Ssanpertrans’® A MEMBER OF THE SEMPERIT-GROUP INSTRUCTIONS FOR JOINING OF RUBBER TEXTILE BELTS BY HOT CURING ‘SELLER DOCUMENT REVIEW ESS Contents: + eee Introduction Work place Tools Equipment Materials Splice dimensions Making the splice Curing peu awe we Health and Safety Regulations while making the splice 1-308-HS.04_A Page 1/8Binding of rubber textile belts by hot curing. 1. INTRODUCTION The process of binding belts by hot curing allows producing splices with high technical characteristics and performance. The process involves suitable pretreatment of belt ends, binding them with rubber compounds, composing together and pressure curing at a specific temperature. The process is recommended especially for new belts. It should not be applied under the following conditions, the belt reveals high irregularities of thickness caused e.g. by high wear which is when the cold binding process is advised instead. 2. WORK PLACE In order to produce the correct durability and quality of the splice, keep the work place clean and tidy, at a correct temperature and humidity, and pay attention to careful production of the splice. Secure the splice areas from deposition of dust and dirt; if necessary, ensure additional protection of the work place as follows: ~a cover (tent) from weather (high atmospheric humidity, rain or strong wind), 3. TOOLS The following set of tools is recommended for the bonding of rubber textile bands by hot curing: © Curved knife ‘© Flat straight or offset knife * Flat straight or curved screwdriver * Pincers © Rubber hammer © Wide and narrow roller © Spiked roller ® Bristle brush © Wire brush © Tallor’s shear (large) © Measure © Chalk line © Knife stone © Round bristle brush © Angle bar 1-308-HS.04_A Page 2/84. EQUIPMENT ‘The following equipment is recommended for the bonding of rubber textile bands by hot curing: © Manual or electric power winch with the minimum traction force of 16 kN for delamination of dividers; Divider delaminating grip; Electrical power grinder, max speed 3000 RPM, with § 100 mm wire ring brush or grinding disk; Safety glasses; Curing press for belt splices with instrumentation (power cables, thermometers); Hand screws for securing the belt ends from disassembly; Curing table, e.g. top made of wooden planks. If the splices are produced outdoor, a cover/canopy is required to protect from rainfall ete. 5. MATERIALS Sempertrans Betchatéw Sp. z 0.0. provides the following materials for binding of rubber textile belts: '* The cover plate for the belt class (40 x 3 mm closing strips); * The core plate for the belt class, length: splice length + chamfer length + 100 mm and 550 mm wide; © Rubber adhesive compound. Note: The core and cover rubber compound classes are selected for each belt type. Use of other materials (than the recommended by the belt manufacturer) will not guarantee the required strength of splices. 1-308-HS.04_A Page 3/8Cover plate Core plate Core plate Core plate Fig. 1. Diagram of binding by hot curing. IMPORTANT: The thickness of cover plates (closing strips) shall be selected for the actual thickness of belt covers. The binding materials shall be stored in cold rooms and away from light. ‘The shelf life of materials for general purpose belts is 6 months from the date of production. Use of expired materials may result in decreased splice strength and result in failure of the conveyor. 1-308-HS.04_A Page 4/8.6. SPLICE DIMENSIONS The splice size L, is the total of stage lengths |, and the chamfer length A: L,=ml +A were: n—the number of joint stages, n= 2~1; ,2” is the number of dividers in the belt |,—the stage length, depends on the divider strength T, acc. to Table 1. ‘A~ the splice chamfer length, depends on the heating plates chamfer of the curing press Define the stage length |, from Table 1 depending on the theoretical strength of the divider T,, which is calculated from the nominal belt strength R and the number of dividers Divider strength Tk [N/mm} Double divider belts 400 ‘Step joint 500 ‘with overlap <160 Belts with 2+ dividers >160 $250 >250 <400 >400 <630 > 630 Table 1. The joint stage length vs. the divider strength The splice chamfer length is A = 0.4xB (or 0.3xB, depending on the press in use), where 8 is the belt width. Fig. 2 presents the diagram of dimensioning and treatment of the belt ends for the hot binding process. 1-308-HS.04_A Page 5/8.Direction of transport Fig. 2. Diagram of dimensioning and treatment of the belt ends for the hot binding process 1-308-HS.04_A Page 6/8EXAMPLE Calculate the splice dimensions for the curing press with the plate chamfer of 0.4 for the belt designation of Sempertrans Betchatéw Sp. z 0.0. as follows: 1200 EP 1000/4 The code designation is broken down as follows: 4 the number of textile dividers in the belt core; EP — denotes the use of polyester and polyamide fibres for the divider structure; 1000 ~ the nominal tensile strength in N/mm; 1200 - the nominal belt width in mm. The number of joint stages n is: n=4-1=3. The theoretical strength of a single divider is Ti = 1000/4 = 250 [N/mm], so from Table 1 the following appli Stage length: 1, = 250 [mm] Chamfer length: A= 0.4x 1200 = 480 [mm] Splice length: L, = 3 x 250 [mm] + 480 [mm] = 1230 [mm] When procuring and managing the stocks of belts, consider the extra quantity of the belt required to produce the splices on the conveyor at the amount of Np x Lp, where Np is the number of splices required to install the belt. 7. MAKING THE SPLICE When producing splices, do the following tasks: Prepare the press to produce the splice; © Mark the chamfer length and the splice length; © Clamp the dividers as required by the marked stages. If the core rubber remains on the divider surface, rasp it of slightly and be careful not to damage the textile fibres; Remove 2 [cm] of the running and bearing covers along the chamfer line; Chamfer the rubber covers; Coat the pre-treated surface and the core rubber section 0.9 to 1.0 {mm thick with glue and once the compound has dried, apply the core rubber over one end of the belt, roll down well with the spiked roller, and then apply the other end over. ‘Fill up the belt edges with the cover compound; ‘* Assemble on the press and cure. 1-308-H5.04_A Page 7/88. CURING Cure the joints of rubber textile belts at the minimum unit pressure per splice of 1.0 [MPa] (10kG/cm’). Curing temperature: 145+/-5°C for 2.5 mins per each mm of belt thickness. Not applicable to heat-resistant belts. Start counting the curing time when the curing press heating plates reach 140°C. The splice curing process has three stages: heating, curing and cooling, Heating starts by exerting the required pressure and turning on the press plate heating. At the plate temperature of approx. 110°C, vent the splice by reducing the pressure to zero for 1 minute. When the plates reach 140°C, start counting the curing time and hold the temperature manually or automatically at the same value. Once the required curing time runs out, shut down the heating and cool the splice under pressure down to approx. 60+70°C. DO NOT reduce pressure during cooling! ‘Once the cooling phase ends, reduce the pressure, disassemble the press, cut off the leaks at the splice edges and when it has cooled down to the ambient temperature, the splice can be commissioned. 9, HEALTH AND SAFETY REGULATIONS WHILE MAKING THE SPLICE When performing curing operations, adequate ventilation must be assured. The adhesive shall be delivered in sealed metal containers and in the quantity that is enough to build the splices. Once the adhesive was used, the containers must be closed immediately and removed from the work place. Be extremely careful to protect the hands from cutting and fouling with the adhesive, as well as to protect the eyes at work. Every worker shall be equipped with work coveralls, gloves and safety glasses. 1-308-HS.04_A. Page 8/8A MEMBER OF THE SEMPERIT-GROUP Joining rubber belts with steel cables with hot curing SEMPERTRANS 1830 ST 5000 19+8 XR+150 (04 2015) Page 1 of 10seampertrans’® A MEMBER OF THE SEMPERIT-GROUP Table of contents: 1. Introduction 2. Materials to make joints 3. Tools 4. Equipment 5. Joint dimensions 6. Making the joint 7. Curing 8. Health and safety regulations while ‘making the joint, 'SEMPERTRANS 1830 ST 5000 19+8 XR+L50 (04 2015) Page 2 of 10sampoertrans’® A MEMBER OF THE SEMPERIT-GROUP 1. INTRODUCTION Joining belts with hot curing enables to obtain joints of high technical and maintenance parameters. This process consists in exposing cables ina joining site, lay them out according to a definite pattern and cure them in rubber. Depending on the belt strength, a number and diameter of cables, the way of laying the cables out, there are distinguished, one- two- three- and four-stage joints. 2. MATERIALS TO MAKE JOINTS For joining the rubber belts with steel cables, the manufacturer Sempertrans Belchatow Sp. 20.0. supplies the following materials: The plates watched fora stable char ot the belt. + With: equal tothe ble width + Length: Jot length + 03. of belt length +100 mm + Thikness matched individually ae. to Facing plates the belt structure “The pistes matched fora sutable anes of the bl. + wish: equal tothe bet witht Coreplates | + Length: Joint length + 03 of belt lenath +100 mm 1 Thess: 2 men «ST 4000; 25 men fr | The Sips maiched Tor @ sable cas of ‘the belt with the fotowing cimensons Interline strips Thickness: 2 mm Width: 11 mn “Te adhesive matched fora wuitable dase Adhesive ofthe bat, 24g/1 mz ofthe eat “ion fabric Taew Fi of hej * in the case of belts wide more than 1000 mm, both facing and core plates are divided into two or three widths For belts with metal or fabric enforcement, we supply facing and core plates, and the reinforcement that shall be doubles with the facing and core plate. The use of other materials than those manufactured by SEMPERTRANS for joining belts does not guarantee the adequate strength of the joints. The materials for joining shall be stored in cool, dark rooms (the information on the way of storage are placed on the package). The guarantee period is located on the material package. The validity date of the materials to make joints for belts with steel cables of class TG(V) is the same as the validity date of adhesive placed on its package. But the validity date of materials for the other strips is 6 months from the production date. The use of outdated materials may by a cause of lowered strength of joints and lead to a failure of the conveyor. ‘SEMPERTRANS 1830 ST 5000 19+8 XR+L50 (04 2015) Page 3 of 10Ssennpertrans® A MEMBER OF THE SEMPERIT-GROUP 3. TOOLS cured joint before and behind the curing/vulcanizing press ee eE EE ee ay to mae Joints * A steal ft suitable too thihness of cred elt ope © Arack to suspend the cables @ Aflat straight ora bent knife * Stee! sheets; thickness: 0.5 - 1.0 mm, min. lige ccrete ier arg or offset width: joint width + 100 mm, and length: the Bes total length of joint and slant + 300 mm © Arubber mallet * Awide and narrow smooth roller © Aroller with spikes 5. JOINT DIMENSIONS ©) Abair brush 5 TaN Batons ang) In table below, the joint dimensions for belts 3 beens of different strength are presented. For untypical oa structures of belt to be joined, the joints and their size shall be selected individually. © Aknife hone © Around hair paintbrush Other dimensions concerning the joints and the © Anangle bar way to lay out cables are shown in Figures 1-4. It is allowable to make straight or diamond-shaped 4. EQUIPMENT joints (the slant length is of 0.3 * width of belt). The equipment necessary to make the joints correctly: * A manual or electro-mechanical hoist, towing power min. 16kN, for delayering * Anelectric grinder with a flexible shaft, max. 1000 rpm, equipped with a ring=shaped steel brush © 100mm. Agrinder or shears to cut cables Safety goggles Wedges or bolts to secure curing slats A hydraulic press, straight or offset, for joining belts, with accessories (power supply cables, thermometers). Minimum length of the press: total length of joint + min. 300 mm; width: width of © Clamps for belts to secure ends against drawing aside © Curing slats (thiner by 1-1.5 mm than the belt thickness, longer than joint by min. 300 mm) © A curing bench - e.g. a worktop made of timber boards, its length of twice length of ‘SEMPERTRANS 1830 ST 5000 19+8 XR+L50 (04 2015) Page 4 of 10samoertrans’® A MEMBER OF THE SEMPERIT-GROUP SPLICING DIAGRAM SEMPERTRANS 1830 ST 5000 19+8 XR+L50 1830 ST 5000 Splice Length - Ly 4290 mm No. of Cables 105 Step Length - Ler 920 mm Cable Diameter 10,6 mm ‘Transition Length - ae La Cable Pitch 17mm Distance between cutting cables ends — 50. mm Number of Stages 4 G Bek Width 1830 mm Cure Time 140 min, ‘Temperature 14545°C Pressure on the joint with Pressure the min. of 1.2MPa (12kG/em’) ‘SEMPERTRANS 1830 ST 5000 1948 XR+L50 (04 2015) Page 5 of 10sampertrans’®© A MEMBER OF THE SEMPERIT-GROUP 6. MAKING THE JOINT In a place to be joined on the conveyor, a curing station shall be prepared. Put the lower cross-beams of curing press in the axis of the belts to be joined, on the levelled plane in such way as there is no space between them. It will make it possible to achieve even distribution of the pressure during curing. Arrange heating plates of the curing press on the cross-beams (according to the curing press manual). Put the steel sheet on the operating surface in order to cover the contact places of the heating plates. Build curing benches of length min, 2 x the length of joint on both sides of the plates, along the axis of the joined belts. Build the benches to make an even surface with the heating plates. 1. Lay the ends of belts one over the other, on the heating plates. Lay out the belts to be joined coaxially with reference to the conveyor and the curing station on the length of approx. 20 m before and behind the curing station. 2. Determine centre lines and contact lines of the joint on both ends of the belts. 3. Cut the upper facing plate up to the cables along the contact line with a knife inclined at an angle 30° to the belt surface. Then, cut ‘out the kerbs on the whole length of joint. 4. Remove the top facing by cutting it with the knife just above the cables. While cutting/ripping, stretch lightly the facing with the use of cable ripper. Remove the facing by ripping it with strips wide about 50cm 5, Fold back the belt ends when the top facing is removed. 6. Determine the contact fines on bottom facings. Cut the facings along these lines up to the cables at the angle 30° to the belt surface. 7. Remove the facing plates on the other side of the belt in a way described in point 4. 8 Remove rubber between the cables by cutting it out with the use of knife, just along the sides of cables. The cables shall be prepared forming their cross-section in a form of octagon, circle or square. On the entire surface of the cables, a layer of rubber shall be left. ‘SEMPERTRANS 1830 ST 5000 19+8 XR+1S0 (04 2015) Page 6 of 10Sseampoertrans® A MEMBER OF THE SEMPERIT-GROUP 9. Roughen slightly cable surfaces using the electric grinder. * Cables shall be prepared just before making the joint and shall be secures against ‘extraneous factors (such as dust, moisture, ete.). 10. Roughen the surfaces of bevelled contacts and the adjacent 30-mm wide belt area. 11. Centre the belt ends to obtain one axis for both joined belt ends. Lay out the flat bars ‘or clamps along the centred belts and fasten them to the benches in such way that the ends of belts cannot move. The belt ends prepared in this way shall be dedusted and cleaned thoroughly. 12, Tighten the cables to the racks and clean the cables and the entire area of joint out of dust. 13. Lay the silicon paper or fibre on the steel sheet. 14. Double core and facing plates. © Ifa metal reinforcement or a fibre breaker are present in the belt, double them with facing and core plates, coating them previously with adhesive. Dry well each time the surfaces of plates/reinforcement. The reinforcements shall be laid between the facing and core plate. 15. Trim to the size the rubber facing plate that bas been doubled previously with the core plate. Make bevels on the belt ends at angle of 300 to the surface of the belt ends. Lay it on heating plates with the core rubber facing to the cables. 16. Coat with adhesive the belt contact and cables, and dry them well. Then, lower the ends of belts and sick together the bevels of belts with bevels of the plate laying on the shelves of the curing press. Clamp thoroughly the bevels (hammer them with rubber mallet). 17. Determine the centre (belt axis) of the joint on the rubber plate laid on the bottom part of the press. Mark the lines with a clean blunt tool (e.g. with a blunt side of knife blade). Cover the plate with a foil or a linen, except the centre part. 18, Coat the cables with adhesive thoroughly from each side. * It is very important to allow the adhesive vapour completely. Not dried cables may lead to form bubbles and affect adversely on the joint strength. SEMPERTRANS 1830 ST 5000 19+8 XR+150 (04 2015) Page 7 of 10Ssampertrans’© A MEMBER OF THE SEMPERIT-GROUP 19. Cut the cables according to the scheme of laying the cables out, starting from the belt axis. If the centre lines of belts are aligned with the cable axes, then lay first cables in the centre of the joint length. If the cable axes do not align with the centre line (belt axis), lay the cables in parallel to the centre line. © The scheme of laying out the cables shalll be selected in such way that the cables located at the belt edges have the longest stage in their run is opposite the belt movement direction. 20. Apply an intercable rubber strip along the side of each laid cable and press it thoroughly. Clamp consecutive cables firmly in such way as the cables and strips adhere each other. While lay the cables out, observe the rule that each cable of one belt end is connected with a corresponding cable of the other belt end at the length of stage Ist. The length between the cable ends that are laid opposite to each other shall be: 3+4xd; where d=cable diameter * Add the strips perpendicularly to the core plate. © The strip thickness shall not be lower than 1.2 + (0.1 x d), where d means the cable diameter. 21. After laying out 5 to 7 cables, check their axial and parallel layout with reference to the belt axis. In the case the parallel layout deviations are found, change the thickness ‘of intercable rubber strips / stretch or double the strips. 22. 23. 24. The unparallel cable layout with reference to the centre line or the curvature of the cables lower the strength of the joint. Fill the free spaces between the cables with intercable rubber strips. ‘Owing to a risk of bubble formation, do not recoat the cables with adhesive. When all the cables are laid out, fill edges of the belt with a rubber plate at the height of the cable surface. Trim to the size the rubber facing plate that bas been doubled previously with the core plate. Bevel the ends of plate at an angle of 30° towards the plate surface. Lay the doubled plates with the core rubber towards the cables, paying attention not to close the air. Clamp thoroughly the contacts (hammer them with rubber mallet). 25. 26. 27. With the use of cord mark the line of joint rim. Cut out the rim surplus in order to equal the width of joint with the width of belt. Cover the joint with silicon paper or fibre. Lay out steel flats (curing slats). Cover the joint surface with steel sheet thick 0.5-1.0 mm and then with heating plates. Lay out the top traverses of hydraulic press on the plates, and then hammer the side slats with wedges. SEMPERTRANS 1830 ST 5000 1948 XR+L50 (04 2025) Page 8 of 10Sampertrans’ A MEMBER OF THE SEMPERIT-GROUP ——e 28. Start the process of curing. 7. CURING Cure the joints of rubber belts with steel! cables applying unit pressure per joint min. 1.2 MPa (12kG/cm*). Recommended terms of curing are the following: © Curing temperature: 14535°C © Curing time: 3 minutes per 1 mm of belt thickness Heating Curing time Belt thickness upto (om) Goring tine FE) sa Figure 1 presents schematically the course of curing the joint. The whole process of curing consists of three stages: heating, curing and cooling. ‘The curing time shall start to be measured when all the heating plates of curing press reach the set temperature. During heating stage, the curing pressure shall be respectively: + 1/3 of the full cure pressure applied up to temperature 50°C; * 2/3 of the full cure pressure should be applied within the temperature range from 50°C up to 100° © Above 100°C the pressure shail be elevated Up to the full curing pressure. should be Curing 145°C#S°C: min. 1.2 MPa/em? [Time] Fig.6. Curing scheme for conveyor belts, ‘SEMPERTRANS 1830 ST 5000 19+8 XR+L50 (04 2015) Page 9 of 10sSampertrans’® A MEMBER OF THE SEMPERIT-GROUP Required unit pressure per the surface area of Joint shall be applied by regulating the pressure of hydraulic fluid in the press. For presses with plates type membrane, hydraulic pressure roughly correspond with the unit pressure. For presses with hydraulic actuators in the traverse beams, use the technical data given by the press manufacturer. Start measuring curing time in a moment when the heating plates reach the set temperature and keep this temperature at the same level. During the curing process, the maximum momentary temperature fluctuations at the level +5°C are permissible. When the required curing time is passed, switch off heating and cool the cured joint under pressure down to temperature approx. 50-60°C. * Please do not reduce the pressure during the process of cooling! Reduce the pressure when joint is cooled down to the required temperature, disassemble the c press, cut out the outflows on the joint edges, grind possible roughnesses and make a precise report with detailed information on the course of making joint. The joint can be commissioned when is completely cooled down to the ambient temperature. HEALTH AND SAFETY REGULATIONS ‘WHILE MAKING JOINTS While making joints with steel cables, observe the following rules: 1. The staff employed to make belt joints shall be trained within the scope of rules: OHAS, fire protection, the technology of making belt joints, and safe operation and maintenance of belt conveyors. 2, Tools with drives, curing equipment, materials for making joints and belts used in, mines have to have a suitable acceptance 10. mark given Authority) by WUG [State Mining Curing equipment and appliances have to be installed and operated in compliance with valid rules and instructions within thi scope, ‘The station for joining belts shall be located in such a way to provide the employees necessary space to free move about, ‘The use and handling open fire near the work station is forbidden. Each person employed to prepare and cure belt joints shall be equipped with a protective suit, gloves and safety goggles. The adhesive shall be delivered in tightly closed metal packages and in amount necessary to make the belt joints. When the task is completed, the empty adhesive packages shall be closed and disposed from the work station. The adhesive contains solvents, the vapours of which are toxic. While conducting the work, avoid breathing in the solvents and observe not to exceed permissible concentrations of solvents. While preparing the joints to be cured in the closed rooms, provide suitable ventilation to prevent exceeding permissible concentrations, It is also recommended to use mask with canisters type PO. ‘SEMPERTRANS 1830 ST 5000 1948 XR+L50 (04 2015) Page 10 of 10sennpertrans’® SPLICING DIAGRAM SEMPERTRANS 1830 ST 5000 1948 XR+L50 Tipo de correa: Type of belt 1830 ST 5000 Namero de cables: No. of Cables 105 El didmetro del cable: Cable Diameter 10,6 mm Paso de los cables: Cable Pitch 17mm ‘Nimero de pasos: Number of Stages 4 Longitud del empaime = Ly Splice Length 4290 mm Longitud del paso - Ls; Step Length 920 mm Largo de transicién -Lx Transition Length 230 mm Distancia de corte entre cables — G Distance between cutting cables ends 50 mm. “Ancho de cinta Belt Width 1830 mm. Tiempo de curado: Cure Time 140 min ‘Temperatura: Temperature 14545°C Presion: Pressure Ta presion en el empaime con el min. de 1.2MPa Pressure on the joint with the min. of 1.2MPa (12kG/cm?) (12kG/oma)sampertrans’®@& conveyor belt technology metas vette om o, LAS BAMBAS PROYECTO LAS BAMBAS EMPALME DE CINTA EN CORREAS TRANSPORTADORAS, CONTRATO N° 25635-320-FC3-MHCB-00001 6.5. | MEDIOAMBIENTAL Ec conveyor belt technology& conveyor belt technology : S265 oe , LAS BAMBAS PROYECTO LAS BAMBAS EMPALME DE CINTA EN CORREAS TRANSPORTADORAS CONTRATO N? 25635-320-FC3-MHCB-00001 6.5 MEDIOAMBIENTAL APLICA | NOAPLICA | | | conveyor belt technologyLAS BAMBAS EMPALME DE CINTA EN CORREAS TRANSPORTADORAS 6.6. GEOTECNICOS Y SERVICIOS DE INGENIERIA HIDRAULICA & conveyor belt technology& conveyor belt technology LAS BAMBAS | | | | PROYECTO LAS BAMBAS EMPALME DE CINTA EN CORREAS TRANSPORTADORAS CONTRATO N° 25635-320-FC3-MHCB-00001 6.6 GEOTECNICOS Y SERVICIOS DE INGENIERIA HIDRAULICA APLICA | NOAPLICA | X & conveyor belt technology