat of STL Cement on the transition zone is nolonger tacky enough, apply another coat and allow bothcoats to dry until they are still slightly tacky.Place the transition zone of the belt onto the bevellededge of the cover pad, press on and tap down with ahammer (Fig. 25).

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lv = Length of splice

lq = Deflection zones of cables

lp = Staggering of cable ends

lst = Minimum step length

ls = Distance between butted cables (3 to 4 x d)

d = Steel cable diameter

5. Matching and laying the cables

Fig. 28

5.1 Completely remove the red protection film from thebottom cover pad and mark the step lines (lst and lp) forlaying the cables according to the specified layingscheme.Scribe these lines on the cover pad with a knife tip. Theselines must still be visible after coating with STL Cement.The step lines can also be marked by placing STZ Noddlerubber strips onto the established lines.Place clean PE film or similar over the bottom cover pad,leaving exposed approx. 4" in the center in length directionof the belt. The tack of the tie gum rubber, which will beexposed further step by step can further be improved byapplying a very thin coat of the STL Cement.

19

Belt center lineand center cable


Belt center lineand leftcenter cable


Fig. 29

Belt running direction




Fig. 30

Fig. 31

Fig. 32

Odd number of cables1-step splices:

The center cable of the second belt end may be cut at the bevel cut. It will not be deflected,but laid directly onto the belt center line.

2-step and multi-step splices

In both cases start with the center cable of the first belt end, which in case of a multi-stepsplice is a long cable. This cable is deflected by half the cable pitch towards the belt center line.

On the second belt end also start with the center cable, which then is deflected towards theother side of the belt center line by half the cable pitch and laid in the matching length in accordancewith the cable cycle. All further cables are laid according to cable laying scheme proceeding tothe edge on both sides.

Even number of cables

On both belt ends start with the left cable of the two center cables (as seen from the first beltend) which are staggered towards the marked belt center line.

Even and odd number of cables

If the number of cables in the belt ends are not matching, start laying the center cable of the beltwith the odd number of cables onto the belt center line and then proceed according to thespecified cable laying scheme.

5.2 Laying the cablesThis operation is always started at the center of the splice.

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The gap between butted cables must correspondto between 3 and 4 times the steel cable diameter!

When laying and pressing on the STZ tie rubberstrips a uniform distance between the cables mustbe ensured, especially at the cable ends, whichare exposed to the maximum rubber shearing forcewithin the splice.

The edge cables must always be long cables fromthe first belt end.

This is achieved by checking the cable laying scheme atleast 10 - 15 cables before the edge cables are reached.If according to the laying scheme the edge cable will notbe a long cable from the first belt end, an initial adjustmentcan be made by cutting a cable from the second belt endat least 10 - 15 cables away from the edge cable.

In case of a 1-step splice a cable has to be cut on onebelt end only which usually is the only way ofcorrecting.

Exceptions are:- when the center cable of the second belt end with

an odd number of cables has been cut in the beginning (para. 5.2) or

- when the number of cables in the first belt end is smaller by one cable and a cable has alreadybeen cut on either side of the splice.

On multi-step splices there is an increased numberof possibilites for adjustment.

Edge cables must never be cut! The cables to becut always have to be at least 10 -15 cables awayfrom the edge.

STZ noodle rubber strips

STZSTB

Fig. 33

5.3 Laying the cablesAfter having determined how to start laying the cables,all further cables are cut according to the marked steplines and pressed onto the bottom cover pad inaccordance with the specified cable laying scheme (Figs.4 to 7).

STZ noddle rubber strip is placed edgewise between thecables, after having removed its protection film (Fig. 33).

The dimensions of the STZ noddle rubber strips areindicated in the table on page 8 and ensure that the cablesare laying straight.

During the laying operation continuously check that thecables are laying straight.

If this is not the case, despite of careful laying of cablesand noodle rubber, proceed as follows:If the cables are bent towards the edges of the splice, tryto move the cables closer together by tapping them witha hammer and pulling the noodle rubber at the same time.If this does not bring the desired result, the only way is tocut a cable on the second belt end first and then, if stillnecessary, also on the first belt end.

If the cables are bent towards the belt center compen-sate by placing additional STZ noodle rubber strips.

Never cut two cables next to each other!

21

Cutting one or more cables will solve a problem for thenecessary adjustment.

If there is sufficient space in the edge area, it isrecommended to place a thicker strip or two strips ofSTZ noodle rubber. A STZ noddle rubber strip is alsoplaced along the edge cables and pressed on.

When the last cables are laid, there should be sufficientspace for the rubber edge.

Fig. 34

5.4 After having laid all cables mark the splice edgeswith a chalk line and trim excess rubber. Apply a coat ofSTL-RF / STL-RF4 Cement to the edge of the bottomcover pad and to the excess STB cover stock. Allowthese coats to dry until they are still slightly tacky (checkwith back of finger). In case of overdrying apply anothercoat.Build up edges with excess STB cover stock to the upperlevel of the cables.The splice should now be slightly wider than the adjoiningcured belt. Excess material will be trimmed later togetherwith the top cover pad (Fig. 34).

5.5 Thoroughly and completely fill up all remaining gapsand cavities slightly above upper level of cables eithermanually or with the REMA TIP TOP STZ extruder gun.

22

Fig. 35

Fig. 36

Fig. 37

6. Placing the top cover pad

6.3 When placing the top cover pad avoid trapping air.Then remove the green protection film.

Press on and stitch the top cover pad vigorously fromthe center outwards or in direction of the butt jointsrespectively and firmly tap down with a hammer in thetransition zones (Fig. 35).

Remaining air within the splice area can be evacuatedby making approx. 4" - 6" long cross cuts down to thecables (not in case of top cover pads with a breaker) andusing a awl.

6.1 Apply a generous coat of STL Cement to the buffedupper bevel cuts of the transition zones on both belt endsas well as to the built up rubber edges and allow to drycompletely.

6.2 Before placing the top cover pad onto cables andrubber edges proceed as follows:

- check the thickness of the cover pad- preheat the heating platens to max. 100o F (40oC),

if necessary- remove the red protection film from the tie rubber

side.Depending on the tack of the already coated tie rubberapply another thin coat of STL Cement. In case of severalpartial cover pads also apply a thin coat of STL Cementto the edges.

6.4 Trim excess rubber in the transition zone with an off-set knife. Mark the splice edge with a chalk line and trimwith a long knife (Fig. 36).The REMA White markingRubber and be appliedat this time (see page 25sec 8.3)

6.5 Again check the correct alignment of the belt centerlines of both belt ends with a string. Deviations can nowstill be corrected. This final control/correction is importantfor straight running of the belt and therefore indispensable(Fig. 37).

23

Fig. 38

Fig. 39

7. Curing the splice

7.1 Apply 8" - 10" wide strips of Pressure Cloth onto thetransition zones of the top cover pad and fold the lowershirting strips around the splice edges(Fig. 24 on page 16).

Then cover the complete heating area with Brown SiliconeRelease Paper and trim on either end of the splice. Nowthe edge bars (edge irons) are applied on both sides ofthe splice and pressed against the belt edges with edgeclamps, which are mounted outside the press area. Theedge bars must be approx. 1/16" thinner than the belt(Fig. 38).

7.2 Assemble top platens and then place the uppertraverses in line with the lower traverses.The upper heating platens also must be at least 8" longerthan the splice on either side and at least 3" wider thanthe belt on each side. The edge bars must be fully coveredby the heating platens. The arrangement or layout of theheating platens must be noted in the splice record.

When aligning the heating platens and the traverses ithas to be ensured that the platen joints in direction of thebelt edges are supported by the traverses and that thefirst and last traverse is located outside the splice area.Now the pressure bolts are installed and have to betightened evenly and simultaneously in each travers.Then secure the edge bars by means of wedges andcome-a-longs (Fig. 39).

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1/4/98 RTT 14 8

8. Completing the splice

Splicing date(day/month/year)01.04.98

ContractorREMA TIP TOP

Splice numberNo. 14

ID abbreviationof vulcanizer

Marking example: 1/4/98 RTT 14 8

8.4 The conveyor belt can be put into operation after thesplice has cooled down to ambient temperature.

8.5 Finally the splice record sheet must be completed.All irregularities occurred during the splicing operationshould be registered. The record sheet should be signedby the Supervisor of the contractor and countersignedby the operator.

7.3 Attach the electrical connections and pressuresystems of the vulcanizing press observing the operatinginstructions of the press manufacturer. The press mustproduce a minimum pressure of 180 PSI (specificpressure: 12 bar).

7.4 Increase pressure while temperature rises andobserve temperature on all heating platens. Platentemperature uniformity should be within +/- 5oF (10oC ) ofthe selected temperature. Higher deviations must berecorded.

7.5 Apply specific pressure when all heating platens havereached a temperature of between 212oF (100oC) and230oF (110oC) and maintain this temperature for a periodof approx. 5 minutes by disconnecting the electricalconnections at 230oF (110oC) and connecting again whenthe temperature has dropped to 212oF (100oC).At this temperature range the rubber develops itsoptimum flowing properties.

Never exceed the permissible specified pressure!

7.6 Then continue increasing the temperature. The curingtime starts when the temperature on all heating platenshas reached 293oF (145oC). The curing time depends onthe belt thickness.REMA TIP TOP products require a curing time of 3minutes per 1/32" belt thickness, but not less than 30minutes.

7.7 Set the electrical connections at a temperature of 298oF(148oC) and connect again when the temperature hasdropped to 293oF (145oC).Repeat this operation until the curing time is completed.

If necessary place thin metal strips over the joints priorto placing the top heating platens.

7.8 When curing is completed allow the heating platensto cool down to 140oF (60oC) before releasing the pressure.

8.1 Remove vulcanizing press, strips of cloth, brownsilicone release paper and inspect the splice. Check forcorrect vulcanization (absence of porosity or blisters,elasticity, thickness and Shore hardness).

8.2 Trim edges, remove material overflow and make anyother appearance modifications as may be necessary.

8.3 The splice should be durably marked with a splicenumber (DIN 22129) by means of theREMA TIP TOP Rubber Cutter or theREMA TIP TOP Branding Iron or theREMA White Marking Rubber.

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VII. Questionnaire

.............................................................. ........................................................... .................................Company Place DateSignature

Belt Manufacturer ......................................................

Belt Specification acc. DIN ST ................................................

Rubber Grade ......................................................

Cable Diameter .................................................

Cable Pitch .................................................

Belt width .................................................

Top Cover Thickness .................................................

Bottom Cover Thickness .................................................

Specified Splice Length .................................................

Splice Geometry ! rectangular ! rhombic (22o)

Breaker ! Carrying side ! Running Side

Please complete and send this questionnaire together with your inquiry or purchase order.

In order to ensure quotation/supply of the correct splicing kit, the following details are required:

REMA TIP TOP Splicing Kitsfor Steel Cable Conveyor Belts

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VIII. REMA TIP TOP Splicing Record Sheet

1. JOB DETAILS

Customer: ................................... Contact Name: .................................. Job Card No.: ................................

Supervisor: ................................. Crew Names: ..................................................................................................

Date/Time: .................................. Scope of Work: ...............................................................................................

Special Instructions: ...................................................................................................................................................

.....................................................................................................................................................................................

2. SITE INFORMATION

Site Conditions: ........................................... Accessibility: ....................................................................................

Weather: .....................................................Temperature: .................oF/oC Humidity: ......................%

Arrival/Dept.: .....................h/..................... h Reported to: .....................................................................................

Belt isolated/locked by: ................................ Waiting time: ....................................................................................

3. BELT DATA

Belt Manufacturer: ....................................... Belt Type:.................................. Belt Length: ................................

Cover Thickness: Bottom Cover: ............... Top Cover: .............................

Cover Grade: ............................................ Belt Condition: .........................................................................

Splice Length: .......................................... Step Length: ..........................

! Cables stripped manually! Cables stripped with RTT Cable Stripping System! Cables buffed with REMA grooved wire brush

Thickness Left Side Right Side

Leading end (first belt end) .............. ................

Trailing end (second belt end) .............. ................

Alignment: 1 2 3

Width of first belt end (leading end) ......... ......... .........

Width of second belt end (trailing end) ......... ......... .........

4. MATERIALS USED

Splicing Product STL Cement STB-Cover Stock STZ - Tie Gum STZ-Noodles

Manufacturing date

Expiry Date

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5. CURING PROCESS

Vulcanizing Press: Manufacturer: ................. Model: ...........................................Pressure System: ! Hydraulic ! Water Bag ! Mechanical

Heating Platens: ! Rhombic (22o) ! RectangularNumber of pairs of traverses: ...................................... Calculated Curing Time: ................minsThickness of edge bars: ......................................Heat up time to 293oF (145oC) Time started: ............h Time reached: ...............h

Cooling down time to 140oF (60oC) Time started: .......h Time reached: ........ h

6. FINAL QUALITY CONTROL

Alignment: ! Correct ! Off center ...........................inchsEdge trimming: ! Yes ! NoRubber Hardness (Shore A): TopCover:.............................BottomCover: ........................................Appearance of top and bottom cover surface: .......................... Splice marking: ......................................Signature of Shift Leader: ..........................................................Date: .....................................................

7. CUSTOMER SATISFACTION Professional Acceptable Unacceptable

Job organization ! ! !Safety regulations ! ! !Job performance / skills ! ! !Tools and equipment ! ! !Work force appearance ! ! !Work finishing / cleanliness ! ! !Time keeping ! ! !Observations: .............................................................................................................................................

...................................................................................................................................................................

Date: ...............................Site Manager: .............................................Signature: ......................................

Curing Time Temperature oF (oC) Pressure (PSI) Heating Platens No. 1 2 3 4 5 6 Gauge 1 Gauge 2

10 mins20 mins30 mins40 mins50 mins60 mins70 mins80 mins90 mins

100 mins110 mins

120 mins

Distributor:

Splice Steel

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