Aac Spec 377008

AAC SPECIFICATION 377008
SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0

BELTING - PVC AND PVC/NITRILE
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CONTENTS PAGE
1 SCOPE 2
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER 2
3 DEFINITIONS 2
4 THE FINGER SPLICE 2
5 THE VULCANISING STATION 2
6 TOOLS AND EQUIPMENT 3
7 SPLICE DIMENSIONS 5
8 MATERIALS 5
9 MARKING AND CUTTING OF SKRIM FABRIC. 6
10 PREPARATION OF SPLICE 9
11 CURING PROCESS 11
12 CHECKING THE FINISHED SPLICE 12
13 BRANDING OF THE SPLICE 12
APPENDIX A : RELATED DOCUMENTS 13
APPENDIX B : RECORD OF AMENDMENTS 13
APPENDIX C : SAMPLE QUALITY PLAN 14
APPENDIX D : SAMPLE QUALITY PLAN (CONTINUED) 16
APPENDIX E : MATERIALS 17
APPENDIX F : INSPECTION CHECKLIST 18
AAC_SPEC_37700800 APPROVED 5 June 2006 Page 1 of 20
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof

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1 SCOPE
This specification details the requirements for the splicing of all solid woven belts with PVC or
Nitrile covers to be spliced using the finger splice method.
The principles of this instruction can be applied when splicing with all belt brands. It is
recommended to check the suitability of the splicing material for given belt types.
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

2.1 Title, number, date and issue of this specification.
2.2 Location of area for splicing operation.
2.3 Type of connection.
2.4 Third party inspectorate.
3 DEFINITIONS
For the purpose of this specification the following definitions shall apply.
AGED BELT : A belt which is more than three years old or has previously been
refurbished
APPROVED : Approved in writing by the Engineer
SABS : South African Bureau of Standards
QAP : AAC Quality Assurance Procedure
The following terms are defined in the General Conditions of Contract:

• AAC, Company, Contractor, Engineer.
4 THE FINGER SPLICE

The method as described in this procedure and using the specified materials must produce a
splice strength of minimum 75% of original belt strength.
5 THE VULCANISING STATION

A well-prepared work site is the prerequisite for a splice. Therefore, the splice station
requirements should be determined in a meeting between the:
• Client
• Belt supplier
• Splicing contractor

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Note: prior to start of the work, allow adequate set-up time.
The following fundamentals apply:
5.1 The work place must be dry and as dust free as possible.
5.2 There must be no dew point precipitation (high heat and humidity or cold).
5.3 Air movement must be kept to a minimum.
5.4 The work place must be adequately lit to ensure a safe working environment.
5.5 When working on a conveyor, a worktable to accommodate the press and a preparation table
are required. If possible, there should be about 5m free space on both ends of the
preparation table to allow correct alignment of the splice.
5.6 Compressed air supply.
5.7 Suitable electrical supply and power points.
5.8 Water reticulation. (In the event of water cooled presses)
6 TOOLS AND EQUIPMENT

a) Chalk Line
b) Measuring tape
c) Blade knives (2) (Stanley type)
d) Crocodile clamp with adequate cable pull
e) Vernier
f) Plane, or slow speed rotary power tool with abrasive head
g) Cutting tool for cutting splice fingers (jigsaw not preferred)
h) Spatula (2)
i) Scissors
j) Curved surforms (2)
k) Hand brooms/brushes (2)
l) Vulcanising press complete with electrical temperature and pressure control, pressure
and water hoses as required, temperature and pressure indicators.
• Temperature accuracy ±3°C
• 600 kPa minimum pressure capacity

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• Platen length = splice length + 150 mm (min)

• Platen width = belt width + 150 mm (min)
m) Cooling plates for carrying and running side of belt, 300 mm > press length.
n) Edge bars (2), approx. 60 mm wide, 0.5-1 mm < belt thickness, approx. 300 mm longer
than press length.
o) Edge bars securing/clamping device (2).
p) Template for marking out splice.
Cover Panel
Butt Line
Belt Width,
Finger Width, Direction of travel
BW
FW
1 Splice Length, SL
2 Platen Length = SL + 200mm
100 6 Finger Length, FL 100

Cover
panel 50 50
4 Carry cover
3 Pulley cover
5 Skrim Width, SW
Figure 1

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7 SPLICE DIMENSIONS
Finger Skrim Fabric Skrim Edge
Finger Width Splice Length
Belt class Length FL Width, SW Length SL
FW (mm) SL (mm)
(mm) (mm) (mm)
1000 750 50 950 1050 1200
1250 900 50 1100 1200 1420
1400 1100 30 1300 1400 1600
1600 1170 50 1370 1470 1800
2000
Seek advice from Belting supplier
2500
Minimum Platen Length = Splice Length + 150mm
Minimum Platen Width = Belt Width + 150mm
Table 1
8 MATERIALS
The dimensions and quantities of the splice material are determined by the following:
• Belt class
• Belt width
• Belt cover thickness
The materials required for one splice are:

• Cover Panel
a) Splice fabric coated with Nitrile rubber on both sides.
b) The inner side of the fabric is coated with 0,5mm nitrile.
c) The inner side is identified with a white cotton strand.
d) The thickness of the Nitrile coating on the outer side is equal to the thickness of the belt
cover.
e) One nitrile panel for the top and one nitrile panel for the bottom of the belt.
f) Panel length: Equal to the length of the splice + 100mm.
g) Skrim fabric: - Width = FL+200mm, Length = Belt width x 2 + 200mm.

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h) PVC paste of high adhesive quality (See table 2 for estimated quantity).
i) Silicon coated paper: Width = Skrim fabric width + 100mm.
Length = 2 x press platen length ± 50mm.
Belt width Guide to quantity of PVC paste ( l )

(mm) Class 1000 or lower Class 1250 or higher
900 3,0 5,0
1050 4,0 6,0
1200 4,5 7,0
1350 5,0 8,0
1500 6,0 9,0
1650 7,0 10,0
Table 2
Note:
PVC paste and nitrile rubber are to be stored in a dust free environment at a temperature as
specified by the manufacturer and at humidity below 65%.
Shelf life of materials as listed below will be as specified by the manufacturer: -

• PVC paste
• Nitrile cover panels
• Skrim fabric
Note that materials/containers must be clearly date and batch marked.
9 MARKING AND CUTTING OF SKRIM FABRIC.

Skrim fabric is supplied in rolls and requires to be marked and cut prior to use for square
press platens only, in the manner shown in figures 2 and 3, which ensures that the fabric is
used on the bias, i.e. the warp and weft yarns run at 45° to those in the belt.
9.1 Draw a 45° diagonal line across the fabric to provide a base line from which to work (line A-B
IN Figure 2).
9.2 Measure along one edge of the skrim from the previously marked line at (A) a distance of LS
= (SW + 100) X 1,42 to (c) as per table 2.
9.3 Draw a line at 45° from point (C) parallel to the base line to point (D).

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9.4 Cut along both lines to make the skrim fabric piece as required.
Notes:
a) When the sides of the skrim fabric are folded over the top of the joint, the two edges
should overlap by 50-100mm.
b) Skrim fabric is usually supplied in physical dimensions (crimp, yarn diameter, strength
etc.) of a single type suitable for all belt classes.
c) In the event that biased platens are utilised, do not cut skrim fabric as per figure 2.
Instead, lay skrim fabric in line with platens ensuring that the warp and weft yarns are at
the same bias as the platens against the longitudinal axis of the belt.
This bias will, with most rhomboid platens, be in the region of 30 degrees.

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1500MM WIDE FABRIC
CUTTING
LINES
45° D C
C
B
Preparing of skrim fabric on bias Lay up of skrim fabric with belting
Figure 2

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10 PREPARATION OF SPLICE
Trailing half finger on

leading belt end
Direction of travel
CL
Cover Panel Butt Line
Figure 3
10.1 MARKING AND CUTTING OF BELT ENDS

10.1.1 Prepare the vulcanising station and assemble the lower half of the press.
10.1.2 Pull the two belts that are to be joined onto the splicing area so that they have the required
overlap length (Splice length + 200mm).
10.1.3 Establish a centre line on both ends of the belt for a distance of 3 m.
10.1.4 Using the template and the established centre line, mark out the fingers to be cut, ensuring
the “leading” end will have the “trailing” fingers as per Figure 3.
10.1.5 Mark cover panel butt lines 100 mm from the end of the fingers as per Figure 1.
10.1.6 Cut fingers as per marks established in Step 8.1.4,
10.1.7 Using slow speed angle grinder fitted with 60 grit disc, remove the cover material from the
carcass. Do not grind into the carcass and always work in the direction of belt travel.
10.1.8 Lightly buff the covers of the belt on both sides for approximately 50mm past the cover panel
butt line.
Note 1: Warm the belt to assist in cutting the fingers. To ease cutting of the higher
strength belts, heating may be applied to the belt up to a maximum of 50°C.
Note 2: It is important to cut fingers accurately to ensure a high joint strength. It is critical
that the cut is perpendicular to the belt surface.

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10.1.9 Lay up the splice allowing a 2mm gap between each finger and ensuring both ends are
correctly centred. The required 2mm gap is obtained by laying both ends down with an
additional 100mm distance between the two cover panel butt lines.
10.1.10 Fix both ends of the belt onto the preparation tables to ensure no movement.
10.2 ASSEMBLY OF SPLICE

10.2.1 Mark the cover panel butt lines onto the lower cooling plate.
10.2.2 Fold back each end of the splice and fasten.
10.2.3 Heat bottom platen to approximately 40°C.
10.2.4 Place release paper over the lower cooling plate.
nd
2 layer of nitrile rubber to match
Short piece of belt carry cover thickness
nitrile
Long Piece of
nitrile
Figure 4
10.2.5 Lay the lower cover panels –0,5 mm nitrile face up on the cooling plate – ensure the bias of
fabric is at 45° along centerline. If two cover panels are utilised it would be preferred that the
panels be butted, rather than overlapping them. This is to avoid uneven thickness across the
splice. The bottom panel must be 120mm wider than the belt width to allow approximately
50mm overlap onto the top when wrapped around the edges of the splice. (See fig. 4).
10.2.6 Spread PVC paste over the lower cover to a thickness of about 1mm.
10.2.7 Smear each finger thoroughly with PVC paste.
10.2.8 Release belt ends allowing the fingers to lie into the spread paste.
10.2.9 Ensure the spacing between the fingers is 2 to 3mm.
10.2.10 Spread the paste over the laid fingers ensuring paste completely fill gaps between fingers
and is spread to a depth of about 1mm.
10.2.11 Spread more paste over surface of fingers, approximately 1mm to ensure it is totally ‘wetted’.
Note: The integrity of the splice relies upon the splice surface being properly
impregnated with paste.
10.2.12 Wrap the longer bottom cover panel over the splice edges to at least cover the outer fingers.
Now lay the shorter top cover panel in position and trim to butt exactly with the wrapped
longer bottom panel.

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10.2.13 The top cover panel must be placed with the 0,5mm nitrile face down on the fingers and
fabric 45° bias. Overlapping of rubber/nitrile should be avoided.
10.2.14 Cover the entire splice with release paper.
10.2.15 Place and secure edge bars/curing irons in the correct position.
10.2.16 Assemble the top of the press, securely clamp edge bars/curing irons as depicted in figure 6
with restraining devices to prevent any movement of the splice during vulcanization.
Figure 5
11 CURING PROCESS
11.1 Assemble the curing press.
11.2 Pre-heat the press to 100 ±5°C WITHOUT ANY PRESSURE
11.3 Maintain the temperature of 100°C for 10 minutes.
11.4 Apply 600kPa pressure and simultaneously increase platen temperature to that specified by
the material manufacturer. Make sure all platens heat evenly (± 3°C). If necessary, manually
control the platens.
11.5 Maintain an even specified platen temperature between ± 3°C during the curing process. The
cure time must be as specified by the materials manufacturer/supplier.
Note 1: The press platens must have an equal carefully controlled temperature across the
full press platen area.
11.6 Cool the press upon completion of curing. It is preferable to use water to achieve rapid
cooling and prevent any possibility of ‘over cure’.

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11.7 Release pressure from the press once all platens have cooled below 50°C.
11.8 Disassemble the press and remove the release paper.
11.9 The conveyor may be tensioned after the belt has naturally cooled to ambient temperature.
12 CHECKING THE FINISHED SPLICE

The splice must be checked from all sides for visual faults.
12.1 Any spewed PVC or Nitrile rubber must be trimmed off.
12.2 Any overrun on the cover panel abutments must be removed by knife or buffing.
12.3 Check for alignment of the splice to the parent belt.
12.4 Check the relevant splice dimensions such as:

• Belt width immediately in front of and behind the splice.
• Belt thickness immediately in front of and behind the splice.
• Splice width.
• Splice thickness.
12.5 All results are to be recorded on the splice record sheet.
13 BRANDING OF THE SPLICE

13.1 Each splice shall be clearly branded, and marked appropriately with a unique number. This
number should give complete traceability of date of splicing, equipment used, batch numbers
of materials, crew and vulcanising record sheets.
13.2 Branding shall be embossed onto the bottom cover of the splice, at least 1mm deep,
approximately 100mm from the edge of the belt. Letters should be approximately 100mm
high.
13.3 Where branding is not possible, the splice number and date should be neatly carved into the
trailing belt end approximately 2 meters from the splice, without damage to the belt carcass.

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APPENDIX A : RELATED DOCUMENTS
Unless otherwise specified the latest issue of the following documents shall be deemed to form part of
this specification:
BS 4890 : Test methods for mechanical joints in conveyor belting
BS EN ISO 1120 : Determination of strength of mechanical fastenings - Static test method
QAP 100 : Quality requirements for critical and major products
SANS 971 : Standard specification for fire-resistant textile-reinforced conveyor

belting (for use in fiery mines)
AAC 377006 : Solid woven conveyor belting
APPENDIX B : RECORD OF AMENDMENTS
Issue 0 : Editorial version: 19 July, 2005

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APPENDIX C : SAMPLE QUALITY PLAN
MINE COMPANY JOB NO BELT TYPE
SPLICER NAME CONTRACTOR
CONVEYOR NO SPLICE NO
SPLICE LENGTH SPLICE TYPE
DATE MATERIAL SUPPLIER
AAC ACTION
QP SPECIFICATION
ACTIVITY
NO CLAUSE NO. MINE THIRD
SPLICER
377/6 COMPANY PARTY
1 Establish type and class of A W

belt
2 Establish work station A W
3 Check splice distance in V W

relation with other splices
4 Check materials V
4A Record batch numbers and A V

date of manufacture
5 Check splicing equipment V
6 Set up press and tables A W
6A Inspect set up
7 Align belt A W
7A Inspect alignment
8 Mark and cut fingers A W
9 Trial assemble splice A
9A Inspect trial assembly W
101 Final assemble splice A W
10A Inspect final assembly W

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11 Pre-cure inspection W
12 Cure splice A W
12A Record cure parameters A V
13 Cool press (Water/air) A W
14 Inspect splice A V
14A Record dimensions V
15 Commission splice H A W
LEGEND: A - ACTION V - VERIFICATION H – HOLD W - WITNESS

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APPENDIX D : SAMPLE QUALITY PLAN (CONTINUED)
CURE STARTED: CURE COMPLETE:
CURING PARAMETERS
TIME PRESSURE TEMPERATURE
COMPLETE CURE RESULTS
SPLICE HARDNESS (SHORE A – NITRILE COVERS)

THICK
LOCATION LENGTH
mm
mm
LOCATION TOP COVER BOTTOM COVER
Leading edge Left hand
Centre Centre
Trailing edge Right hand
Average hardness
Nominal hardness

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APPENDIX E : MATERIALS
Materials used for a splice shall be supplied by an Approved manufacturer of conveyor belt splicing
materials.
LIST OF MATERIALS
Nitrile cover stock
PVC paste
Silicon paper or suitable release agent
Cleaning solvent
Skrim fabric

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APPENDIX F : INSPECTION CHECKLIST
F1 SET UP YES NO
QC plan Approved and available
Working station suitable for splicing
Idler rolls & brackets adjacent to splice removed
Top surface of bottom platen level with top of troughing roller (if applicable)
Bottom platen edges parallel to direction of run of belt
Wooden boards approximately 250mm 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 3m
ALL SPLICING MATERIALS TO SPECIFICATION AND WITHIN RECOMMENDED SHELF LIFE
F2 ALIGNMENT YES NO
Belting is lined up in either direction for a minimum distance of 3m
Belt is central on the conveyor supporting rollers
Ends overlap on the bottom platen
Overlap is sufficient
Centre line is established in either direction for a minimum of 3m
Chalk reference lines are drawn across the ends of each belt
F3 PREPARATION YES NO
Centre line established and fingers cut to diagram as per specification
Fingers cut perpendicular to belt surface.
Splice leading end fingers outermost as per diagram.
Cover material removed from fingers using slow speed grinder or plane
Carcass not over buffed or degraded in any way.
Carcass lightly buffed for 50mm past cover panel butt line.
Belt ends pulled back to provide 2 to 3mm gap between fingers
Belt firmly clamped to preparation table (outside splice area)

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F4 ASSEMBLY YES NO
Cover panel butt lines marked onto lower plate surface
Belt ends folded back and fastened
Release agent or silicon paper placed over lower plate.
Lower cover panel laid as per 8.2
Gaps between fingers 2 to 3mm
Paste spread over lower panel to a thickness of 2 to 3mm
Fingers laid into paste and alignment correct.
Paste spread between fingers completely filling gaps
Bottom and top cover panels laid as per 8.2
Release agent or silicone paper completely covering splice, including splice
edges
Edge bars (curing irons) correctly positioned
Top platen correctly positioned
Press traverses correctly positioned
Edge bars (curing irons) securely clamped.
F5 CURING YES NO
The temperature of the platens is 100°C
The length of splice is correct
Alignment is correct
Upper platen is positioned to match lower platen
Traverses correctly positioned
Pre-tensioned bolts are uniformly tightened
Pressure reaches 600kPa
Curing temperature reaches specification

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F6 TESTING YES NO
Dimensions within tolerance
Splice/parent belt alignment within tolerance
Spew PVC/Nitrile removed
No blistering
No lack of adhesion
Shore hardness of covers within tolerance
Commissioning satisfactory and Engineer’s approval obtained

Aac Spec 377008

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AAC SPECIFICATION 377008

SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0

AAC_SPEC_37700800 APPROVED 5 June 2006 Page 1 of 20

SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

2.2 Location of area for splicing operation.

2.3 Type of connection.

2.4 Third party inspectorate.

APPROVED : Approved in writing by the Engineer

SABS : South African Bureau of Standards

QAP : AAC Quality Assurance Procedure

The following terms are defined in the General Conditions of Contract:

4 THE FINGER SPLICE

5 THE VULCANISING STATION

AAC_SPEC_37700800 APPROVED 5 June 2006 Page 2 of 20

SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0

Note: prior to start of the work, allow adequate set-up time.

The following fundamentals apply:

5.3 Air movement must be kept to a minimum.

5.6 Compressed air supply.

5.7 Suitable electrical supply and power points.

5.8 Water reticulation. (In the event of water cooled presses)

6 TOOLS AND EQUIPMENT

c) Blade knives (2) (Stanley type)

d) Crocodile clamp with adequate cable pull

f) Plane, or slow speed rotary power tool with abrasive head

g) Cutting tool for cutting splice fingers (jigsaw not preferred)

j) Curved surforms (2)

k) Hand brooms/brushes (2)

SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0

• Platen length = splice length + 150 mm (min)

o) Edge bars securing/clamping device (2).

p) Template for marking out splice.

2 Platen Length = SL + 200mm

100 6 Finger Length, FL 100

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SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0

1250 900 50 1100 1200 1420

1400 1100 30 1300 1400 1600

1600 1170 50 1370 1470 1800

Minimum Platen Length = Splice Length + 150mm

Minimum Platen Width = Belt Width + 150mm

The materials required for one splice are:

a) Splice fabric coated with Nitrile rubber on both sides.

b) The inner side of the fabric is coated with 0,5mm nitrile.

c) The inner side is identified with a white cotton strand.

f) Panel length: Equal to the length of the splice + 100mm.

g) Skrim fabric: - Width = FL+200mm, Length = Belt width x 2 + 200mm.

AAC_SPEC_37700800 APPROVED 5 June 2006 Page 5 of 20

SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0

i) Silicon coated paper: Width = Skrim fabric width + 100mm.

Length = 2 x press platen length ± 50mm.

Belt width Guide to quantity of PVC paste ( l )

900 3,0 5,0

1050 4,0 6,0

1200 4,5 7,0

1350 5,0 8,0

1500 6,0 9,0

1650 7,0 10,0

Shelf life of materials as listed below will be as specified by the manufacturer: -

Note that materials/containers must be clearly date and batch marked.

9 MARKING AND CUTTING OF SKRIM FABRIC.

SPLICING OF SOLID WOVEN CONVEYOR ISSUE 0