Aac Spec 377003

AAC SPECIFICATION 377003
SPLICING OF STEEL CORD REINFORCED ISSUE 3

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1 SCOPE 2
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER 2
3 DEFINITIONS 2
4 PROCEDURES 2
4.1 GENERAL 2
4.2 PROCEDURE FOR CHECKING SPLICING EQUIPMENT 3
4.3 PROCEDURE FOR SETTING UP VULCANISING PRESS AND TABLES 4
4.4 PROCEDURE FOR ALIGNMENT 4
4.5 PROCEDURE FOR COVER REMOVAL 5
4.6 PROCEDURE FOR SPLICE ASSEMBLY 7
4.7 PROCEDURE FOR CURING 8
5 QUALITY ASSURANCE PROVISIONS 9
5.1 QUALITY MANAGEMENT SYSTEM 9
5.2 QUALITY PLAN 9
5.3 RECORDS 9
5.4 MATERIAL CERTIFICATION 9
5.5 QUALITY CONTROL 9
5.6 GUARANTEE OF SERVICES 10
6 TEST AND INSPECTION 10
6.1 DIMENSIONS 10
6.2 SOUNDNESS 10
6.3 HARDNESS 10
6.4 VISUAL 10
6.5 COMMISSIONING 11
7 MARKING 11
APPENDIX A: RELATED DOCUMENTS 12
APPENDIX B: RECORD OF AMENDMENTS 12
APPENDIX C: TOOLS 14
APPENDIX D: QUALITY PLAN 16
APPENDIX D: QUALITY PLAN (CONTINUED) 17
APPENDIX E: MATERIALS 18
AAC_SPEC_37700303.DOC APPROVED 14 MARCH 2006 Page 1 of 25
For information or comments on this document please contact ATD QA
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.

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APPENDIX F: INSPECTION CHECKLIST 19

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1 SCOPE
This specification details the procedures for splicing steel cord reinforced conveyor belting.
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

• Title, number, date and issue of this specification.
• Location of area for splicing operation (see Clause 4.1.2).
• Type of connection (see Table 2).
• Third party inspectorate (see Clause 4.1).
3 DEFINITIONS
For the purpose of this specification the following definitions shall apply:
AGED BELT : A belt which is more than three years old or has previously been
refurbished
APPROVED : Approved in writing by the Engineer
SANS : South African National Standards
QAP : AAC Quality Assurance Procedure
The following terms are defined in the General Conditions of Contract:

• AAC, Company, Contractor, Engineer.
4 PROCEDURES
4.1 GENERAL
The mine company may employ third party inspection or use mine personnel to implement
witness and hold points as required by Appendix D. The Contractor shall not proceed beyond
a witness point until agreed by third party inspectorate and or the mine company personnel.
The following, shall be checked by the Contractor prior to any work commencing:
4.1.1 Belt information: The Contractor shall obtain the age, type and class of the belts to be
spliced from the mine records.
4.1.2 Splicing workstation: The Contractor shall determine, in conjunction with the Engineer, the
splicing workstation to ensure the best possible splice.

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4.1.3 Splice proximity: No two splices shall be made within a length of the belt less than or equal
to the total length of belting within the drive system, unless otherwise specified by the
Engineer.
4.1.4 Materials: to be used for splicing shall be as recommended by the original belt manufacturer
and shall be sourced from proprietary manufacturers of conveyor belt splicing materials. All
materials shall be batch coded, have date of manufacture on the packaging and shall clearly
identify shelf life. Cover material shall have a nominal Shore A hardness specified by the
material manufacturer. See Appendix E for a list of materials.
The Contractor shall demonstrate that all the materials used in the splice are compatible with
the original belt(s).
4.1.5 Age limits: no material should be used for splicing if the following age limits have been
exceeded:
Non-Fire Resistant : 3 months
Fire Resistant : 1 month
4.1.6 Splicing site reticulation: A sufficient water supply shall be provided.
Electricity of the following voltages shall be available 500V, 380V and 220V. If necessary a
portable generator shall be provided by the contractor.
4.1.7 Safety: The provisions of AAC procedure CDE PP 801 shall apply.
4.2 PROCEDURE FOR CHECKING SPLICING EQUIPMENT

Prior to commencing any splicing, the Contractor shall:
• Ensure that all required tools are available (see Appendix B).
• Ensure that the following are suitable and that calibration certification is current:
Thermocouple gauges
All press heating platens and cross beams
Pressure gauges
Hydraulic/pneumatic cylinders on beams
Control boxes, cables, plugs, platen elements and plugs
Control thermostats
Rubber hardness meter (Shore ‘A’)

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Recommended interval for calibration and testing:
TABLE 1
ITEM ACTIVITY INTERVAL
Thermocouple gauges Calibration Monthly
Platen Temp. stability 3 Monthly
Pressure gauges Calibration 3 Monthly
Cylinders Press test, even load spread 6 Monthly
Electrics Correct contact and safety 6 Monthly
Thermostat Calibration Monthly
Hardness meter Calibration 3 Monthly
It is recommended that the Contractor utilize a minimum of 3 thermocouples.
4.3 PROCEDURE FOR SETTING UP VULCANISING PRESS AND TABLES

4.3.1 Remove all idler rolls and brackets from the splice area.
4.3.2 Assemble the bottom traverses so that:

• The outer traverse is at least 25mm outside the bias line.
4.3.3 Position the bottom platen such that the edges are parallel to the direction of the run of belt
and the platen overlaps the splicing joint by a minimum of 150mm in the belt direction.
4.3.4 Frames shall be erected on either side of the platens and between the nearest adjacent idlers
to facilitate alignment of the belts to be spliced. Frames shall be securely clamped to the
conveyor structure.
4.3.5 Erect wooden boards on each side of the platen a minimum of 250mm wider overall than the
belt and 3m long.
Ensure that the top surfaces of the boards are at the same level as the top surface of the
bottom press platen and that the table is stable.
4.3.6 Totally enclose the work area such that there is no ingress of rain or dust. Dusty areas shall
be thoroughly dowsed with water 5m on either side of the splice. Ensure that there is
adequate light.
4.3.7 Establish if the belt has, become aged by examining mine company records and determine
splice length as specified in Table 2.

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4.4 PROCEDURE FOR ALIGNMENT

4.4.1 Ensure that the belt is central on the conveyor supporting rollers/frames.
4.4.2 Line the belting up in both directions for a minimum distance of 3m from the splice.
4.4.3 Determine splice length and type according to Table 2.
TABLE 2
DIMENSIONS (MM)
BELT TYPE NEW TO AGED
SPLICE
KN/m NEW TO NEW OR
TYPE
WIDTH AGED TO AGED
L1 L2 L1 L2
ST 500 1 650 -- 1000 --
ST 630 1 650 -- 1000 --
ST 800 1 700 -- 1050 --
ST 1000 1 700 -- 1050 --
ST 1250 1 900 -- 1350 --
ST 1600 1 1000 -- 1500 --
ST 2000 2 1200 600 1800 900
ST 2500 2 1500 750 2250 1125
ST 3150 2 1800 900 2700 1350
ST 4000 3 2700 900 3600 1200
L1 = Length of the splice along centre line of belt
L2 = Length of each step for 2 and 3 stage splices
For belts having strengths greater than 4000kN/m, or for belts having differing configurations,
refer to the belt manufacturer for splice details.
4.4.4 Ensure that the belt ends overlap on the bottom platen by a minimum of: splice length + (0.3 x
belt width) + 200mm.
4.4.5 Establish the Centre Line of each belt end by marking points at 500mm intervals, going back
along the belt for a minimum of 3m and join by means of a chalk line.
4.4.6 Once aligned, the belt should be firmly clamped to the platform (outside the splice area).
4.4.7 At the end of the uppermost belt mark off a Reference Line at right angles to the centre line
close to the end of the belt.

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4.5 PROCEDURE FOR COVER REMOVAL

4.5.1 On the upper belt draw the transverse oblique lines across top cover as follows. Starting at
the Reference Line at the end of the belt mark the bias of 0.3 x belt width off on one belt edge
and from this mark the overall splice length. The overall splice length is then marked off along
the other edge. Mark oblique lines with chalk line. Transfer marks to edges of both belts and
mark oblique lines on remaining covers.
Note that for 90° edged platens no bias is required. However, the internal configuration of the
splice shall be as for trapezoidal platens.
4.5.2 On the back cover make a 45° chamfered cut along the oblique line furthest from the belt end
and a vertical cut along the oblique line at the belt end ensuring that sufficient cover is left on
the cables (±1mm).
4.5.3 Remove the solid rubber edge of the belt from the splice area.
4.5.4 Separate the cover rubber from the cords at the acute point formed by the belt edge and the
oblique cut which defines the belt length.
4.5.5 Fix a clamp to the belt and a ratchet rope puller.
Remove the cover using a motorized load plough, Don Carlos knife or approved equivalent
producing a rough surface. Leave a layer of rubber approximately 1mm thick covering the
steel cord.
4.5.6 Repeat 4.5.2 to 4.5.5 for the top cover.
4.5.7 Any moisture evident shall be removed by an approved means.
4.5.8 Mark off the cord ends for parent and mating cords (this will vary with type of splice).
For Type 2 and 3 splices, configurate the splice to remove damaged or corroded areas of
cords.
4.5.9 Remove the rubber between the cords, leaving a thin layer, approximately 1mm thick, of
rubber on the cord, and cut off at the inner end of the splice in line with the marking for the
end of the mating cord.
Cut the cords to length using cable shears at the leading end of the splice in line with the
marking and remove the excess belt. Ensure that cable shears are sharp to produce a clean
cut and ensure that cords do not fray.
No individual cords are to be cut out of the splice. In the event that this is not possible, then
removal of cords shall be recorded in the Quality Plan and authorized by the responsible
mine official.

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Any corrosion or evidence of poor cord to rubber bonding shall be recorded and brought to
the immediate attention of the responsible mine official.
In the event of corrosion or poor bonding:

• Remove all loose rubber surrounding the cord/s using a clean wire brush.
• Clean the cord/s using a lint free cloth and suitable solvent and allow to dry completely.
• Brush apply one uniform coat of an approved metal to rubber primer e.g.
(ECORRLOK VS 20) to the cord/s.
• Allow the primer to thoroughly dry ensuring there are no runs, bubbles or tears.
4.5.10 Tie the cords together in bundles of approximately 10 to prevent tangling.
4.5.11 Using the edge marks transferred from the upper belt repeat steps 4.5.2 - 4.5.12 for the lower
belt.
4.6 PROCEDURE FOR SPLICE ASSEMBLY

4.6.1 Extra care and attention shall be taken when joining belts of differing thicknesses (i.e. new to
aged). In such cases, the cover shall be chamfered to match the aged belt thickness.
4.6.2 Roughen the edges of the diagonal cut in the vulcanized rubber with a polisher and buff
attachment and remove all buffing dust. Do not buff the cords. Care to be taken not to
degrade the belt.
4.6.3 With both ends of the belt turned back on the bench, clean the chamfer with solvent. Give the
chamfer and each cord two coats of splicing cement and allow to dry between coats. Care to
be taken to avoid solvent entrapment.
4.6.4 Place a piece of light weight release or silicon paper on the bottom platen, smooth out
creases.
4.6.5 Preheat the bottom press platen to 50°C + 5° and maintain this temperature throughout the
building operation.
4.6.6 Lay the un-vulcanized cover panel ensuring that its bonding layer is uppermost on the bottom
press platen. Lower each belt end in turn onto the un-vulcanized cover and mark off the exact
length required. Cut the cover to shape such that the chamfered ends will mate with the belt
ends.
4.6.7 Lower the belt ends in turn to mate the chamfer on the belt with the chamfer on the un-
vulcanized cover panel. Hammer the joint ends well down.
4.6.8 Using the existing belt alignment marks (see Clause 4.4.5), draw a splice line along the
centre of the splicing area using a chalk line.

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4.6.9 Ensure that the cords are clean and dry then lay the cords as per splice type starting from the
centre and alternating outwards. A minimum of 2.0mm and a maximum of 4.0mm is required
between each cord. No part of a cord shall be less than 15mm from the edge of the belt after
final trimming.
4.6.10 Fill the spaces between adjacent cords with strips of bonding compound, which have been
cleaned immediately prior to laying and press vertically alongside the cable just placed. Lay
the bonding compound around the ends of the cords. Fill any gaps at the ends of the new laid
cords with bonding compound.
4.6.11 Prick the strips to expel trapped air.
4.6.12 Ensure that the cords are parallel and that all of the cords are included in part of the joint. No
individual cords are to be cut out.
4.6.13 Using strips of freshly cleaned cover stock, build up the edge of the splice outside of the steel
cord section level with the top of the cords.
4.6.14 Apply a final coat of splicing cement to the prepared area and allow to dry.
4.6.15 Lay the top cover panel onto the prepared cord carcass with its integral bonding layer
downwards towards the cords. Remove the entrapped air with an awl before sealing with the
pressure roller.
4.6.16 Trim the edges of the un-vulcanized cover.
4.6.17 Place a sheet of light weight release or silicon paper on top of the prepared splice such that
the fabric overlaps the ends of the splice and onto the existing belting.
4.7 PROCEDURE FOR CURING

4.7.1 In the event that the press has to be relocated to effect the correct splice length, the leading
edge of the splice shall be cured first. Subsequent press location shall overlap the previous
position of the press by 50mm. This method is not preferred. Press should be adequate for
single cure.
4.7.2 Clamp edge irons of the correct gauge (approximately 2mm less than nominal belt thickness)
firmly against the side of the splice.
4.7.3 Position the upper platen such that it matches the lower platen.
4.7.4 Position the upper traverses and tighten the pre-tensioning bolts. It is important that bolts are
tightened in a sequence that will ensure a uniform load.
4.7.5 When the transverses are placed under pressure the temperature of the platen should be
greater than 50°C and the specific pressure greater than 0.3MPa.

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4.7.6 Increase the specific pressure to a minimum of 1.2MPa as the temperature rises to 115°C
ensuring that the alignment is correct. During the heating cycle maintain the platen
temperature at 110°C-115°C for a period of 10 minutes to allow full flow of splice materials by
switching the platens off at 115°C and switching on at 110°C. After 10 minutes allow
temperature to increase to full curing temperature, as specified by compound manufacturer.
Required hydraulic pressure should be calculated for the particular press in use, taking into
account ram diameters.
4.7.7 Start the curing time measurement when the press platen reaches recommended curing
temperature as specified by compound manufacturer.
Note that it is advisable to consult the materials manufacturer's recommendations with regard
to curing times.
4.7.8 Curing takes place at the specified temperature with the temperature uniform and maintained
as well as possible.
Under no circumstances shall temperature exceed the compound manufacturers

specifications.
4.7.9 In unfavorable windy or cold conditions protect the edges of the press by fabric or wooden
shields.
4.7.10 Once the cure is complete keep joint under full hydraulic pressure until the platens have
cooled down to 60°C.
Forced cooling by compressed air or water is permitted.
5 QUALITY ASSURANCE PROVISIONS

5.1 QUALITY MANAGEMENT SYSTEM
AAC QAP 100 shall apply.
5.2 QUALITY PLAN

The Contractor shall submit a quality plan at time of tender for review by the Engineer.
A sample quality plan is given in Appendix D.
5.3 RECORDS
The following records, shall be kept by the Contractor for a minimum period of 12 months
from conclusion of the contract:

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• Mine Company.
• Conveyor No.
• Job No.
• Splice No.
• Batch numbers and date of manufacture of splicing materials.
• Curing pressure and temperature measured at 15 minute intervals.
• Finished splice dimensions (i.e. length and thickness) measured at both edges and
centre.
• Splicing date.
• Splicers name.
• Hardness of splice.
5.4 MATERIAL CERTIFICATION

Materials for categories M, N and F as defined in SANS 1366 shall be certified as complying
with the requirements of SANS 1366.
5.5 QUALITY CONTROL

5.5.1 General: the Contractor shall provide all the facilities necessary to ensure a satisfactory
splice. All workmen shall at all times be under the supervision of an experienced supervisor.
The supervisor shall demonstrate to the Engineer that he has adequate skills to complete a
successful splice of the applicable type and that he has completed such splice within the
previous 12 months.
5.5.2 Access: the Engineer's representative shall have access at all reasonable times to inspect
the splicing and curing compliance with this specification. An inspection checklist for use by
the Engineers representative is given in Appendix F.
5.6 GUARANTEE OF SERVICES

The Contractor shall guarantee his workmanship and materials for the remaining life of the
belt as per the requirement of the relevant AAC Purchasing contract.

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6 TEST AND INSPECTION

6.1 DIMENSIONS
After dismantling the platens, the joints shall be checked for dimensions and straightness (the
maximum edge length deviation is 1.5mm) and also for any excess rubber, which should be
removed where necessary.
6.2 SOUNDNESS
The splice shall be visually examined for blistering and physically examined for soundness.
Any such area shall be opened and re-jointed by re-vulcanizing.
6.3 HARDNESS
Using the method specified in DIN 53505, determine the hardness of the splice as follows:
• Select 9 locations on the top and bottom covers (i.e. 3 across the leading edge, 3
across the centre and 3 across the trailing edge) and record the hardness obtained.
• The average Shore A hardness obtained shall be within 5° of the nominal hardness as
specified by the materials manufacturer (see Clause 4.1.4).
• Any individual reading of more than 5° shore A below the nominal hardness specified
by the materials manufacturer shall be cause for investigation and possible rejection.
6.4 VISUAL
By means of a chalk line create a grid across the entire surface of the splice as follows:
• Lines at right angles to the belt travel at 100mm centres.
• Lines in the direction of the belt travel at 100mm centres.
After running the belt (See clause 6.5) check for gross distortion of the grid pattern.
6.5 COMMISSIONING
Prior to the Contractor leaving the site the belt shall be run by the client in the presence of the
Contractor and re-inspected for compliance with Clauses 6.1 and 6.2 of this Specification.
7 MARKING
Each splice shall be marked as follows:
• Markings shall be a minimum of 0.5mm deep and within 150mm of the belt edge.
• Contractor's name or logo.
• A unique splice number.

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• Month and year completed.

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APPENDIX A: RELATED DOCUMENTS
The latest issues of the following documents shall be deemed to form part of this specification:
DIN 53505 : Testing of elastomers: Shore A & D hardness testing
SANS ISO 9002 : Quality management systems
CDE PP 801 : AAC Coal Division Safety Procedures
SANS 1366 : Steel cord reinforced conveyor belting
QAP 100 : Quality requirements for critical and major products
APPENDIX B: RECORD OF AMENDMENTS
Issue 2 : Para 3.0 QAP Definition added Para 4.1 revised for optional 3rd party or mine personnel
Para 4.5.9 revised to include rectification and protection of corroded or poorly bonded
cords
Solvent cleaning of cords moved from para 4.5.11 (deleted to 4.6.9)
QAP 100 added to Quality Assurance Provisions
Para 5.6 revised to include Guarantee requirements of the Conveyor Belt Contracts
Rubber to Steel Primer added to Appendix E List of Materials Corrosion Protection added
to Appendix F Section F3
G. Dryden/A. Miles (September24, 2000)
A.Miles/P.Nel (July 29, 2005)
Editorial version: 27 January 2004
Issue 3 : Procedure for checking splicing equipment (4.2) revised.
Procedure for belt alignment (4.4.2) revised.
Procedure for cover removal revised (4.5.5, 4.5.9)

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Table 2 revised.
Procedure for splice assembly revised (4.6.4 – 4.6.17) and 4.6.18 deleted.
Procedure for curing, (4.7) completely revised.
QAP procedure revised (5.4 and 5.6)
Appendix C, E and F revised.
P. Nel/A. Miles (November14, 2005)

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APPENDIX C: TOOLS
The following tools are recommended for belt splicing:

• Vulcanising press (Wagner or approved equivalent)
• Pressure roller
• Wire cutter or cable shear
• Wire brush (rotary)
• Polisher
• Rubber mallet
• Standard mallet
• Soft hand brush
• Hand vice/eccentric clamp/frog clamp
• Ratchet rope puller and pulling cables
• Cutting pliers
• Chalk
• Chalk string
• Awl
• Pricker roller
• Scribing knife
• Saddler's knife
• Saddler's pliers
• Cutting knife (straight blade, Don Carlos or equivalent)
• Paring knife (offset blade)
• Scissors
• Screw clamps
• Whetstone
• Steel rule
• 5m Tape measure
• Rubber hardness meter

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• Hand drill
• Buffing attachments
• Edge irons
• Set square
• Belt support frames (6 off)
• Cord plough

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APPENDIX D: QUALITY PLAN
MINE COMPANY JOB NO
SPLICER NAME COMPANY
CONVEYOR NO SPLICE NO
SPLICE LENGTH SPLICE TYPE DATE
QP AAC ACTION
NO ACTIVITY SPECIFICATION MINE THIRD
SPLICER
CLAUSE NO. 377/3 COMPANY PARTY
1. Establish age, type and class
4.1.1 A W
of belt
2. Establish work station 4.1.2 A W
3. Check splice proximity 4.1.3 V W
4. Check materials 4.1.4 V
4A. Record batch numbers and
date of manufacture 5.3.5 A V
5. Check splicing equipment 4.2 V
6. Set up press and tables 4.3 W
A
6A. Inspect set up Appendix F1
7. Align belt 4.4 W
A
7A. Inspect alignment Appendix F2
8. Remove covers 4.5 A
8A. Inspect cords Appendix F3 W W
8B. Corrosion Protection of Cords 4.5.9
9. Trial assemble splice
A
9A. Inspect trial assembly Appendix F4 W
10. Final assemble splice 4.6.9 - 4.6.18
A
10A. Inspect final assembly Appendix F4 W
11. Pre-cure inspection Appendix F5 W
12. Cure splice 4.7 A
12A Record cure parameters 5.3.6 - 5.3.10 A V
13. Inspect splice 6.0 and Appendix A
13A Record dimensions F6 V
5.3.7

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14. Commission splice 6.4 H A W
ACTION LEGEND: A-ACTION V-VERIFICATION H-HOLD W-WITNESS

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APPENDIX D: QUALITY PLAN (CONTINUED)
CURE STARTED: CURE COMPLETE:
CURING PARAMETERS
TIME PRESSURE TEMPERATURE
COMPLETE CURE RESULTS

SPLICE
THICK.
LOCATION LENGTH HARDNESS (SHORE A – NITRILE COVERS)
mm
mm
TOP BOTTOM
LOCATION
COVER COVER
Leading edge Left hand
Centre Centre
Trailing edge Right hand
Average hardness
Nominal hardness

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APPENDIX E: MATERIALS
Materials used for a steel cord splice shall be supplied by a proprietary manufacturer of conveyor belt
splicing materials or other approved source.
LIST OF MATERIALS
Cover stock (including bonding layer)
Bonding compound strips between each steel cord
Splicing cement
Release agent for use between heating platens and cover compound
Cleaning solvent
Rubber to Steel Primer (ECORRLOK VS20) or approved equivalent

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APPENDIX F: INSPECTION CHECKLIST

F1 SET UP YES NO
Work station suitable for splicing
Platen edges parallel to direction of run of belt
Wooden boards approximately 250 mm wider than belt
Top surfaces of boards are same level as top surface of bottom press
platen
Tables are stable with a minimum length of 3 m
F2 ALIGNMENT YES NO
Belting is lined up in either direction for a minimum distance of 3 m
Belt is central on the conveyor supporting rollers
Ends overlap on the bottom platen
Overlap is sufficient
Centre line is established for a minimum of 6m
Chalk reference lines are drawn across the ends of each belt
Belt if firmly clamped to the platform (outside the splice area)
Belt has been checked for age
Splice length according to Table 2
F3 CORDS YES NO
Sufficient rubber has been separated from the cords
Cover strips removed producing a non smooth surface
Thin layer of rubber covering the steel cord

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Rubber between cords removed leaving a thin film of rubber over the
cord
Cords checked for damage and corrosion
Cords suitably protected against Corrosion
Cords tied together in bundles
Cords brushed and cleaned with solvent
F4 SPLICE ASSEMBLY YES NO
Edges of diagonal cut in the vulcanized rubber chamfered
Roughed with a polisher and buff attachments
No degradation
Chamfer cleaned with solvent and dry
Bonding compound cleaned with solvent and dry
Shirting fabric placed over the bottom platen and smoothed
Pre-heat on bottom press platen is 50°C
Un-vulcanized bottom cover cut to size and shape. Bonding layer

uppermost
Bonding layer and steel cords coated
Belts aligned to within 1mm
Trial assembly satisfactory
Cords are parallel
All cords included in the joint
No individual cords are cut out
All spaces filled with bonding compound

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Strips pricked to expel trapped air
Cords are dry
Edge of the splice cover stock level with top of cords
Top cover laid onto cord carcass with bonding layer downwards
Entrapped air removed before sealing
Edges of un-valcanised splice trimmed to width
Release agent overlaps ends of the splice
Release agent 100mm wide over each join
F5 CURING YES NO
The temperature of the platen is >50°C
Length of splice is correct
Alignment is correct
Upper platen is positioned to mach lower platen
Transverses correctly positioned
Curing temperature reaches manufacturer’s specified temperature
Pre-tensioning bolts are uniformly tightened
Pressure reaches 1.2MPa
F6 TESTING YES NO
Dimensions within tolerance
Edges straight
No excess rubber

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No blistering
No lack of adhesion
Shore hardness within tolerance
Commissioning satisfactory
No distortion of the grid

Aac Spec 377003

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AAC SPECIFICATION 377003

SPLICING OF STEEL CORD REINFORCED ISSUE 3

For information or comments on this document please contact ATD QA

SPLICING OF STEEL CORD REINFORCED ISSUE 3

APPENDIX F: INSPECTION CHECKLIST 19

AAC_SPEC_37700303.DOC APPROVED 14 MARCH 2006 Page 2 of 25

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

APPROVED : Approved in writing by the Engineer

SANS : South African National Standards

QAP : AAC Quality Assurance Procedure

The following terms are defined in the General Conditions of Contract:

AAC_SPEC_37700303.DOC APPROVED 14 MARCH 2006 Page 3 of 25

For information or comments on this document please contact ATD QA

SPLICING OF STEEL CORD REINFORCED ISSUE 3

Non-Fire Resistant : 3 months

Fire Resistant : 1 month

4.1.6 Splicing site reticulation: A sufficient water supply shall be provided.

4.2 PROCEDURE FOR CHECKING SPLICING EQUIPMENT

AAC_SPEC_37700303.DOC APPROVED 14 MARCH 2006 Page 4 of 25

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

 Recommended interval for calibration and testing:

4.3 PROCEDURE FOR SETTING UP VULCANISING PRESS AND TABLES

4.3.2 Assemble the bottom traverses so that:

AAC_SPEC_37700303.DOC APPROVED 14 MARCH 2006 Page 5 of 25

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

4.4 PROCEDURE FOR ALIGNMENT

4.4.3 Determine splice length and type according to Table 2.

L2 = Length of each step for 2 and 3 stage splices

AAC_SPEC_37700303.DOC APPROVED 14 MARCH 2006 Page 6 of 25

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

4.5 PROCEDURE FOR COVER REMOVAL

4.5.5 Fix a clamp to the belt and a ratchet rope puller.

4.5.6 Repeat 4.5.2 to 4.5.5 for the top cover.

4.5.7 Any moisture evident shall be removed by an approved means.

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

In the event of corrosion or poor bonding:

4.5.10 Tie the cords together in bundles of approximately 10 to prevent tangling.

4.6 PROCEDURE FOR SPLICE ASSEMBLY

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

4.6.11 Prick the strips to expel trapped air.

4.6.16 Trim the edges of the un-vulcanized cover.

4.7 PROCEDURE FOR CURING

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

Under no circumstances shall temperature exceed the compound manufacturers

Forced cooling by compressed air or water is permitted.

5 QUALITY ASSURANCE PROVISIONS

5.2 QUALITY PLAN

A sample quality plan is given in Appendix D.

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SPLICING OF STEEL CORD REINFORCED ISSUE 3

5.4 MATERIAL CERTIFICATION

5.5 QUALITY CONTROL

5.6 GUARANTEE OF SERVICES

AAC_SPEC_37700303.DOC APPROVED 14 MARCH 2006 Page 11 of 25

Recommended interval for calibration and testing: