Splicing Instructions

4165 Old Salisbury Rd Tel: 336-956-3956

Lexington, NC 27295 Fax: 336-956-3913
 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Table of Contents

Multiple Layer........................................................................................1-11

Texlam 1250, 1500, and 2000........... 12

Viton Cold Splice ....13

Viton Splicing and Vulcanizing ...14

EPDM Cold Splicing ......15

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Splicing Instructions for Multiple Layer Expansion Joints

Confidential Note: The information contained in this instruction manual contains legally privileged and confidential
information, which is intended only for the use of Frenzelit customers. Customer shall not, at any time, disclose or in any
manner reveal such information to any third party, nor reproduce, copy or distribute such information in any shape or form
without the express written consent of Frenzelit.

Fig.1:

Secure open cuff to the flange

and apply cold-curing silicone
on the overlapping area (approx. 4)
(silicone film thickness approx. 3/64).

Fig. 2:

Place the part of the expansion joint with the

bonded cuff on top of the just prepared area
and immediately apply pressure on the
overlapping portion.

Fig. 3:

Fold back the next single

fabric layer

Fig. 4:

Place the single wire gauze plies

one on top of each other (overlapping
approx. 4), and cut off any excess material.
NOTE: It is important to ensure a smooth cut
at the wire mesh edges that must also be
bend over to avoid damage to the PTFE foil
caused by frayed wire pieces sticking out.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 5:

Sew up wire mesh with a piece of wire

thread taken from the mesh.

Fig. 6:

At the cuff region carefully apply cold-

curing silicone to the width of the cuff.

Fig. 7:

Again, place the next fabric layer on top

(overlapping approx. 4) and cut off any
excess material.

Fig. 8:

Carefully secure fabric layers in place

and apply pressure to ensure proper
bonding of the material.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 9:

With a hand roller press and flatten entire

cuff area to remove any air bubbles and to
smoothen the fabric layers.

Fig. 10:

Secure joint area of fabric layers

by simple stitching.

Fig. 11:

Now complete the seam with cross-

Stitching over the entire joining
area of the fabric.

Fig. 12:

Fold back PTFE film of the lower portion of the

expansion joint and allow the
upper film to overlap by approx. 4.
Carefully cut off and remove any excess
material.

NOTE:
Please be advised that there are two options of joining the PTFE film. Either by (a) folding or (b) by thermal
sealing. If the folding option (a) is to be applied, follow instructions from figure 13 through figure 17 and then skip
to figure 24.
If thermal sealing (b) is to be used, please skip to figure 18 and follow instructions accordingly.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 13: (option A)

Fold back overlapping upper PTFE film,

apply cold-curing silicone on lower
PTFE film (only for better adhesion of the
two films)

Fig.14: (option A)

Place upper film back and facing

towards the cold-curing silicone.
Apply pressure over entire area.

Fig. 15: (option A)

Pull up the two PTFE films sticking

together and carefully fold them according
to the illustration on the right.

Fig. 16: (option A)

Fold edge tightly and maintain a right angle

to the cuff region on both sides as much as
possible.

Fig. 17: (option A)

Secure joint folding of which is completed

laterally and press thoroughly.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 18: (option B)

Place both PTFE films one on top of the

other and allow to overlap by approx. 4. Cut
off any excess material and slide backing
strip between the last fabric ply and PTFE
film.

Fig. 19: (option B)

Slide thermal sealing film between

the two PTFE films in the overlapping area with
approx. 2 in width.

Fig. 20: (option B)

Using clamping devices, secure the two

PTFE films and the thermal sealing film
in place.

Fig. 21: (option B)

Place the preheated welding tool on the welding

seam and apply slight pressure.(Please refer to the
working instructions accompanying the welding tool).

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 22: (option B)

Apply pressure on the sealing unit for 1-2

min or until PTFE films are glassy.

Fig. 23: (option B)

Finish the entire seam along the width of the

Expansion joint, according to the
procedures described above.

Fig. 24:

Carefully apply the cold-curing vulcanize

at both cuff and overlapping area
(approx. 4) with spatula (coat thickness
1/16).

Fig. 25:

Fold fabric ply to inside and apply

firm pressure on the bonding area.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 26:

Carefully apply equal pressure

on the entire bonding area.

Fig. 27:

Lay covering ends one on

top of each other and mark the edge,
then proceed to fold back top ply.

Fig. 28:

Carefully apply cold-cured vulcanize

with spatula to the cuff and
overlapping area to approx. 4 (coating
thickness max. 1/32).

Fig. 29:

Apply cold-cured vulcanize approx.

2 wide on the reverse side
of the fabric layer that is folded back
(coat thickness max. 1/32).

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 30:

Fold covering layer to the inside.

Fig. 31:

Place the backwards folded layer carefully

under the cuff and apply firm pressure.

Fig. 32:

Carefully press entire bonding area

while smoothening the area in order to
remove
folds and unwanted bulges in the material.

Fig. 33:

Carefully apply cold-cured vulcanize

with spatula in the cuff area (coat
thickness max. 1/16).

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Fig. 34:

Fold cuff portions to the inside and press

firmly.

Fig. 35:

Carefully press cuff without folds.

Fig. 36:

Secure both sides with clamping strip and

screw clamps, thus subsequently
sealing the edges of the covering layers.
After a minimum of 1 hour the clamping
devices can be removed.

Reasonable care has been taken to ensure that the data content is accurate and up-to-date, however, Frenzelit North
America Inc. makes no warranties or representations about the accuracy or completeness of the information content. FNA
Inc. shall not be liable for any direct, incidental, consequential, indirect or punitive damages arising out of access to or use of
content from this data, regardless of the accuracy or completeness of any such content. The data appearing in this file is
exclusively owned by FNA Inc. The use or misuse of this data or any other content, without prior written permission, is strictly
prohibited. YOU ARE HEREBY NOTIFIED THAT ANY DISSEMINATION, DISTRIBUTION OR COPYING OF THIS
INFORMATION IS STRICTLY PROHIBITED.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Splicing Instructions for TEXLAM 1250, 1500, AND 2000

Expansion Joints

In order to splice Texlam to itself you must have PTFE splicing film to
place between the two layers of TEXLAM.

1. Pull any slack out of both ends of the belt and clamp it to the frame
at 12 from the end of each tail.
2. Overlap the ends of the Texlam by approximately 2.
3. Place a piece of PTFE welding film (2.25 wide by longer than
the height of the belt) between the overlapped ends.
4. Staple the three layers of material together at the edges (both top
and bottom).
5. Place a block with insulating material between the joint and the
frame to prevent heat from being lost during the sealing process.
6. Place a Sealing Iron on top of the Texlam at the edge of the joint
while applying pressure for 3 minutes @ 420C (788F). For
Texlam 2000 apply pressure for 4 minutes.
7. Move the iron over the entire length of the joint making sure to
overlap the last position each time the iron is moved to a new area
of the joint. Be sure to keep the iron in position long enough to
allow for a full 3 minutes in each area (4 minutes for Texlam 2000).

We recommend if you have never done this procedure to practice with

some Texlam and some PTFE Splicing Film to assure the proper
technique before attempting to splice an installed belt.

If you have any questions, assistance can be supplied by calling Chuck

Hill at
704.219.4753.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Splicing Instructions for Viton Cold Splice

1. Remove the material thickness of opposite surfaces of the Viton

approximately 3 wide. This can be accomplished by literally
skinning the material away. (you are trying to make a 3 wide lap
joint)

2. Clean surfaces to be joined with M.E.K. solvent or acetone to

remove all oils and debris.

3. Apply Viton to these surfaces and evenly distribute with putty knife
or something similar.

4. Join ends of Viton together.

5. Cover them with PTFE film to prevent material from adhering to

clamping surfaces.

6. Use pieces of steel plate or boards to completely cover overlapped

area and clamp tightly for 24 hours.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Splicing Instructions for Viton Splicing and Vulcanizing

1. Using an Orbital Sander, sand the area from the edge of the Viton inward
approximately 60mm. Repeat this step on the reverse side at the opposite
edge of the material. This will increase the surface area at the region chosen
for splicing.

2. Using the grinding device shown, the thickness of the Viton will be decreased.
This will decrease the overall thickness of the splice. After securing the Viton to
the base of the grinder, using double-sided tape, take small amounts of Viton
away until the Glass fabric core is visible. Repeat this step on the reverse side
at the opposite edge of the material. See figure # 1 and # 2

3. Using the special board, secure the Viton and prepare for the next few steps of
the splicing process. See figure # 3

4. Cut five (5) strips of 0.8mm Unvulcanized Viton at the described dimensions.
Cut 2 @ 3/8 / 2 @ / 1 @ 2 .

5. Using the solution known as MEK, clean the surfaces that will be part of the
vulcanizing process. There is no need to clean the surfaces of the
Unvulcanized Viton. After cleaning, apply MEK only to the surfaces that are
intended to be permanently sealed at this time. The person doing this process
must view the diagram in order to know where the strips of Unvulcanized Viton
should be placed. The placement and application of MEK with the strips is very
important to ensure that a gas tight seal will be made. See figure # 5 and # 6

6. Once the strips of Unvulcanized Viton have been properly placed, the proper
heat and temperature must be applied immediately. Equal pressure will be
applied by the orange colored clamps along the entire surface of the special
board while 340oF is applied for one (1) hour.

7. After one hour of heat and pressure the entire splice and special board
combination must be immediately placed onto a cooling block of metal to
complete the vulcanization process.

8. It may be necessary to increase some dimensions for differing applications.

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 Hi-Tech Bellows and Expansion Joints, Gasket Materials and Insulation

Splicing Instructions for EPDM Cold Splice

1. Remove the material thickness of opposite surfaces of the EPDM

approximately 3 wide. This can be accomplished by literally
skinning the material away. (you are trying to make a 3 wide rough
lap joint)

2. Clean surfaces to be joined with solvent or acetone to remove all

oils and debris. The Material has to be absolutely clean!

3. Apply the two-component glue (follow instructions on the can) to

these surfaces and evenly distribute with putty knife or something
similar.

4. Join ends of EPDM together.

5. Cover the splice with PTFE or other nonstick material to prevent

material from adhering to clamping surfaces.

6. Use pieces of steel plate or boards to completely cover overlapped

area and clamp tightly for 24 hours.

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