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Thread: Best Belt Splicing Practice

  1. #1
    jstrabav Guest

    need advice on belt splicing best practice

    I recently was involved in a "root cause analysis" of one of our belt failures, and was given an action item to investigate best practices in belt splicing with which I could "audit" our contractor. Does anyone have any advice as to preference between mechanical, cold, or hot splices? Any info would be greatly appreciated.
    Thanks,
    John S.

  2. #2
    Join Date
    Jun 03
    Posts
    24

    Belt Splicing

    There are a lot of factors that influence the life of a splice. Having said that, chemical bond and hot vulcanize spilces are stronger splices (CEMA - Belt Conveyors for Bulk Materials- fifth edition).

    As I see it, the following are areas you should review:

    1. Belt Manufacturer - I have worked on many diferrent brands of belt, and there characteristics all vary. Some are recommended for chemical or hot splicing only, because of the carcass. Others have poor adhesion levels because the carcass is not treated and mechanical splices are the preferred choice.

    2. Operating conditions - If this is a high heat application you must follow the manufacturers recommendations and I recommend using only there hot splice kits.

    3. Used Belt - Resplicing existing belt, in my experience, gives you lower adhesion levels. The factors that contribute are: moisture, uneven belt wear (vulcanizer cannot give you even pressure throughout the spice area), and belt fatigue.

    4. Action Plan - When a chemical or hot spliced belt fails and emegency service is required it can be best to install a mechanical splice. The reason I say this is that the environmental conditions may not be satisfactory, at this time, to do a chemical or hot bond. Also the pressure to get the system up and running usually means short-cuts are taken and the splice results are not the optimum adhesions. Install a mechanical splice and then schedule a time for a resplice at a later date.

    5. Scheduled Service - The time factor also applies to this. If a short window is allowed to perform a resplice the splice is subpar. If you get your service quoted by a number of different companies you want to educate yourself to know what it takes to give you the best final product. Lower initial cost may cost you more in the longterm if the price is too low to do a proper job.

  3. #3
    jstrabav Guest
    thanks for the input - I'll be checking into that book you mentioned. I really appreciate it!

  4. #4
    Join Date
    Jun 03
    Posts
    24
    I ran out of room in my first reply.

    I will shotly point out other factors: proper step size in the splice, proper splicing procdures, proper splice area, proper spicing gums and a proven cold bond cement, carcass fatigue, cover thickness, etc.

    If you would like to give me more details on exactly where the splice failed,what type of spice, what type of belt, and system details I will give you my opinion.

  5. John,

    The three splice methods (mechanical, cold cure, and vulcanized) are all acceptable means of splicing fabric carcass belts. Vulcanized splices should be used for steel cord and aramid fabric belt splices.

    As far as a comparison is concerned, vulcanized splices and cold cure splices give comparable splice strength ratings, while mechanical splices give ratings at, or slightly higher than, the belt's ratings. Mechanical splices tend to have a shorter life span and require more maintenance than cold cure or vulcanized splices.

    Mechanical splices can generally be done quickly by facility maintenance personnel. Cold cure and vulcanized splices, to be done properly, generally are done by technicians trained for the work -- do to the sensitivity of the belt for proper stripping and splice lay-up.

    The short term cost (including down time costs) comparison for the three splicing choices are cold cure most expensive, vulcanized medium, and mechanical least expensive. The long term cost comparison has mechanical splices as the most expensive because of multiple down times, cold cure as medium expensive, and vulcanized as least expensive.

    Because vulcanized splices provide the highest strength ratings and also are the most cost effective over the life of the belt, these splices are normally the splice of choice. Mechanical splices should be used in emergency situations, where speed to get the belt back up and running is the paramount consideration, or in situations where cold cure or vulcanized splices are not practical.

    Cold cure splices should be used where the capital cost of the vulcanization equipment is prohibitive to the user.

    Literature sources on the subject include the CEMA book mentioned, belt manufacturer literature, Mr. Mulani's book, the RMA guide on conveyor belts, et al.

    Regards,
    Dave Miller
    ADM Consulting
    10668 Newbury Ave., N.W.,
    Uniontown, Ohio 44685 USA
    Tel: 001 330 265 5881
    FAX: 001 330 494 1704
    E-mail: admconsulting@cs.com

  6. #6
    Lawrence K. Nordell

    Lawrence K. Nordell

    President and CEO

    Conveyor Dynamics Inc. [eDir]

    Conveyor Dynamics Inc.

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    WOW!! Good Thread responses:

    Might I add questions to separate the variables of damage due to splice, belt, product damage, bad loading station design, enviromental influences, et al. and the generals. I believe the above have a good start on it and will continue.


    A better response might be forth comming if we know:

    1. Type of belt material PVC, SBR, Cloroprene .....

    2. Product

    3. Environment temperature range,

    4. Muck build up, pulley configuration and their isssues

    5. Lump sizes

    6. Width, speed, loading config., tonnage, .....

    7. Age in service

    8. Dynamics (start/stop) and splice stress

    9. Tensile members - steel, polyester, nylon, ......

    This can get pretty lengthy to do it all.

    Lawrence Nordell
    Conveyor Dynamics, Inc.

  7. #7
    jstrabav Guest
    here's the info I have:

    belt = Goodyear Pathfinder Supreme
    36" wide
    3 ply
    1/16 x 1/16 covers
    conveyor box = approx. 625 ft.
    total length of belt = approx. 1350 ft.
    product = common dent corn kernels, dried
    troughed rollers
    gravity take-up at drive end
    no muck, conveyor is covered, inside of box remains fairly clean, but dusty
    loadings & speed I will work on

  8. Hi John,

    Pathfinder Supreme is an excellent belt for your application. It has good carcass strength characteristics and the rubber is designed for your bulk material.

    Since you have experienced a problem, or problems, with the splice and are tasked to do an analysis, you should consider the following:

    [1] Examine the failed splice to determine the nature of failure ? fabric failure, tie gum cohesive failure, or tie gum adhesion failure. Confirm that the splice tie gum was adequately cured and is not porous. Confirm that that the rubber and fabric in the splice are not heat damaged (i.e. overcured). Confirm that the fabric is not damaged. Look for signs of contamination between the tie gum and fabric. Take photographs for your records.

    [2] If unsure about your own splice analysis, give the failed splice to the Goodyear, Marysville plant for analysis. They will be able to tell if the splice was done correctly.

    [3] Find out the operating conditions of the conveyor at the time of splice failure.

    [4] Gather normal operating conditions data on the conveyor.

    [5] Obtain a history of past belt experiences on the conveyor.

    Unfortunately, getting an accurate picture of how the belt and conveyor have been running is difficult, as many operators tend to ignore their systems until there is a major problem. Thus, from their viewpoint the system will have given no signs of a problem before the catastrophic event occurred. Even with this impediment, you can learn how the system was operating by examining the conveyor and belt.

    Good luck!
    Dave Miller
    ADM Consulting
    10668 Newbury Ave., N.W.,
    Uniontown, Ohio 44685 USA
    Tel: 001 330 265 5881
    FAX: 001 330 494 1704
    E-mail: admconsulting@cs.com

  9. #9
    Join Date
    Jun 03
    Posts
    24

    Splicing

    A couple other areas I would look at are:

    1. Pulley Diameter - with the 1/16 cover, you have to ensure the pulley diameters are correct. Top point on the splice may be opening up due the forces as you wrap the pulley.

    2. Breaker - I would also recommend putting breaker material at the points. If you are hot vucanizing, breaker with a thin skim of rubber will flow niceley. This will keep that top point from wanting to open.

    Let me know what happened to the splice

    Good Luck!

  10. #10
    Check out Goodyear's website as per link below for vulcanized splice troublesooting.


    http://www.goodyearindustrialproduct...leshoot.html#P

    Gary

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