Splicing of Steel

Cable Conveyor Belts

Splicing Manual

1
Contents

I. Range of Application Page3

II. Products for Splicing

Steel Cable Belts 4

III.Tools and Equipment 4

IV. General Conditions for Splicing

Steel Cable Belts 5
1. Work place 5
2. Conveyor belt 5
3. Equipment and tools 5
4. Splicing products 5
5. Ambient conditions 5
6. Documentation 5
7. Precautions 5

V. Construction and Dimensions

of Steel Cable Belt Splices 6
1. Splicing methods 6
2. Construction 6
3. Determination of splice”and step length 8

VI. Splicing of Steel Cable Belt 10

1. Preparations for splicing 10
2. Preparing the belt edges 11
3. Assembly of cover pads 16
4. Preparing and placing the ”bottom cover pad 16
5. Matching and laying the cables 18
6. Placing the top cover pad 22
7. Curing the splice 23
8. Completing the splice 24

VII. Questionnaire for

REMA TIP TOP Splicing Kits 25

VIII. REMA TIP TOP Splicing Record Sheet 26

2
I. Range of Application

This manual describes the splicing of steel cable

conveyor belts (DIN 22131) with rubber covers made of
the 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 conveyor

belt about the rubber grade.

For splicing steel cable belts with a breaker please

contact your REMA TIP TOP distributor.

Splicing can ce done in the workshop or on site.

* Abbreviations according to DIN ISO

3
II. Products for Splicing III. Tools and Equipment
Steel Cable Belts
STB COVER STOCK in rolls of 10 kg Splicing shelter / tent
Ref. No. 538 0505 2 - 6 mm x 500 mm Polyethylene film (PE film)
Cover cloth
STZ TIE RUBBER in rolls of 10 kg Screw clamps
Ref. No. 538 0907 2 mm x 500 mm Measuring tape
Ruler (mm/in.)
STZ TIE RUBBER STRIPS 2 kg box Metal rule
Ref. No. 538 0952 2 mm x reqd width Flat angle
Marking crayon (white)
HEATING SOLUTION STL-RF Rubber marker
Ref. No. 538 1951 1 kg* Plumb line
Ref. No. 538 1243 6 kg 6ô knife
Ref. No. 538 1298 12 kg Off-set knife
* LOBA-NW Nr.18.43.21 IX 23 Whetstone
or Scissors
Pincers
HEATING SOLUTION STL-RF4 CFC-free Vise grip No. 2
Ref. No. 538 1274 3,5 kg Vise grip No. 3
Ref. No. 538 1267 7,0 kg Chain or cables winches
Cable cutters
CLEANING FLUID Angle grinder
Ref. No. 595 9022 800 ml* Hand brush
Ref. No. 595 9084 5 l Solution brushes
Ref. No. 595 9091 10 l Stitcher
* LOBA-NW Nr. 12.22.64-1-25 Hammer
or Cable drum
Safety goggles
CLEANING FLUID R4 CFC-free Work gloves
Ref. No. 595 9118 800 ml Buffing motor with flexible shaft
Ref. No. 595 9125 5l Rotating wire brushes
Grooved wire brushes
SILICONE PAPER RTT Belt stripping system
Ref. No. 538 1078 1200 mm wide Vulcanizing press incl. edge bars and clamps
Ref. No. 538 1023 2180 mm wide Thermometers
Rubber Cut
HOLLAND CLOTH Thickness Gauge
Ref. No. 538 1009 1250 mm wide STZ Extruder gun

SHIRTING black
Ref. No. 538 0990 1000 mm wide

STZ-EXTRUDER GUN
Ref. No. 517 5174

STZ-EXTRUDER RUBBER 2 kg box For detailed information about equipment,

Ref. No. 538 0969 4 x 20 mm measuring instruments and tools please refer
to: REMA TIP TOP Industrial Programme.

REMA TIP TOP Splicing Kits for steel cable

belts (grade M/N) are available on request!
Please see section VII on page 25.

Explanations and changes in terminology:

LOBA NW = Landesoberbergamt Nordrhein-Westfalen

CFC-free = does not contain chlorinated hydrocarbons

STB cover stock = Uncured cover rubber STB

STZ tie rubber = Uncured intermediate rubber STZ
STZ tie rubber strips = Uncured intermediate rubber strips
Holland cloth = Pressure compensation cloth

4
IV
IV.. General Conditions for Splicing
Steel Cable Belts
´
1. Work place
In order to ensure quality and durability of a
splice, a clean and sheltered work place as
well as correct use and application of the
splicing products are essential.
The exposed surfaces of stripped cables,
bevel cuts and cover pads must be kept
absolutely clean.

2. Conveyor belt
Only clean and dry conveyor belts can be
spliced reliably.
Dirty or contaminated belts must be cleaned.
Water-soluble contaminations should be scraped
off and then washed away with water and dried.
Oil and grease should be removed with Cleaning
fluid.

3. Equipment and tools

Tools and equipment must be in perfect working
order. Measuring instruments have to be
calibrated.

4. Splicing products
REMA TIP TOP Splicing products are suitable
for cable belts with grade M and N rubber
covers. Splicing products have to be stored in
a dry and dark place at a temperature of max.
25oC (77oF) in accordance with DIN 7716.
Check expiration dates and dispose of outdated
and contaminated products.

5. Ambient conditions
Any influence of humidity, e.g. formation of
condensation water (temperature fallingbelow
due point) must be absolutely avoided.
Precondition products to ambient temperature
if necessary.
Erect a splicing shelter/tent for protection
against sun, dust, wind, rain etc.

6. Documentation
During the splicing operation all irregularites
and special conditions have to be recorded.
The record sheet must be signed by the
supervisor at the end of each shift.

7. Precautions
Observe safety precautions on the cans.

Note:
Our recommendations result from field tests
and years of experience. However, in view of
the different materials and work conditions
beyond our control, we recommend to make
corresponding tests locally in any case.
We cannot assume any kind of liability resulting
from these recommendations.

5
V. Construction and Dimensions of
Steel Cable Belt Splices
1. Splicing methods
Splices on steel cable belts in accordance with DIN 22131 can be 1-step or multi-step splices in
rhombic ( belt width x 0,3) or rectangular shape.

Fig. 1

Rectangular shape Rhombic shape

The loadability of both the rectangular and the rhombic

shaped splice is similar. Usually a rectangular splice is
preferred, 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 the
minimum breaking strength of a cable and the dynamic
cable tear-out strength in the splice area dictate length
and 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 spluice area
(tie rubber thickness).
The construction is also influenced by
- distance between butted cables
- stepping of cable ends
- Cable laying corrections and laying
cycle modifications.
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 the
pulleys.
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 opposite
running direction of the belt.
Deviations of the cable laying scheme should be
moved to the belt center area, because the edge
zones are exposed to a higher load.

6
Fig. 2

Transition Transition
zone zone

If a steel cable belt is equipped with a breaker, a breaker

lv = Length of splice
lq = Deflecting zones of cables
lp = Staggering of cable ends
should be applied in the splice area corresponding to
the belt construction.
Between breaker and transition zones where the top
covers are bevelled, there should be a gap of approx.
50 mm.

lst = Minimum step length

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

d = Steel cable diameter

Fig. 3

Transition zone 50 mm
20O - 30O

Top cover pad

Breaker
Steel cable

Belt Bottom cover pad

Splice

20O - 30O

7
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

Step lengths and splice lengths STZ tie rubber

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

St 1000 1 600 800 2 x 6

St 1250 1 600 800 2 x 7

St 1600 1 600 800 2 x 7

St 2000 2 400 1150 2,5 x 7

St 2500 2 500 1350 2,5 x 10

St 3150 2 650 1650 2 x 10

St 3500 3 650 2450 2,5 x 11

St 4000 3 750 2750 2,5 x 11

St 4500 3 800 2900 2 x 12

St 5000 4 900 4250 2,5 x 13

St 5400 4 1000 4650 2,5 x 13

For belts made in accordance with other industrial Example 2:

standards than DIN, the splicing system can be Cable pitch (t), cable Ø (d) = 3 mm
determined with the following formulas: According to formula 1 the result is as follows:
a = 8mm/2 – 3 mm = 4 mm – 3 mm = 1 mm
Formula 1 for 1-step splice: a = t/2 d The result for the tie rubber layer is therefore 1 mm.
Formula 2 for 2–step splice: a = t/1,5 d The minimum dimension of 1,5 mm is not achieved and
Formula 3 for 3-step splice: a = t/1,33 d therefore a 1–step splice is not recommended.
But according to formula 2 the result is:
The simple calculation with these formulas is clearly a = 8mm/1,5 – 3 mm = 5,33 mm – 3 mm = 2,33 mm
described in the following examples:
In this case a 2–step splice is recommended!
a = tie rubber thickness in mm (minimum 1,5mm!) Whether a 3 – or even a multi-step splice is necessary,
t = cable pitch in mm is calculated as in above examples following formula 3.
d = cable diameter in mm
( for cable pich (t) and cable Ø (d) please refer to the
delivery documents of the belt manufacturer or
measure it yourself)

Example 1:
Cable pitch (t) = 8mm, cable Ø (d) = 2mm
According to formula 1 the result is as follows:
a = 8mm/2 –2 mm = 4 mm – 2 mm = 2 mm
The result for the tie rubber layer is therefore 2 mm.
This exceeds the minimum dimension of 1,5 mm - a
1–step splice is possible!
Other splicing methods
The cable laying schemes as well as the step lengths,
deflecting zone lengths and the splice lengths
indicated may be modified if necessary; e.g. when
splicing different belt types (mixed splice).
Such modifications require the approval of the plant
operator.

8
 Running direction of belt

1-step splice
(sectional view) Fig. 4

Gurtlaufrichtung
Running direction of belt

2-step splice
(sectional view) Fig. 5

Gurtlaufrichtung
Running direction of belt

3-step splice
(sectional view) Fig. 6

Gurtlaufrichtung
Running direction of belt

4-step splice
(sectional view) Fig. 7
9
VI. Splicing of Steel Cable Belt

1. Preparations for splicing

1.1 Prepare tools, equipment and splicing materials.

1.2 Erect a splicing shelter, install a work table and

the vulcanizing press:
The entire work area has to be adequately protected
by the shelter from environmental influences.
The work area consists of the lower part of the press
(traverses and heating platens) and approx. 3 - 4 m
long wooden work tables at either end of the press.
150mm
Fig. 8 50mm
The heating platens must be flush with the surfaces of
the work tables in order to avoid tensions at the belt
ends.
The heating platens must be at least 150 mm longer
than the splice on either side and at least 50 mm wider
than the belt on each side (edge bars must be fully
covered by the heating platens).

1.3 Aligning the belt ends

Place and align belt ends on lower part of press

and work tables, ensuring that both ends
are overlapping on the press by at least the
splice length lv plus 100 mm.
Secure belt ends in this positon with clamps.

Fig. 9

10
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 measuring

across width of belt at three points in length of each belt
end at a distance of approx. 2 m. At least two center
markings on each belt end must be outside the splice
area. Belt center line
The establishment of the center line is easiest done with Fig. 10
two rulers (Fig. 10).
The three center markings on each belt end are then
connected by means of a chalk line
which represents the belt center line. This center line
ensures exact alignment of the belt ends, which is
indispensable for straight belt running.
The center line outside the splice area must be durable
enough to remain evident throughout the entire splicing
operation!

Destroyed or missing rubber edges must be considered. Placing the rulers

The width of the rubber edge is established by measuring
the width of the carcass at suitable areas of the belt Fig. 11
ends.

Establish a perpendicular reference line across both

belt ends outside the splice area.
On narrow belts this can be done by placing a metal
square onto the center line.

On wide belts it is recommended to establish the

reference lines as follows (Figs 11 to 13):
Outside the splice area select a point A on the center
line. Mark points B and C on the center line equidistant
to point A (AB=AC) (Fig. 11).
Fig. 12

Now describe a circle with the same radius around points

B and C by means of a plumb line and a pen. The points
of intersection of both circles must still be on the belt.
These intersections are points D and E (Fig. 12).

Reference line
Fig. 13

A line drawn between these two points will be

perdendicular to the belt edges and forms the reference
line, which should pass point A for additional control
(Fig. 13)

11
The reference lines are now marked by cutting small For exact measuring, another 100 mm are added to
notches into the belt edges. the splice length on either side and marked

The notch marks of the reference lines on both edges of The marks now established for the splice length are
the belt ends are now the reference points from which connected on the belt with a chalk line or with a rule
the splice length lv is measured and marked ( Fig. 14). and a pen.

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

Fig.14
Reference line Reference line

Belt end Transition line Center line Transition line Belt end

100 100
mm mm

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

Fig. 15 Transition line

Center line

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

Transition line
Fig. 16 100 mm

Center line

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

12
2.4 Removing top and bottom cover and”
stripping of steel cables

a) Conventional manual procedure Center line

Cut the rubber covers on the carrying and running side

into parallel strips with a Don Carlos knife (400 - 700
mm wide according to belt width) in length direction of
the belt.
Fig. 17
Lift the rubber cover with pincers at one corner of a strip Transition line
in the area of the belt transition line and cut it free with
the Don Carlos knife just above the steel cables, until
the cover can be gripped with a REMA TIP TOP Vise
Grip.
By means of the vise grip, a winch and continuous cutting
(just above the steel cables) the complete rubber cover
is removed
(Fig. 17).

Center line

ca. 10 - 20 mm
Fig. 18
During this operation the rubber cover is under tension Transition line
and has to be secured with a rope in order to protect the
men in case the vise grip slips off. When cutting off the
rubber cover hold the knife at such an angle that the
steel cables remain covered with rubber.

The exposed carcass must be protected from

contamination and placed onto a clean surface
(e.g. PE film).

After having removed the rubber covers on both sides

of the belt, cut out the rubber between the steel cables
with a 6" knife to within 10 - 20 mm of the bevelled
transition zone (Fig. 18).

Fig. 19
The stripped cables should still be covered with rubber
(cubed cable rubber). On cables which are strongly
twisted 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 notch
Fig. 20
the 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 only

and placed onto a clean surface (PE sheet).

13
b) Stripping the steel cables with the Now install the REMA TIP TOP Cable Stripping System
REMA TIP TOP Cable Stripping System according to instructions and start stripping the cables
from the left side of the belt in direction belt end.
With the REMA TIP TOP Cable Stripping System the
cables are stripped in one single, Please make sure to use cutting blades corresponding
time-saving operation, without prior removal of the top to the cable diameter.
and bottom cover.
After stripping, the result should be a nearly round, with
This mechanical stripping system requires the following 0,3 mm rubber embedded cable.
additional preparations:
- Approx. 150 - 200 mm from the transition line draw Stripped cables should be handled with clean gloves only
an additional, parallel line on carrying side and and placed onto a clean surface (PE film).
runningside of the belt ends.
- Cut the rubber cover along this line straight down
to the carcass.
- Remove the rubber cover between transition line
and the vertical cut in the conventional, manual way.

Fig. 21 REMASTRIP-Cutting unit Pulling cable Pulling unit

150 - 200 mm

2.5 Buffing the rubber embedded cables (Fig. 22)

Carefully buff the rubber embedded cables with a

grooved wire brush. Avoid overheating, shiny spots and
scorching of the rubber. Buffing will automatically break
the edges of cubed cable rubber. Non-adhering or loose
rubber has to be removed. A minimum of bare metal
should be exposed. A small amount of such exposure Fig. 22
can be tolerated. The strength of a splice depends on
the level of cable adhesion to the original rubber
embedding it. The new tie rubber bonds to the original
cable rubber. The splice strength depends on the shear
adhesion of a rubber to rubber bond, rather than a rubber
to metal bond.
Damaged, corroded or bare cables have to be buffed
until they are bright. An excessively damaged cable
has to be removed. In case of several damaged or
corroded cables the operator should be informed
immediately, who will have to decide whether the
splicing job should be continued or a new belt installed.
The number and condition of such cables and partially
bare cables should be noted in the splicing record.

14
2.6 Buffing the transition zones
On the carrying and running side of both belt ends the
rubber surfaces of the transition zones and another 20 -
30 mm on either side of them must be thoroughly buffed
with a rotating wire brush. Overheating, shiny spots and
scorching of the rubber should be avoided.

2.7 Removing the buffing dust

The buffing dust has to be thoroughly removed with a
clean hand brush. Place belt ends back
onto the work tables and arrange the cables on a clean
surface (PE film).

Fig. 23

center line

approx 10 - 20 mm approx 10 - 20 mm

2.8 Applying heating solution PE protection film

Apply two thin and even coats of REMA
TIP TOP STL-RF heating solution to the transition zones
and the cables (Fig. 23). STL-RF heating solution
Allow the first coat to dry completely before applying the
second coat.

2.9 Aligning the belt ends

Align lower part of the vulcanizing press (traverses and
heating platens). In case of low ambient temperature
preheat the heating platens to max. 40 oC (104 oF).
Establish number of cables of each belt end and mark
the carcass center.

Align the belt ends under consideration of splice length

lv, the belt center line and the carcass center line on
each belt end and mark correct alignment with a chalk
line. Now the center lines on both belt ends must form
one straight line. The distance of the reference lines on
both belt edges must be equidistant (a = a - see Fig. 14
on page 12). Secure both belt ends with clamps.

15
3. Assembly of cover pads

The assembly of top cover pad and bottom cover The tie rubber side is covered with a red protection
pad is usually done in the workshop. They consist film; the cover stock side is covered with a
of 2 mm thick STZ tie rubber and STB cover stock. green protection film.

Required minimum thickness of cover pads:
- Thickness of belt cover plus 1 mm.
Dimensions of the cover pads:
- Belt width plus 150 mm
- Splice length plus 250 mm
For large splice lengths and wide belts the cover
pads may be made up in two or more parts.
For splices with breaker the STZ tie rubber is
3 mm thick. The breaker is placed between STB
cover stock and STZ tie rubber and should not
extend into the rubber edge zones and leave
50 mm between breaker edge and both transition
zones. In this case the minimum cover pad thickness
is: Thickness of belt cover plus 2 mm.
Type and construction of the breaker required should
be coordinated with the operator or the belt manufacturer.

4. Preparing and placing the bottom cover pad

4.1 If necessary place thin metal compensation sheets
on lower heating platens. Cover the complete heating
area first with Holland cloth and then with silicone paper.
Place additional strips of 250 - 300 mm wide Holland
cloth over the transition zones and the splice edge zones
in such a manner, that they can be folded up later in
order to cover the complete rubber edge
(Fig. 24).
4.2 Remove the green protection film from the cover
stock side of the cover pad. Place the cover pad onto
the covered heating platens and align. The red protection
film (tie rubber side) is now on top.
In case of several partial cover pads also coat the
bevelled edges with STL-RF heating solution and allow
to dry until they are still slightly tacky. Then join the coated
edges without trapping air and stitch on .

Fig. 24 Holland cloth Silicone paper

Shirting

Shirting
strips
Holland
cloth
Shirting
Silicone
paper

16
4.3 In the area of the transition zone remove the red
protection film by approx. 100 mm. Place one belt end
onto the cover pad and mark first splice edge. Fold belt
end back again and bevel cut the cover pad at an angle
of approx. 30o corresponding to the bevel cut angle of
the transition zone.
Before handling the belt ends bundle the steel cables
and wrap them into PE film.
Fig. 25
4.4 The transition zone of the other belt end is matched
and placed in the same way (Fig. 26).
Fig. 26
Again check the correct alignment of the belt center lines
and also the splice length lv and adjust/correct if required
(Fig. 27).
Fig. 27
Now apply a thin and even coat of STL heating solution
to the bevelled edge of the cover pad.
If the coat of STL heating solution on the transition zone
is no longer tacky enough, apply another coat and allow
both coats to dry until they are still slightly tacky.
Place the transition zone of the belt onto the bevelled
edge of the cover pad, press on and tap down with a
hammer (Fig. 25).
2 mm STZ
8 mm STB
Cover pad
17
5. Matching and laying the cables

5.1 Completely remove the red protection film from the

bottom cover pad and mark the step lines (lst and lp) for
laying the cables according to the specified laying
scheme.
Scribe these lines on the cover pad with a knife tip. The-
se lines must still be visible after coating with STL-RF
heating solution.
The step lines can also be marked by placing tie rubber
strips onto the established lines.
Place clean Holland cloths or similar over the bottom
cover pad, leaving exposed approx.
100 mm in the center in length direction of the belt. The
tack of the tie rubber, which will be exposed further step
by step can further be improved by applying a very thin
coat of STL-RF heating solution.

Fig. 28

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

18
5.2 Laying the cables
This operation is always started at the center of the splice.

Odd number of cables

1-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.

Belt running direction

Belt center line

and center cable
Fig. 29

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-step
splice is a long cable. This cable is deflected by half the cable pitch towards the belt center line.
Belt running direction

Belt center line

and center cable
Fig. 30

On the second belt end also start with the center cable, which then is deflected towards the
other side of the belt center line by half the cable pitch and laid in the matching length in accordance
with the cable cycle. All further cables are laid according to cable laying scheme proceeding to
the 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 belt
end) which are staggered towards the marked belt center line.
Belt running direction

Belt center line

and left
center cable
Fig. 31

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 belt
with the odd number of cables onto the belt center line and then proceed according to the
specified cable laying scheme.

Belt running direction

Belt center line

and center cable

Fig. 32

19
5.3 Laying the cables
After having determined the laying scheme, starting with
the center cable, all cables are cut according to the
marked step lines and pressed onto the bottom cover
pad in accordance with the specified cable laying
scheme
(Figs. 4 to 7).
The gap between butted cables must correspond
to between 3 and 4 times the steel cable diameter!
A STZ tie rubber strip is placed edgewise between the
cables, after having removed its protection film (Fig.
33).
When laying and pressing on the STZ tie rubber
strips a uniform distance between the cables must
be ensured, especially at the cable ends, which
are exposed to the maximum shearing force
within the splice.
The dimensions of the STZ tie rubber strips are
indicated in the table on page 8 and ensure that the
cables are laying straight.
During the laying operation continuously check
that the cables are laying straight.
If this is not the case, despite of careful laying of cables
and tie rubber, proceed as follows:
If the cables are bent towards the edges of the splice,
try to move the cables closer together by tapping them
with a hammer and pulling the tie rubber at the same
time. If this does not bring the desired result, the only
way is to cut a cable on the second belt end first and
then, if still necessary, also on the first belt end.
Fig. 33 STZ Tie rubber strips
20
Never cut two cables next to each other!
If the cables are bent towards the belt center compen-
sate by placing additional STZ tie rubber strips.
The edge cables must always be long cables from
the first belt end.
This is achieved by checking the cable laying scheme at
least 10 - 15 cables before the edge cables are reached.
If according to the laying scheme the edge cable will not
be a long cable from the first belt end, an initial adjustment
can be made by cutting a cable from the second belt end
at least 10 - 15 cables away from the edge cable.
Edge cables must never be cut! The cables to be
cut always have to be at least 10 -15 cables away
from the edge.
In case of a 1-step splice a cable has to be cut on one
belt end only which usually is the only way of correcting.
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 already
been cut on either side of the splice.
On multi-step splices there is an increased number
of possibilites for adjustment.
STZ
STB
Cutting one or more cables will solve a problem for the
necessary adjustment.

If there is sufficient space in the edge area, it is

recommended to place a thicker strip or two strips of
STZ tie rubber. A STZ tie rubber strip is also placed
along the edge cables and pressed on.

When the last cables are laid, there should be sufficient

space for the rubber edge.

Fig. 34

5.4 After having laid all cables mark the splice edges
with a chalk line and trim excess rubber. Apply a coat of
STL-RF heating solution to the edge of the bottom cover
pad and to the excess STB cover stock. Allow these
coats to dry until they are still slightly tacky (check with
back of finger). In case of overdrying apply another coat.
Build up edges with excess STB cover stock to the upper
level of the cables.
The splice should now be slightly wider than the adjoining
cured belt. Excess material will be trimmed later together
with the top cover pad (Fig. 34).

5.5 Thoroughly and completely fill up all remaining gaps

and cavities slightly above upper level of cables either
manually or with the REMA TIP TOP STZ extruder gun.

21
6. Placing the top cover pad

6.1 Apply a generous coat of STL-RF heating solution 6.3 When placing the top cover pad avoid trapping air.
to the buffed upper bevel cuts of the transition zones Then remove the green protection film.
on both belt ends as well as to the built up rubber edges
and allow to dry completely. Press on and stitch the top cover pad vigorously from
the center outwards or in direction of the butt joints
6.2 Before placing the top cover pad onto cables and respectively and firmly tap down with a hammerin the
rubber edges proceed as follows: transition zones (Fig. 35).
- check the thickness of the cover pad
- preheat the heating platens to max. 40oC, Remaining air within the splice area can be evacuated
ifnecessary by making approx. 150 mm long cross cuts down to the
- remove the red protection film from the tie rubber cables ( not in case of top cover pads with a breaker).
side.
Depending on the tack of tie rubber apply thin coat of
STL-RF heating solution. In case of several partial cover
pads also apply a thin coat of STL-RF heating solution
to the edges.

Fig. 35

6.4 Trim excess rubber in the transition zone with an

off-set knife. Mark the splice edge with a chalk line and
trim with a long knife (Fig. 36).

Fig. 36

6.5 Again check the correct alignment of the belt center

lines of both belt ends with a string.Deviations can now
still be corrected. This final control/correction is
important for straight running of the belt and therefore
indispensable ( Fig. 37).

Fig. 37

22
7. Curing the splice
7.1 Apply 200 - 250 mm wide strips of Holland cloth
onto the transition zones of the top cover pad and fold
the shirting strips around the splice edges
(Fig. 24 on page 16).
Cover the complete heating area first with silicone paper
and then with Holland cloth. Now the edge bars (edge
irons) are applied on both sides of the splice and pressed
against the belt edges with edge clamps, which are
mounted outside the press area. The edge bars must
be approx. 2 mm thinner than the belt (Fig. 38).
Silicone paper Holland cloth
Fig. 38
Fig. 39
Prior to placing the top platens apply thin sheet metal
for thicknes compensation, if necessary.
7.2 Assemble top platens and then place the upper tra-
verses in line with the lower traverses.
The upper heating platens also must be at least 200
mm longer than the splice on either side and at least 75
mm wider than the belt on each side. The edge bars
must be fully covered by the heating platens. The
arrangement or layout of the heating platens must be
noted in the splice record.
When aligning the heating platens and the traverses it
has to be ensured that the platen joints in direction of
the belt edges are supported by the traverses and that
the first and last traverse is located outside the splice
area.
Now the pressure bolts are installed and have to be
tightened evenly and simultaneously in each travers.
Then secure the edge bars by means of wedges
(Fig. 39).
23

7.3 Attach the electrical connections and pressure
systems of the vulcanizing press observing the operating
instructions of the press manufacturer. The press must
produce a minimum pressure of 1,2 N/mm² (specific
pressure: 12 bar).
7.4 Increase pressure while temperature rises and
observe temperature on all heating platens. Platen
temperature uniformity should be within +/- 10oC (50oF)
of the selected temperature. Higher deviations must be
recorded.
7.5 Apply specific pressure when all heating platens
have reached a temperature of between 100oC (212oF)
and 110oC (230oF) and maintain this temperature for a
period of approx. 15 minutes by disconnecting the
electrical connections at 110oC (230oF) and connecting
again when the temperature has dropped to 100oC
(212oF).
At this temperature range the rubber develops its
optimum flowing properties.
Never exceed the permissible specified pressure!
7.6 Then continue increasing the temperature. The
curing time starts when the temperature on all heating
platens has reached 145oC (293oF). The curing time
depends on the belt thickness.
REMA TIP TOP products require a curing time of
3 minutes per mm belt thickness, but not less than
30 minutes.
7.7 Disconnect the electrical connections at a tem-
perature of 148oC (298oF) and connect again when the
temperature has dropped to 145oC (293oF).
Repeat this operation until the curing time is completed.
If necessary place thin metal compensation sheets prior
to placing the heating platens.
7.8 When curing is completed allow the heating platens
to cool down to 60oC (140oF) before releasing the
pressure.
24
8. Completing the splice
8.1 Remove vulcanizing press, strips of shirting, Holland
cloth or silicone paper and inspect the splice. Check for
correct vulcanization (absence of porosity or blisters,
elasticity, thickness and Shore hardness).
8.2 Trim edges, remove material overflow and make any
other appearance modifications as may be necessary.
8.3 The splice should be durably marked with a splice
number (DIN 22129) by means of the
REMA TIP TOP Rubber Cut or the
REMA TIP TOP Branding Iron.
Marking example: 1/4/98 T 14 8
1/4/98 T 14 8
Splicing date
(day/month/year)
01.04.98
Contractor
REMA TIP TOP
Splice number
No. 14
ID abbreviation
of vulcanizer
8.4 The conveyor belt can be put into operation after
the splice has cooled down to ambient temperature.
8.5 Finally the splice record sheet must be com-
pleted. All irregularities occurred during the splicing
operation should be registered. The record sheet
should be signed by the Supervisor of the contractor
and countersigned by the operator.
VII. Questionnaire

REMA TIP TOP Splicing Kits

for Steel Cable Conveyor Belts

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:

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

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

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

Cable Diameter ................................................ mm

Cable Pitch ................................................mm

Belt width ................................................ mm

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

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

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

Splice Geometry o rectangular o rhombic (16o)

Breaker o Carrying side o Running Side

......................................................................................................................................................................................
Company Place Date Signature

25
VIII. REMA TIP TOP Splicing Record Sheet
(Recommendation)
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: ................. oC/oF 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: ........... mm Top Cover: .................... mm

Rubber Grade: ............................................ Belt Condition: ......................................................................

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

o Cables stripped manually

o Cables stripped with RTT Cable Stripping System
o Cables buffed with grooved wire brush

Thickness Left Side Right Side

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

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

Alignment: 1 2 3

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

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

4. MATERIALS USED

Splicing Product STL STB STZ STZ-Strips

Manufacturing date

Expiry Date

26
5. CURING PROCESS

Vulcanizing Press: Manufacturer: ..................Model: ...........................................

Pressure System: o Hydraulic o Water o Mechanical
Heating Platens: o Rhombic (16 ) o
o Rectangular
Number of pairs of traverses: ...................................... Calculated Curing Time: ................mins
Thickness of edge bars: ............................ mm
Warming up (to 145oC/293oF) Time started: ....... h Time reached: ............... h

Curing Time Temperature (oC/oF) Pressure (N/mm²)

Heating Platens No. 1 2 3 4 5 6 Gauge 1 Gauge 2
10 mins
20 mins
30 mins
40 mins
50 mins
60 mins
70 mins
80 mins
90 mins
100 mins
110 mins
120 mins

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

6. FINAL QUALITY CONTROL

Alignment: o Correct o Off center ...................mm

Edge trimming: o Yes o No
Rubber Hardness (Shore A): Top Cover: .............................................
Bottom Cover: ........................................
Appearance of top and bottom cover surface: ...................... Splice marking: .............................
Signature of Shift Leader: .................................................... Date: ............................................

7. CUSTOMER SATISFACTION
Professional Acceptable Unacceptable
Job organization o o o
Safety regulations o o o
Job performance / skills o o o
Tools and equipment o o o
Work force appearance o o o
Work finishing / cleanliness o o o
Time keeping o o o
Observations: .................................................................................................................................................
.......................................................................................................................................................................
Date: ........................................... Site Manager: ............................................. Signature: ............................

27
 Printed in Germany

Distributor:
VII.01
582 0319 E

TIP TOP STAHLGRUBER

Otto Gruber GmbH & Co. KG
INDUSTRIAL DIVISION
Gruber Straße 63
D - 85586 Poing
Tel.: (08121)707 - 158
Fax: (08121) 707 - 222
E-Mail: industry-info@tiptop.de
28 8