Belt Splicing QC

Standard Technology
Title: Textile Ply Belt Splicing Quality Unique Identifier: 240-55864585

Control Standard
Alternative Reference Number: RES-RR-02-19324
Area of Applicability: Engineering
Documentation Type: Standard
Revision: 1
Total Pages: 33
Next Review Date: November 2015
Disclosure Classification: CONTROLLED

DISCLOSURE
Compiled by Approved by Authorised by
………………………………….. ………………………………….. …………………………………..
J Hlabangana A Wiid I Atiya

Senior Engineer Corporate Specialist Corporate Specialist
Date: …………………………… Date: …………………………… Date: ……………………………
Approved by TDAC
…………………………………..
D Odendaal
TDAC Chairperson
Date: ……………………………
Textile Ply Belt Splicing Quality Control Standard Unique Identifier: 240-55864585
Revision: 1
Page: 2 of 33
CONTENTS
Page
1. INTRODUCTION ...................................................................................................................................................... 4
2. SUPPORTING CLAUSES ........................................................................................................................................ 4
2.1 SCOPE .............................................................................................................................................................. 4
2.1.2 Purpose ..................................................................................................................................................... 4
2.1.3 Applicability................................................................................................................................................ 4
2.2 NORMATIVE/INFORMATIVE REFERENCES .................................................................................................. 4
2.2.1 Normative .................................................................................................................................................. 4
2.2.2 Informative ................................................................................................................................................. 5
2.3 DEFINITIONS .................................................................................................................................................... 5
2.3.1 Classification ............................................................................................................................................. 5
2.4 ABBREVIATIONS .............................................................................................................................................. 5
2.5 ROLES AND RESPONSIBILITIES .................................................................................................................... 5
2.6 PROCESS FOR MONITORING ........................................................................................................................ 5
2.7 RELATED/SUPPORTING DOCUMENTS ......................................................................................................... 5
3. TEXTILE PLY BELT SPLICING QUALITY CONTROL STANDARD ..................................................................... 5
3.1 CONCLUSIONS ................................................................................................................................................ 5
3.1.1 RECOMMENDATIONS ............................................................................................................................. 6
3.1.2 INDUSTRY PERSPECTIVE ...................................................................................................................... 6
3.1.3 KEYWORDS.............................................................................................................................................. 6
3.2 APPENDIX A (REFERENCE CHECKLIST) ...................................................................................................... 6
3.2.1 Appendix B (Tools checklist) ..................................................................................................................... 6
3.2.2 Appendix C (Quality control plan).............................................................................................................. 6
3.2.3 Appendix D (Inspection checklist) ............................................................................................................. 7
3.2.4 Appendix E (Data sheet) ........................................................................................................................... 7
3.2.5 Appendix F (Shore hardness mapping) .................................................................................................... 7
3.2.6 Appendix G (Procedure illustration) .......................................................................................................... 7
3.3 APPENDIX H (SPLICE COMMISSIONING) ..................................................................................................... 8
3.3.1 Test and Inspection 2.8.1.1 Dimensions ................................................................................................... 8
3.3.2 Soundness................................................................................................................................................. 8
3.3.3 Hardness ................................................................................................................................................... 8
3.3.4 Clear the Permit to work (PTW) ................................................................................................................ 8
3.3.5 Visual ......................................................................................................................................................... 8
3.3.6 Commissioning .......................................................................................................................................... 8
3.3.7 Requirements from Contractor by the Client ............................................................................................. 8
3.4 CONCLUSION ................................................................................................................................................... 9
3.4.1 Tools and Equipment ................................................................................................................................ 9
3.4.2 The Heating System .................................................................................................................................. 9
3.4.3 The Control System ................................................................................................................................... 9
4. REVISIONS ............................................................................................................................................................ 10
5. DEVELOPMENT TEAM ......................................................................................................................................... 10
6. ACKNOWLEDGEMENTS ...................................................................................................................................... 10
APPENDIX A :REFERENCE CHECKLIST................................................................................................................ 11
7. REFERENCE CHECKLIST .................................................................................................................................... 11
APPENDIX B :TOOLS ............................................................................................................................................... 12
APPENDIX C : QUALITY CONTROL PLAN ............................................................................................................. 13
8. QUALITY CONTROL PLAN .................................................................................................................................. 13
SITE INFORMATION ............................................................................................................................................ 13
CONTROLLED DISCLOSURE
When downloaded from the EDMS, this document is uncontrolled and the responsibility rests with the user to ensure it is in line
with the authorised version on the system.
Revision: 1
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APPENDIX D : QUALITY CONTROL PLAN ............................................................................................................. 16

APPENDIX E : DATA SHEET .................................................................................................................................... 19
9. DATA SHEET ......................................................................................................................................................... 19
APPENDIX F : SHORE HARDNESS MAPPING ....................................................................................................... 20
10. SHORE HARDNESS MAPPING .......................................................................................................................... 20
APPENDIX G : PROCEDURE ILLUSTRATION ........................................................................................................ 21
11. PROCEDURE ILLUSTRATION ........................................................................................................................... 21
11.1 SPLICE DIMENSION .................................................................................................................................... 21
11.2 MASTER LINE ............................................................................................................................................... 21
11.3 MARKING AND PREPARING FIRST END .................................................................................................. 22
11.4 SPLICING THE BELT.................................................................................................................................... 23
11.5 NOTE: ............................................................................................................................................................ 33
FIGURES
Figure H 1: Square and Straight Edge .................................................................................................................... 21
Figure H 10: Square and Straight Edge .................................................................................................................. 26
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1. INTRODUCTION
a. This working document identifies steps to be followed by Generation Group personnel when
splicing textile/ply conveyor belt and conducting a quality review during splicing.
b. This document is to be used to control quality during splicing of the textile/ply belting
throughout Eskom Power Stations, it also outline the responsibility of different parties.
c. In undertaking splicing, the Splicer, his personnel and the personnel of the client shall comply
to the ruling Safety Regulations and Codes of the client.
d. The instruction and procedures given in this docement shall be observed at all times during the
preparation and manufacture of joints in conveyor belting.
2. SUPPORTING CLAUSES
2.1 SCOPE
a. Even with recent improvements in the rubber chemistry relative to static and dynamic ply
adhesion, splices continue to represent the weak link in conveyor systems and even more so
in fabric reinforced textile/ply belting.
b. The splice is needed to join the ends of a length of conveyor belting to create an endless belt
and needs to be done in-situ. The splicing activities are often executed under difficult
atmospheric conditions and time constraints.
2.1.2 Purpose
2.1.3 Applicability
To increase the splice life expectancy on textile/ply belting on all Power Stations by providing the
user with the quality manual to be used for quality control during belt splicing.
 Literature survey.
 Site visits to witness textile belt splicing.
 Develop splicing procedure illustration for textile/ply belt.
 Compile Quality Control Plan (QCP).
2.2 NORMATIVE/INFORMATIVE REFERENCES
In order to increase the splice life expectancy on textile/ply belting, this quality plan should be
followed as outlined under the following topics:
2.2.1 Normative
[1] Appendix A: Reference checklist Appendix B: Tool checklist

[2] Appendix C: Quality control plan Appendix D: Inspection checklist Appendix E: Data sheet
[3] Appendix F: Shore hardness mapping Appendix G: Procedure illustrationAppendix A:
Reference checklist Appendix B: Tool checklist
[4] Appendix C: Quality control plan Appendix D: Inspection checklist Appendix E: Data sheet
[5] Appendix F: Shore hardness mapping Appendix G: Procedure illustration
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2.2.2 Informative
None
2.3 DEFINITIONS
2.3.1 Classification
Controlled Disclosure: Controlled Disclosure to external parties (either enforced by law, or

discretionary).
2.4 ABBREVIATIONS
Abbreviation Description
Portfolio MATERIALS HANDLING - POWER GENERATION
Report Number RES/RR/02/19324
Project Number PRJ02-00246600-1350
Project Leader Goitse Choabi
Contact Number 629 5424
Customer Research
2.5 ROLES AND RESPONSIBILITIES
None
2.6 PROCESS FOR MONITORING
None
2.7 RELATED/SUPPORTING DOCUMENTS
None
3. TEXTILE PLY BELT SPLICING QUALITY CONTROL STANDARD
3.1 CONCLUSIONS
Following a proper stringent splicing procedure and quality control is crucial when splicing
conveyor belt to ensure the following:
 Increased splice life expectancy
 Increased splice strength
 Reduced down time due to splice failures
 Increased reliability and availability of conveyor systems
 Reduced expenditure on belt jointing
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3.1.1 RECOMMENDATIONS
a. It is recommended that this document be read in conjunction with Procedure for on-site
Splicing of Plied Textile Conveyor Belting (document no: GGP 1045).
b. This quality plan should be compiled as an Eskom guideline to support Procedure for on-site
Splicing of Plied Textile Conveyor Belting (document no: GGP 1045).
3.1.2 INDUSTRY PERSPECTIVE
Splicing is undertaken in all Eskom Power Stations utilising conveyor belt systems to transport
material. These splices are often incorrectly undertaken due to time constraints and unavailabity of
formal procedure, resulting in pre mature failures.
3.1.3 KEYWORDS
a. Textile/Ply belt, Textile/Ply reinforced conveyor belting, Quality assurance, Technical

requirement, properties, splicing, test, inspection, checklist, material certification, vulcanising,
safety guidance, splicing geometry.RETURN ON INVESTMENT
b. In total, Eskom Power Stations utilise about 173 km of textile / plied belting to convey both ash
and coal. Assuming an average failure rate of textile/ply splice to be once every two years per
belt (based on experience), all coal fired Eskom Power Station combined, spend about R 848
620.00 and an additional 3 hours per splicing down time averaged per annum.
c. The implementation of the quality control plan can double the textile/ply splice life expectancy,
yielding a potential saving of about R 424 310.00 and a reduction of 50 % in production loss
averaged per annum.
3.2 APPENDIX A (REFERENCE CHECKLIST)
a. A reference checklist to procedure no. GGP 1045 REV 0 “PROCEDURE FOR ON-SITE
SPLICING OF PLIED TEXTILE CONVEYOR BELTING”. This procedure provides details from
arranging a permit until the splice is commissioned. The procedure outlines the responsibilities
of each party (the generation group representative and the splicer). On completion of the
splicing, this document must be signed by both the splicer supervisor and the generation group
supervisor or engineer.
b. The client may employ a third party inspection agent or use its own personnel to implement,
witness and enforce hold points if necessary. The Contractor shall not proceed beyond a
witness point until agreed by third party inspectorate or the client’s supervisor.
3.2.1 Appendix B (Tools checklist)
The checklist indicates the minimum tools that are recommended for belt splicing. These tools
must be brought to site by the splicing team. Condition of the tools must be checked before leaving
to the site and also to ensure that the calibration certificates are valid.
3.2.2 Appendix C (Quality control plan)
A quality control plan supplying the following information:

 The site where splicing is to be carried out.
 The plant where this splice is to be carried out.
 Belt to be spliced.
 Vulcanising press to be used.
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 Splice vulcanising time parameters.
 Comment on the condition of the splice once it is completed.
 The details of the splicer as well as generation group
representative.
3.2.3 Appendix D (Inspection checklist)
The client's representative shall have access at all reasonable times to inspect the following during
splicing:
 Setting up splicing equipment,
 Alignment of the belt,
 Preparation and assembly of the belt
 Splicing material,
 Curing
 Testing
3.2.4 Appendix E (Data sheet)
a. Completing the datasheet must commence as soon as the press is switched on. Both the top
and bottom element should be recorded against time (every five minutes) for ramping,
vulcanising and cooling periods as well as the vulcanising pressure.
b. The curing parameters are as follows:
 Temperature: 145°C+/- 2°C
 Minimum Pressure: 1.2 MPa
 Time: 3 minutes/mm belt thickness
c. Note: that it is advisable to consult the materials manufacturer's recommendations with regard
to curing times.
3.2.5 Appendix F (Shore hardness mapping)
a. After completion of the splice, the splice hardness should be measured with a shore hardness
tester once the splice has cooled to ambient temperature. Test results must be compared with
the data sheet of the splice-kit supplier.
b. Select 9 places on both the top and bottom covers (i.e. 3 across the leading edge, 3 across the
centre and 3 across the trailing edge) and record the hardness obtained. (See page 22).
c. The average Shore hardness obtained shall be within 50 of the nominal hardness as specified
by the materials manufacturer.
d. Any individual reading of more than 50 below the nominal hardness specified by the materials
manufacturer shall be cause for investigation and possible rejection. This deviation must be
reported to the client's representative.
3.2.6 Appendix G (Procedure illustration)
This illustrates step by step procedure for splicing textile/ply belting in the following categories:
 Setting up vulcanizing press and tables
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 Procedure for alignment and belt positioning
 Procedure for ply stripping
 Procedure for splice assembly
 Procedure for curing
3.3 APPENDIX H (SPLICE COMMISSIONING)
When commissioning the belt after splicing, the following procedure should be followed;
3.3.1 Test and Inspection 2.8.1.1 Dimensions
After dismantling the platens, the joints shall be checked for dimensions and straightness (the
maximum edge length deviation is 1.5 mm) and also for any excess rubber which should be
removed where necessary.
3.3.2 Soundness
The splice shall be visually examined for blistering and physically examined for soundness. If any
sign of poor curing is visible the splice shall be examined by the Splicer Supervisor and the client's
representative. The client's representative will decide on the acceptance / rejection of the splice.
3.3.3 Hardness
See Appendix F above
3.3.4 Clear the Permit to work (PTW)
After the splice is completed the contractor has to clear the permit with the client supervisor before
the commissioning of the conveyor installation.
3.3.5 Visual
By means of a chalk line create a grid across the entire surface of the splice as follows:-
 Lines at right angles to the belt travel at 100 mm centres.
 Lines in the direction of the belt travel at 100 mm centres. After running the belt check for
gross distortion of the grid pattern.
3.3.6 Commissioning
The client's representative must give immediate feedback to the Splicer in respect of any non-
conformance (e.g. Splice skewness etc.) after commissioning of the conveyor installation.
3.3.7 Requirements from Contractor by the Client
a. The contractor when complete with his splice should provide the client with the following:
 Completed data sheet;
 Any concerns noted through the vulcanising procedure. 2.8.2 Marking Each splice shall be
marked as follows:
 Markings shall be a minimum of 1.5 mm to 2 mm deep and within 150 mm of the belt edge.
 Steel stencil plates positioned within the vulcanising press on the return side of the belt.
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 Contractor's name or logo.
 A unique splice number.
 Month and year completed
 Letter size shall be 50 mm (minimum) 2.8.3 Leaving site
b. After establishing that the joint is sound and neatly made, all equipment shall be cleaned and
removed. All waste material shall be removed and the immediate area around where the work
has been carried out shall be cleaned.
c. Finally, the belt shall be commissioned by the client ideally in the presence of the contractor
and then re-inspected to ensure that the joint is satisfactory. Documentation, including the
signing-off of any permit to work (Workmen’s Register), shall be completed and the client
advised that the work has been completed.
3.4 CONCLUSION
The success of a splice for textile belting relies on a number of principles that must be satisfied
before the process can be continued. The main principles are:
3.4.1 Tools and Equipment
Suitable tools and equipment to complete the desired task within the prescribed time allowed.
These tools and equipment must be in a safe and working order and the calibration certificates
must be valid were applicable.
3.4.2 The Heating System
The elements must be calibrated in such a way that the desired 3 °C per minute ramp is
achievable. The heating element circuit is checked as to provide constant heat across the face. In
most cases any cooling facility would be an added advantage. High temperature accuracy is
required especially in the vulcanising area of 145 °C zone. The thermocouple readings are
normally 10 °C less than the surface contact probe. All monitoring of heating element temperatures
should be monitored only with surface contact probes embedded on the raw rubber surface when
vulcanising takes place. No thermocouple reading is recorded due to the deviation and influence
for the air surrounding the press. Once the press is assembled a blanket is placed over the
elements to control the temperature on top and bottom elements throughout the ramp, vulcanising
and cooling stages.
3.4.3 The Control System
The control system is a very important part of the overall performance. The controller is viewed as
important from the control point of view balancing the temperatures within the desired parameters
and more important throughout the vulcanising period.
4. AUTHORISATION
This document has been seen and accepted by:
Name Designation
Document Approved by TDAC 16 July 2013
Revision: 1
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5. REVISIONS
Date Rev. Compiler Remarks
November 2012 0.1 E Seitei Draft Document for review
created from RES-RR-02-19324
Senior Engineer
November 2013 1 E Seitei Final Document approved
6. DEVELOPMENT TEAM
The following people were involved in the development of this document:
 None
7. ACKNOWLEDGEMENTS
 None
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APPENDIX A:REFERENCE CHECKLIST
8. REFERENCE CHECKLIST
QP NO ACTIVITY ESKOM ACTION

SPECIFICATION No
GGP 1045 Rev 0
CLAUSE NO.
SPLICER BUSSINNESS THIRD
UNIT PARTY
1 Arrange for permit to work 5.1.7 V A A

2 Establish type and class of A W
belt 10.1.1
3 Establish work station 10.1.2 A W
4 Check splice proximity 10.1.3 V W
5 5A Check materials 10.1.4 V A V
Record batch numbers and 10.3.5 W
date of manufacture
6 Check splicing equipment 10.5 V W
Set up press and tables 10.6 A W
7 7A
Inspect set up Appendix F1
Align belt 10.7 A W
8 8A
Inspect alignment Appendix F2
9 Remove covers 10.8 A W W
Appendix F3
Trial assemble splice Inspect A W
10 10A
trial assembly Appendix F3
11 11 Final assemble splice 10.9 A W
A Inspect final assembly
Appendix F4
12 Pre-cure inspection Appendix F4 W
Cure splice 10.10
13 13A A A W V
Record cure parameters 11.3.6 - 11.3.10
14 14A Inspect splice 6.0 and Appendix F6 A A V
Record dimensions 11.3.7
15 Clear the permit 12.5 H A V
16 Commission splice 12.5 H V A
ACTION LEGEND: A - ACTION V - VERIFICATION H - HOLD W-WITNESS
NOTE:WHERE A THIRD PARTY IS NOT REQUIRED, THE DUTIES UNDER THE THIRD PARTY COLUMN SHOULD
BE PERFORMED BY THE BUSINESS UNIT
SIGNED:___________________ ______________________
SPLICER SUPERVISOR SUPERVISOR/ENGINEER
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APPENDIX B:TOOLS
The following minimum tools are recommended for belt splicing: These tools must be brought to
site by the splicing team. Condition of the tools must be checked before leaving to the site
 Vulcanising press (Wagner or approved equivalent)
 Pressure roller
 Pressure roller (double acting)
 Wire cutter or cable shear
 Wire brush (rotary)
 Polisher
 Rubber mallet
 Standard mallet
 Soft hand brush
 Hand vice/eccentric clamp/frog clamp
 Ratchet rope puller and pulling cables
 Cutting pliers
 Chalk
 Chalk string
 Awl
 Pricker roller
 Scribing knife
 Saddler's knife
 Saddler's pliers
 Cutting knife (straight blade, Don Carlos or equivalent)
 Paring knife (offset blade)
 Scissors
 Screw clamps
 Whetstone
 Steel rule
 5m Tape measure
 Rubber hardness meter
 Hand drill
 Buffing attachments
 Edge irons
 Set square
 Belt support frames (6 off)
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APPENDIX C: QUALITY CONTROL PLAN
9. QUALITY CONTROL PLAN
SITE INFORMATION
Site Condition
Accessibility
Weather Temperature (°C) Humidity (%)
Time arrived on site h
PLANT DETAILS
Belt KKS No. Defect No.
Permit No.
Responsible Person Tel Fax:
Time PTW Issued :
Workers Register:
BELT DATA
Location of the conveyor
Incline conveyor  Surface conveyor  Belt Manufacturer
Belt Class:
Approx. Length Insert spec Number of Plies Cover Thickness Top Bottom:
General Condition of Belt :
Rubber Top Cover Type M  Type N 
Rubber Bottom Cover Type M  Type N 
Rubber Type Top SBR  NR  IR  NBR 
Rubber Type Bottom SBR  NR  IR  NBR  Belt Specifications
Batch No:
Belt Width (mm) :
SPLICE DETAILS (Type of Press Used)

Press details Wagener  Shaw Almex 
Other 
Hydraulic Yes  No 
Air Cooled Yes  No 
Water Cooled Yes  No 
Press Manufacture
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Country Year of Manufacture Serial No.
Heater Elements 2  4
Supporting Beams 3 4 5 6
Gauges 2  3 4 5
Manufacturer:
Thermometer Yes  No 
Temperature (°C)
Difference in Temperature (°C)
Hydraulic Pump (bars) MAX
Compressor (bars) MAX
Power Supply 380V  525A  65A
Mobile Diesel Generator Yes  No 
Welding Socket Yes  No 
Using Diesel Generator Total Amps Red Phase (Amps) White (Amps) Blue Phase (Amps)
SPLICE STANDARDS
Splice type (bias): Normal  Curve Arc  Finger 
Splice type: Aged to Aged  New to Aged 
Time Started h Complete h
Length of Splice (mm) Hot:  Cold: 
Marking of Splice Yes  No 
Top Cover Removed Yes  No 
Removed Bottom Cover Yes  No 
Buffed Leading and Tailing Edge Yes  No 
Marked Centre-line of Belt (two tape measures)
Assembled Press Bottom Beams:
Assembled Lower Heater Elements:
Marked and Installed Bottom Cover:
Thickness One Sections Two Sections
Place sections of Belt on Rubber Yes  No 
Centre-line Yes  No 
Start from Centre Outwards Yes  No 
SPLICE VULCANISING TIME

Assembled Press h
Start Diesel Generator/Welding Socket h
Record Amps on Diesel Generator Yes  No  Ambient Temperature Reading (thermometer) (°C)
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Reaching 145°C h
Vulcanising Period (X minutes/mm of belt) .
Total Thickness of Belt (mm)
Total Period calculated from belt thickness
Completed Vulcanising Period h ( minutes)
Ambient Temperature (°C)
Cooling Down Period (145°C)(START) h
Cooling Down Period (125°C)(COOLING) h
Cooling Down Period (100°C)(COOLING) h
Cooling Down Period (80°C) (COOLING) h
Cooling Down Period (60°C) (COOLING) h
Completed Cooling Down h
Removing of Press h
Cleaning of Area h
CONDITION OF SPLICE
Physical Condition Acceptable Yes  No 
Comments:
SPLICER
Date:
Splicer Name:
Contractor :
Job No:
Signature:
ESKOM APPROVAL
Date:
Name:
Position:
Department:
Unique No:
Order No:
Signature:
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APPENDIX D: QUALITY CONTROL PLAN

BUSINESS UNIT: ____________________________ JOB NO: __________________
SPLICER NAME: ______________________ CONTRACTOR: __________________
CONVEYOR NO: _________________________SPLICE NO: __________________
SPLICE LENGTH: ____________ SPLICE TYPE: _________ DATE: _____________
a. F1 SET UP
 Work station suitable for splicing:
 Top surface of bottom platen level with top of troughing roller:
 Platen edges parallel to direction of run of belt:
 Wooden boards approximately 250 mm wider than belt:
 Top surfaces of boards are same level as top surface of bottom press platen:
 Tables are stable with a minimum length of 3 m:
b. F2 ALIGNMENT
 Belting is lined up in either direction for a minimum distance of 6m
 Belt is central on the conveyor supporting rollers

 Ends overlap on the bottom platen
 Overlap is sufficient
 Centre line is established for a minimum of 6 m
 Chalk reference lines are drawn across the ends of each belt
 Belt if firmly clamped to the platform (outside the splice area)
 Belt has been checked for age
 Splice length according to Table 2
c. F3 CORDS
 Sufficient rubber has been separated from the cords
 Cover strips removed producing a non smooth surface
 Thin layer of rubber covering the steel cord
 Rubber between cords removed leaving a thin film of rubber over the cord.
Cords checked for damage and corrosion Cords suitably protected against
Corrosion
 Cords tied together in bundles
 Cords brushed with clean dry brush
____________________ _____________________
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APPENDIX D: INSPECTION CHECKLIST

(continued)
BUSINNES UNIT: ________________________ JOB NO: ______________________
SPLICER NAME: __________________CONTRACTOR: ______________________
CONVEYOR NO: _____________________SPLICE NO: ______________________
SPLICE LENGTH: ________________ SPLICE TYPE: ______________DATE: _____
d. F4 SPLICE ASSEMBLY
 Edges of diagonal cut in the vulcanised rubber chamfered Length of splice is correct
 Roughed with a polisher and buff attachments
 No degradation
 Chamfer cleaned
 Bonding compound cleaned with solvent and dry
 Shirting fabric placed over the bottom platen and smoothed
 Non-vulcanised bottom cover cut to size and shape. Bonding layer uppermost
 Bonding layer and steel cords coated
 Belts aligned
 Cords are parallel
 All cords included in the joint
 No individual cords are cut out
 All spaces filled with bonding compound
 Cords are dry
 Edge of the splice cover stock level with top of cords
 Top cover laid onto cord carcass with bonding layer downwards
 Edges of un-vulcanised splice trimmed to width
 Shirting fabric overlaps ends of the splice Shirting fabric 100 mm wide over each join
e. F5 CURING
 The temperature of the platen is within manufacturers recommendation
 Upper platen is positioned to mach lower platen
 Transverses correctly positioned
 Curing temperature reaches manufacturers recommendation ±5 °C
 Pre-tensioning bolts are uniformly tightened
 Pressure reaches Manufacturers recommendation
___________________ _____________________
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APPENDIX D: INSPECTION CHECKLIST

(continued)
BUSINNESS UNIT: ____________________________ JOB NO: ___________________
SPLICER NAME: _______________________CONTRACTOR: ____________________
CONVEYOR NO: ________________________SPLICE NO: ______________________
SPLICE LENGTH: ___________SPLICE TYPE: _____________ DATE: ______________
f. F6 TESTING
 Dimensions within tolerance
 Edges straight
 No excess rubber
 No blistering
 No lack of adhesion
 Shore hardness within
 tolerance No gross distortion
 of the grid Commissioning
 satisfactory
___________________ _____________________
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APPENDIX E: DATA SHEET
10. DATA SHEET

DATA SHEET
Date: Plant:
Conveyor No. Top cover
Pressed Used: Bottom cover
Belt width: Ambient temp.
Class: Humidity %
Time start: Time Stop:
Time (every 5 Top Element Bottom Element Pressure (bar) Pressure (bar)
minutes) (°C)
(°C) <100°C <145°C
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APPENDIX F: SHORE HARDNESS MAPPING
11. SHORE HARDNESS MAPPING
COMPLETE CURE RESULTS

LOCATION THICK. Mm SPLICE HARDNESS (65 SHORE A +/-5)
LENGTH
mm
LOCATION TOP BRIDGE BOTTOM BRIDGE
Leading edge Left hand

Centre Centre
Trailing edge right hand
Average hardness
Nominal hardness
Conveyor belt
hardness
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APPENDIX G: PROCEDURE ILLUSTRATION
12. PROCEDURE ILLUSTRATION

The quality of the finished splice is highly dependent upon the cleanliness of the work area during
all stages of splice preparation. Good work practices and cleanliness go hand in hand and are
essential in achieving this goal.
12.1 SPLICE DIMENSION
Individual splice drawings for each splice will be furnished specifying the proper dimensions for
assembly.
12.2 MASTER LINE
This is normally the first line to be made on the belt on each of the two ends. The master line is a
line drawn straight across the belt width at a distance from the belt end equal to the splice length
plus the bias length plus a 50 mm tab length. This method of locating and squaring the master line
is as follows:
Figure H 1: Square and Straight Edge
a. From the end of belt, measure the length of splice plus trim allowance.
b. Use a square and straight edge to draw master line
c. Check the master line by laying the square along the opposite edge. Repeat the procedure on
the other belt.
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12.3 MARKING AND PREPARING FIRST END
a. Measure the bias length on the correct edge and mark Point B. The bias length is selected so
that the bias will match the vulcaniser angle.
b. Draw the bias line AB and mark the edges with a vertical line at these points for opposite cover
marking. As in Figure H-3
c. From A, measure the splice length and mark point C

d. From B, measure the splice length and mark point C. Join C and C
e. From C, measure 50 mm and mark point D
f. From C, measure 50 mm and mark point D. Join D and D
g. Remove a strip of cover rubber about 12 mm wide down to the plies by cutting at
approximately 45° on either side of line DD
h. Place a suitable piece of lumber underneath the belt to facilitate cutting and prevent the cut off
saw from damaging the underlying belt or splice press platen.
i. Cut the belt along line DD
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12.4 SPLICING THE BELT
a. The belt shall first be checked to ensure that there is no twist in it. The centerline of the belt
shall be marked out over the joint length by measuring off 5 to 6 points in the center of the belt
width for a distance of 2 to 3 cutbacks into the belt from the end and joining these together.
This centerline shall be used as a datum for all other measurements; the belt edge shall not be
used as a reference.
b. The technique for splicing fabric belt is essentially the same for any number of plies. A 3 ply
construction is illustrated in sketches and instructions which follow:

c. Measure the splice length plus 25 mm trim starting from the end of the belt (Fig H-4). Draw the
master line. A square and straight edge is generally used to mark the master line on the belt as
described somewhere in this report. In checking both edges if there is a difference it can be
halved and the result will usually give an accurate line.
d. Measure off the bias length and draw the bias line to the end of the master line on the opposite
edge (fig H-5). This line marks the location of the top ply cut after the cover gum is removed.
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e. Extend the end of the bias line down over the belt edge.
f. From the bias line measure towards the end of the belt a distance equal to the total number of
steps plus 25 mm trim.

g. Lay out the cover strip for removal. Draw one line parallel to and approximately 13 mm from
the bias line and on the splice side. Draw a second line on the belt side of the bias line but at a
distance of 50 mm (Fig H-6)
h. Cut along the two cover cut lines just made. The line on the belt side of the bias line should be
skived per fig H-6. The other cut may be vertical. Do not cut too deep. If you feel fabric you
have damaged the belt.
i. Cut off the belt at the cut-off line (Fig H-4)
j. Remove the cover strip. Note the one skived and one vertical cut in the cover (Fig H-7)
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k. From the marks made down the edges, redraw the bias line where the cover was removed.
Then cut the top ply along this line (Fig H-8).
l. Prod the top ply loose along the bias line where the cut was just made. Be very careful as you
can easily damage the fabric (Fig H-9).
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m. Turn the belt end over and mark the cover strip for removal (Fig H-10)
n. Cut and remove this cover strip (Fig H-11)
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o. Turn the belt end back down and remove the cover and top ply (Fig H-12). This is a very
difficult pull. If a winch or equivalent is not available, use a come-a-long and very carefully cut
the inside gum with a ply knife, do not knick the fabric. Damage to the underneath ply will
cause premature splice failure.
p. The other end of the belt is torn down from the opposite side using the same system. Note the
bias length on this end must be measured from the opposite edge that was used on the first
end.
q. Use a lightweight, high-speed buffer with a wire wheel brush and remove most of the gum from
the fabric (Fig H-13). Do not contact the fabric. Buffing the fabric not only reduces its strength
but removes the chemical treatment from the fabric which reduces adhesions. Roughen up the
cover cut edges on top and pulley side as well as an inch or so of cover surface adjacent to the
cuts. Blow or brush away all rubber dust.
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r. Mark a centerline on each end of the belt by connecting three center marks, the furthest being
a minimum of three times the splice length distance from the master line. Align the belt using
the center marks and dry fit the ends to ensure the steps fit together properly. Do not allow any
steps to overlap, trim to fit as necessary. After completing adjustment, secure the belt ends in
this position. It is common to C-clamp the belt to the work table and nail blocks of wood to the
table flush with the belt edges to prevent lateral movement.
s. Clean all rubber areas with the appropriate solvent and allow to dry thoroughly (Fig H-14).
t. Apply two coats of proper cement over the entire fabric step area starting at the first ply fabric
cut (Fig H-15). Allow first coat to dry thoroughly before applying second coat.
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u. After cement is dry apply inside gum to the fabric step area starting at the first ply cut and
proceeding to the end of the splice area (Fig H-16). Be sure the correct gauge gum and the
proper number of layers are used. Roll gum thoroughly with a 50 mm roller. The gum is applied
to only one of the stepped ends. Do not remove film from the gum at this time.
v. On the end, which now has the splice gum, mark a ply cut-off line as follows: Measure both
edges from the master line. On one other edge measure only the total step length plus bias
length, on the other edge measure only the total step length then draw the cutoff line.
w. Cut film, gum and the one ply with a smooth straight cut across the line just marked.
x. About 50 to 75 mm from the cut just made, make a cut through the film only. Remove the 50 to
75 mm strip of film.
y. Assemble breaker, fill-in gum and release material on the pulley side using the same system
except the pulley gum is to overlap the original cover 1 to 2 mm.
z. With the belt edges properly aligned, carefully lay the ends together making a tight uniform
joint at the bottom ply. Make sure fabric is not overlapped (Fig H17).
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aa. Remove the remaining film and lower the remainder of the splice into place. Keep edges
aligned.
bb. Trim the top ply step making a tight joint with no gap (Fig H-18
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cc. Apply a second coat of the proper cement (after the first coat of cement is dry) to the fill-in area
on the topside (Fig H-19). Lay in the breaker (Fig H-20). The breaker is 6 mm narrower than
the exposed fabric.
dd. Cement a strip of top cover, roll it into place and trim.
ee. Use a small straight edge to check for the proper gauge of fill-in gum. The straight edge should
make imprints on the gum (Fig H-21). Any low spots should be built up.
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ff. Prick the fill-in gum with an awl to release trapped air. Cover with a cemented strip of release
material 50 mm wider than the gum strip (Fig H-22).
gg. To ensure solid edges, guides of the proper gauge must be used. The guides must contact the
belt edges for the full length of the splice and extend 150 mm on both ends of the press (Fig H-
23). Note: an exception to the above splice directions sometimes occur when splicing a new
belt into an old one. If the old belt covers are badly worn then both ends of the new section
should be stepped from the pulley side. This leaves new unworn top cover on both splice and
will provide more uniform vulcaniser pressure. In doing this, one splice will run in reverse to the
usual recommendation.
hh. After cure, trim the edges of the splice. It is normal for the fabric joints to be spaced 6 mm or so
during cure due to shrinkage.
ii. Refer to section 10.10 of this procedure for vulcanising instructions.
jj. The splice must not be put into service until it has cooled to ambient temperature.
kk. Buff inserts and overflow, down to original belt gauge to prevent damage from scrapers.
ll. Each joint shall be branded with the jointing contractor’s identification and date.
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12.5 NOTE:
After preparing the belt ends, joint assembly and vulcanizing should be completed without delay in
order to avoid contamination by moisture, dirt, etc. If it is necessary to leave the prepared ends for
some time before vulcanization then they should be securely covered with, for example, plastics
sheeting and extra care taken to ensure that the belt ends are clean before assembly and
vulcanizing

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Standard Technology

Title: Textile Ply Belt Splicing Quality Unique Identifier: 240-55864585

Alternative Reference Number: RES-RR-02-19324

Area of Applicability: Engineering

Documentation Type: Standard

Next Review Date: November 2015

Disclosure Classification: CONTROLLED

Compiled by Approved by Authorised by

………………………………….. ………………………………….. …………………………………..

J Hlabangana A Wiid I Atiya

Date: …………………………… Date: …………………………… Date: ……………………………

APPENDIX D : QUALITY CONTROL PLAN ............................................................................................................. 16

2.2 NORMATIVE/INFORMATIVE REFERENCES

[1] Appendix A: Reference checklist Appendix B: Tool checklist

Controlled Disclosure: Controlled Disclosure to external parties (either enforced by law, or

2.5 ROLES AND RESPONSIBILITIES

2.6 PROCESS FOR MONITORING

2.7 RELATED/SUPPORTING DOCUMENTS

3. TEXTILE PLY BELT SPLICING QUALITY CONTROL STANDARD

3.1.2 INDUSTRY PERSPECTIVE

a. Textile/Ply belt, Textile/Ply reinforced conveyor belting, Quality assurance, Technical

3.2 APPENDIX A (REFERENCE CHECKLIST)

3.2.1 Appendix B (Tools checklist)

3.2.2 Appendix C (Quality control plan)

A quality control plan supplying the following information:

3.2.3 Appendix D (Inspection checklist)

3.2.4 Appendix E (Data sheet)

3.2.5 Appendix F (Shore hardness mapping)

3.2.6 Appendix G (Procedure illustration)

3.3 APPENDIX H (SPLICE COMMISSIONING)

3.3.1 Test and Inspection 2.8.1.1 Dimensions

See Appendix F above

3.3.4 Clear the Permit to work (PTW)

3.3.7 Requirements from Contractor by the Client

3.4.1 Tools and Equipment

3.4.2 The Heating System

3.4.3 The Control System

QP NO ACTIVITY ESKOM ACTION

1 Arrange for permit to work 5.1.7 V A A

9. QUALITY CONTROL PLAN

SPLICE DETAILS (Type of Press Used)

SPLICE VULCANISING TIME

APPENDIX D: QUALITY CONTROL PLAN

 Belt is central on the conveyor supporting rollers

APPENDIX D: INSPECTION CHECKLIST

APPENDIX D: INSPECTION CHECKLIST

APPENDIX E: DATA SHEET

10. DATA SHEET

Conveyor No. Top cover

Pressed Used: Bottom cover

Belt width: Ambient temp.

Time start: Time Stop:

APPENDIX F: SHORE HARDNESS MAPPING

11. SHORE HARDNESS MAPPING

COMPLETE CURE RESULTS

Leading edge Left hand

APPENDIX G: PROCEDURE ILLUSTRATION

12. PROCEDURE ILLUSTRATION

12.1 SPLICE DIMENSION