Splicing is a method of repairing broken conveyor belts in manufacturing, construction, and mining operations to avoid downtime and financial losses. Mechanical joining using metal fasteners is a fast and versatile method preferred for field repair, while some belts require heat or cold curing. Good installation practices and using manufacturer-recommended techniques and materials are crucial for a leak-proof and long-lasting joint. Preform splicing is a cost-effective and stronger alternative to typical vulcanized splicing.
Splicing is a method of rejoining a broken conveyor belt, whether the break is new or an already joined belt has been damaged or has come undone. Broken conveyor belts in production environments in manufacturing, construction sites or mining operations can lead to considerable downtime for workers dependent on their production, and reduced production and financial losses can mount rapidly. There are many types of belt conveyors in operation and they are made from different materials; thus, splicing techniques are designed to quickly create splices that last and preserve the integrity of the conveyor belt. Many belts can only be repaired using a particular joining technique recommended by the manufacturer and using only materials supplied by the manufacturer.
A conveyor belt joining method called mechanical joining, which uses several types of metal fasteners, is a fast and versatile method in use in dirty, confined environments such as mining operations. These fasteners join belts together using rows of connecting grips and are preferred for conveyor belt field repair. They are relatively inexpensive, appropriate for holes and rips, and require only basic mechanical aptitude and skill to use in splicing conveyor belts. Because the fasteners are hinged and separable, they can be quickly removed and replaced without having to remove the belt from its mounting system, which can significantly reduce splicing time.
Conveyor belts come in one or more layers of strength and the thickness of the layer and the diameter of the pulleys will determine which type of fastener to use for joining the conveyor belt. Regardless of the type, starting with a straight edge squared off at the end and being careful not to bury the fasteners too deeply can help keep the joined edges from becoming damaged or causing excessive wear to the hinge pins. Since fasteners may need to be replaced later, good installation practices will preclude traceability issues and help avoid further downtime and possible employee injury and equipment damage.
Some thermoplastic belts may not use metal fasteners, but are instead secured using plastic rivets. These rivets are installed using a handheld machine that spins them. There are also plastic spirals in a webbed material that are vulcanised at the ends for splicing conveyor belts. Skilled craftsmen and experts in vulcanization techniques must install them.
Some conveyor belts need to be joined by heat curing, using heated presses, or cold curing, using chemicals to join the materials into a seamless repair. Good conveyor belt splicing technique in thermoplastic joint curing or casting requires special conditions such as a clean, dust-free, temperature and humidity controlled environment. Conveyor belt splicing technicians in these cases are engineers, skilled in the techniques of making conveyor belt repairs to manufacturer specifications, using only manufacturer-supplied materials.
Curing provides a leak-proof joint, without any interference or friction on the joint to wear on the support system, and although it is a more expensive repair, this conveyor belt joint will typically last much longer. Another type of conveyor splicing recommended by a manufacturer and installed by manufacturer-trained employees are preform splicing techniques performed on certain steel conveyor belts. Splicing the preforms is more cost effective and has been tested to be up to 11% stronger than typical vulcanized splicing and between 16 and 25% faster than typical curing procedures.
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