Conveyor Belt Fabric Splice Manual www.contitech.us Job #: 1090966 Element: 437_Splice Manual v#: FA3 Date: 6 April 2015 11:23 AM Proof-English: Proof-Spanish: Copy: Art: B Barlow / CD/CFW/cph/CD/cph Notes: 3 Hole Drill (Die layer does not print) Creative Director: SP Production:RG AS/Fullfilment: NT Other:MC/RK Bleed: .125" Trim or Flat: 17" x 11" Live: Finished Size: 8.5" x 11" # of pages: 68 Colors: 4-Color Scale/Resolution: 100%, 300 dpi Bindery: Saddle Stitch Conveyor Belt Fabric Splice Manual 2 Table of Contents I. Splice Technologies I. Splice Technologies V. Belt Splicing Procedures Splicing Best Practices White Dot Procedure Splicing Best Practices 2 Fabric Belt Bias Step Splice 19 Splice Materials - Do’s and Don’ts, Age Limits 3 Splice Dimensions 19 1. The White Dot Procedure is a method to identify the 9. Place a noodle or narrow strip of the inside rubber over Most Common Fabric Splice Mistakes 4 Splice Bias 19 “Factory Cut Edges” of narrow belts that are slit from the ply seam/joint. Procedures 19 wider belts. 10. Apply a sheet of the specified inside rubber over the fabric II. Belt Installation 2. On rare occasions the narrow belts may camber or bow surface only. Do not allow the inside rubber to advance Bias Step Finger Splice 26 towards the Factory Cut Edge side of the slit belts. onto or over the 45° cover skives. Belt Storage and Installation 5 Handling the Roll of Conveyor Belt 5 Long Life Full Carcass Finger Splice 29 3. The Factory Cut Edges are clearly marked and identified 11. Using a porcupine roller, roll the sheet of inside rubber Stringing the Belt 6 from the factory before shipping the belt. flat and remove all possible trapped air. Tensioning the Belt 7 ContiPipe™ Belt Splicing 34 4. The words “Factory Edge” are spray painted on the side 12. Using a clean, lint-free cloth and the specified solvent, wipe Take-Up Travel and Initial Position 8 of the belt. the top surface of the freshly installed inside rubber sheet. Cutting the Belt to Length 9 Mechanical Splice (Fasteners) 36 Squaring the Belt End 36 5. When the narrow slit belts are being spliced together on 13. Using a clean, lint-free cloth and the specified solvent, wipe III. Fabric Splice Preparation Classes of Mechanical Fasteners 36 the same conveyor, the Factory Cut Edges must be aligned the bottom surface of the specified breaker. Tightening Fasteners 37 on the same side of the conveyor. 14. Apply the breaker over the ply seam/joint. Carefully center Preparation of Work Area 10 Hazard to the Belt 37 6. To match the Factory Cut Edges on the same side of the the breaker so that equal lengths are positioned on each Splice Tools 11 Fasteners for Special Requirements 37 conveyor, one of the narrow slit belts must be re-rolled. side of the ply seam/joint. Direction of Splice and Bias 13 Fastener Application Cover Skive Instruction 38 This belt will have the “Factory Edge” side marked as well Existing Splices Loaded onto a Conveyor System 14 15. The breaker is approximately 3.5 in. x full width. This will as “Re-Rolled” spray painted on the other side of the belt. Establishing a Master Line 14 Elevator Belt Splice 40 allow approximately 1/4 in. of space from each edge of Establishing a Center Line 15 Installation 40 7. Many times belts that bow/camber can run straight on the the breaker to the base of the 45° cover skive. Dry Fit Splice Alignment 15 Splicing 40 system after initiating belt tension and running the belt for 16. Do not allow the breaker to advance to the 45° cover skive. Addressing Belts with Damaged Edge(s) 15 Attaching Buckets 41 a break-in period. However, some belts that bow/camber Addressing Belts with Unequal Widths 15 may be difficult/impossible to train and run straight on 17. Using a porcupine roller, roll the breaker flat and remove Solar-Shield® XL 750 Splicing 42 the system without matching up the “Factory Cut Edge” all possible trapped air. IV. Vulcanizing Splice Dimensions 42 sides on the same side of the conveyor system. 18. Using a clean, lint-free cloth and the specified solvent, Splice Bias 42 Building the Fill Strips wipe the top surface of the breaker and the bottom of Cure Time and Temperature 16 Step Length/Curing Chart 42 the specified cover rubber. Pressure 16 Splicing Material 43 1. A leading cause of fabric belt premature splice failures is Power Failure: 50% Rule 17 Building the Fill Strips 43 the breakdown of the fill strips. 19. Install the cover rubber. Be sure of a tight fit against Pressure Failure 17 Procedure 43 the 45° cover skives. 2. The typical specified cover skive is 4 in. at the base Vulcanizing the Splice 17 x full width. 20. Using an awl, puncture holes throughout the cover Press Platen Cooling 18 Special Belt Splices 48 rubber insert. Splice Completion 18 Wedge-Grip 48 3. Cover rubber skives are cut at 45° angles. Buff the cover General Curing Notes 18 Bareback 48 skives and approximately one inch of the surrounding 21. Using a small straight edge verify that there is sufficient Cleated Belt 48 belt cover. rubber in the fill strip area to prevent low pressure. Fold Belt 600 2 Ply 49 4. Remove all buffing debris from the splice area. Ply Seam Gaps 5. Using a clean, lint-free cloth, wipe the 45° cover skives and 1. All ply seams must have a gap measuring approximately the buffed surrounding rubber with the specified solvent. 1/32 in. to 1/16 in. wide. 6. The ply seam/joints must have a 1/32 in. to 1/16 in. gap. 2. Never butt the ply seams/joints tight together. Do not butt the fabric plies tight or allow them to overlap. 3. Never allow the ply seams/joints to overlap. 7. Apply one even layer/coat of the specified cement to the 4. Place a noodle or narrow strip of inside rubber over the exposed fabric only. Do not cement the 45° cover skives. ply seams/joints. 8. Allow the cement to dry until tacky. Do not allow the 5. Each ply seam/joint must be properly aligned using steps cement to dry past the tacky stage. #1 - #3 when dry fitting the splice. NOTICE: Continental ContiTech does not typically specify cementing rubber to rubber interfaces. Testing has proved the best rubber to rubber bonding is achieved by wiping with the specified solvent. However, for those rare occasions when additional green tack is needed, apply a layer/coat of the specified cement to the rubber surfaces. Conveyor Belt Fabric Splice Manual 3 Conveyor Belt Fabric Splice Manual 4 Proper Storage, Handling and Use of Splice Materials 50% Rule – Be Here Now – In Case of Power Failure 7. Do handle splice materials in accordance with all federal, 6. Reducing the specified step lengths of the splice to fit state and local laws. Become familiar with MSDSs for into a short vulcanizer or to save time will significantly 1. It is the responsibility of the splicing company and/or the 1. It is very important that someone is watching over the all materials. reduce the vulcanized splice strength. end user/customer to properly store and handle all splice vulcanizer and documenting the cure time, the cure materials. It is also their responsibility to dispose of any temperature from each thermocouple and the cure 8. Do use only the specified materials for the belt to be spliced. 7. Assembling a splice with contamination can reduce ply unused or unwanted materials properly. pressure at given intervals throughout the cure cycle. and cover adhesion/bonding. 9. Do not use splice materials that are beyond their 2. Material shelf life may be extended if stored in a 2. In case of a power failure while curing the splice, do not shelf life/age limits. 8. Using over age, incorrect or improperly stored materials refrigerated storage area. release or lower the curing pressure, but hold it until can significantly reduce ply and cover adhesions. 10. Do not store splice rubber in direct sunlight or heat. power is restored and then bring the vulcanizer back 3. Each material will have the Refrigerated and Non- 9. Using incorrect compounds and/or cements can to cure temperature. At that time: refrigerated date posted on them. significantly reduce adhesions as well as cause ply and › If the splice had less than half its specified cure time Unrefrigerated cover blows. 4. Do not use splice materials that have exceeded their before the power failure, repeat the entire splice. Age Limits (But Cool and Dry) Refrigerated shelf life/expiration dates. 10. Improper splice alignment can cause off-center tracking. All Rubber and Breakers Except › If the splice had cured one half or more than the 6 Months 12 Months 5. Keep all splice rubber completely wrapped with film/poly. Solar-Shield® XL 750 11. Overlapping and/or misaligned plies and/or carcass specified cure time, then finish curing the remaining Solar-Shield® XL 750 Rubber fingers: Align the splice with a gap of approximately 6. All splice materials must maintain identification and time after all the thermocouples again register the 3 Months 6 Months and Coated Breakers 0.063 in. (1.6 mm) at ply seam/joint and between fingers. expiration periods attached. specified cure temperature. M-856-C Cement 3 Months 6 Months Fill the gaps with the specified inside rubber.