Working instructions for splicing
fabric belts using a cold process
Pg1
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
Contents
3-4 Material requirements and legend
5-6 Safety instructions
7 1. Preparations
8 2. Preparing the ends of the belt
2.1 Splicing guidelines
8 2.2 Splice lengths in accordance with DIN
8 2.3 Belt slice for conveyor belts
9 2.4 Running direction
9 2.5 Plotting the belt splice
9 2.6 Conveyor belts with three plies
10 2.7 Activating the adhesive
3. Processing the ends of the belt
10-12 3.1 Work steps for producing the splice
Pg2
Material requirement
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
Cobbler’s knife Pulling hook Stop bracket
Chalked string
with powder Pliers Double roller
Whetstone with
Wire grip Angled blade wooden handle
Rotary sander for
working rubber Wheel wire brushes Piercing roller
Knurled roller
Flat roller Screw clamp
Hand brush Rubber scissors Layer-separating
knife
TOPGUM TD / TDG
Folding rule Rubber hammer
Filling layer with
adhesive covering on
one side
Sanding machine, flexible
shaft
Pg3
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
Material requirement and legend
TOPGUM TL-T50, TOPGUM TL-T60,
TOPGUM TL-T70, 1000 g
700 g can 700 g can can Two-component cold
COLD Two-component COLD Two-component COLD adhesive,
cold adhesive, cold adhesive, dichloromethane-based
benzine-based benzine-based
Type B, 0.5 L
B H Brush
Cleaning agent, Universal hardener,
benzine-based 40 g bottle
Safety goggles Protective gloves
Legend
Add hardener -
00:00:00 Processing time Stir activate
cold adhesive
Coat thinly
Ready for processing
and evenly Test on back of hand
Remove
protective film
Pg4
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
Topgun TL-T50/60
Safety instructions:
Keep away from heating, spark, open flames, hot sur faces. Do not smoke! Wear
safety gloves/safety clothes/safety glasses and face mask. Avoid effluent on
environment. Avoid electrostatic charging.
IF SWALLOWED: Contact poison center or a doctor. If contact with skin or hair:
Remove all wet clothes and wash/shower skin/hair.
Rinse with water for a few minutes. Remove lenses and rinse again.
Danger instructions:
Liquid and vapors inflammable. Skin irritation possible. Provoke strong
irritation of eyes. Can bring sleepiness and numbness. Can bring death if
swallowed. Toxic for water organism by longtime effect.
Topgun TL – T70
Safety instructions:
If medical advice is needed, have product container or label at hand. Keep
out of reach of children. Avoid breathing dust/fume/gas/mist/vapors/spray.
Wear protective gloves/protective clothing/eye protection/ face protection.
Avoid release to the environment.
IF ON SKIN: Wash with plenty of soap and water. IF IN EYES: Rinse
cautiously with water for several minutes. Remove contact lenses, if present
and easy to do. Continue rinsing. IF exposed or concerned: Get medical
advice/attention. Collect spillage. Store locked up.
Danger instructions:
Harmful if swallowed, in contact with skin, if inhaled. Skin irritation possible.
May cause an allergic skin reaction. Provoke strong irritation of eyes. Can
bring sleepiness and numbness. Suspected of causing genetic defects. May
cause cancer. May cause damage to organs (or state all organs affected, if
known) through prolonged or repeated exposure. Harmful to aquatic life with
long lasting effects.
Pg5
Universal Hardener
CSG Splicing (Pty) Ltd SafetyEmail:
instructions:
info@csgsplicing.com Cellphone: 083 383 8533
If medical advice is needed, have product container or label at hand. Keep out of reach of
children.
Protect from moisture. Do no eat, drink or smoke when using this product. Avoid release
Pg6
1. Preparations
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
1.1. Belt Transport
For transportation, conveyor belts are usually wound onto wooden cores or, for greater loads, steel cores. (Steel
cores are only used in the case of excessive stress and multiple-use, however.) To protect the belt edges and cover
plates from excessive sun exposure, you can wrap up the entire belt coil in a film that will also simultaneously
protect the belt from transport damage. The belts are often dis- patched on drums with no flanged pulleys. This
applies specifically to dispatches overseas, as special protection and added security are often desired for the belt
edges of transport coils. The belt is then secured against slipping out of place too.
1.2. Loading and unloading
Avoid damaging the belt edges and cover plates when loading and unloading using forklifts, cranes, fixings, etc.
Remember before unloading that the belt must be rolled counter to the winding directions. This saves you from
having to reposition the belt. If the belt is especially heavy, set distancing beams between the cords and place old
belt material or something similar underneath the coil if the surface is sharp-edged.
1.3. Storage
To prevent premature ageing, the formation of cracks, hardening and swelling, protect the belt from the following
during storage:
1. Heat and sun exposure.
2. Mechanical damage
3. Contact with chemicals, grease and oils.
4. Moisture (especially if storing outdoors)
1.4. Jacking up the belt coil
Fit the belt reels and winding shafts to the belt weights and coil diameters. Use cable drum winches with
appropriate load-
bearing capacity when jacking up. If your belt is heavier, and if it is delivered at a spiral angle, please contact
the belt manufacturer regarding the details for jacking up.
1.5. Feeding the belt
Prepare the start of the belt according to the size. Lift a narrow / short belt using a cable hand winch and in the
case of heavy belts, fasten a draw bar at the start of the belt so that it can be connected to a pulling cable. Heavy
belts require a motor-driven cable winch or cables in conjunction with a tractor unit such as a lorry or tracked
vehicle. Tie up the corners at the start of the belt in the form of a trough before the feed-in or cut them back
diagonally.
Pg7
Safety instructions for descending or ascending areas of the facilities: Install a retaining device. If the brakes
should fail or the cord should rupture during the feed-in process, significant damage and safety risks could occur.
2. Preparing the ends of the belt
2.1. Splicing guidelines
When preparing for vulcanisation, pay attention to the corresponding splicing guidelines that apply to the type
of belt you are working with.
2.2. Splice lengths.
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
Type of belt as per DIN No. of steps Minimum step Minimum step Breaking force of a
length ℓst length ℓl ply N / mm
315/3 150 300 80 - 100
400/3 2
200 400 125 - 160
500/3
630/4 200 600 125 -160
3
800/4 250 750 200 -250
1000/5
250 1000 200 - 250
1250/5
1600/5
4 300 1200 315 - 400
2000/5
2500/5
350 1400 500 - 630
3150/5
2.3. Belt splice for conveyor belts.
(with two or more plies and bonding layers)
ℓb = bevel
ℓl = Splice length
ℓst = min. step length
B = belt with
If b = 16˚42’ ℓb ≈ 0.3. B
If b = 22˚ ℓb ≈ 0.42. B
Pg8
2.4. Running direction
Please observe the running direction of the conveyor belt.
2.5. Plotting the belt splice
1. First lift the ends of the belt to prepare work surfaces. Align them and
fix them.
2. Next, draw a horizontal crossline at one end of the belt.
3. Push the two ends of the belt together to inspect them. This will allow
1. Plot the centreline
you to determine whether the centrelines drawn on both ends of the belt
are identical and whether they form one long line without interruption.
4. Now draw the individual splice sections and a right-angled crossline
(see Figure). The crossline serves as a reference line for plotting the
bevelled splice.
2. Plot the crosslines
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
Pg9
2.7. Activating the adhesive
Stir the adhesive for 2 minutes.
Thoroughly mix the hardener with the adhesive for 2 minutes.
COL
COL
D
D
3. Processing the ends of the belt
3.1. Steps in producing the splice.
The following work steps must be performed mirror-inverted for each end of the belt.
1. Score the rubber edge using a cobbler’s knife and remove the seam strips using pliers.
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
Pg10
2. Next, score the layer using a layer separating knife and peel up the steps using a wire grip or pulling hook.
Always take care to ensure that the fabric is not harmed or damaged!
3. Cut the rubber edges off of the step height according using an angled blade. Carefully remove loose rubber material and then
clean it up using a hand brush. Thoroughly brush off dust. Carefully roughen the rubber edge, the splice bevel and
approximately 30 – 50cm above the splice with a wheel wire brush.
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
4. Coat both ends of the belt thinly and evenly with the activated cold vulcanizing cement, depending on the respective quality
of the rubber, and allow the coating to dry completely. Repeat the procedure at each end of the belt two more times.
Pg11
5. Align and bring together both ends of the conveyor belt considering the
reference line (centre line) and use the hand roller to roll from the centre
towards the outside edges in order to expel air cushions.
6. Roll over the entire splice area using the double roller from the centre
towards the outside to avoid air cushions.
7. Prepare the filling layer strips TD / TDG for the bridges in the rubber
cover plate on both the top and bottom sides. Remove the protective film if
30 minutes
necessary and coat the holding surface with adhesive to dry and then test it
with the back of the hand. The surface must be tacky.
TD /
TDG
COLD
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com
8. Fill the two bridges with the TOPGUM Cellphone:
TD / TDG strips, roll8533
083 383 over
everything carefully using a hand roller and cut the edges extending past the
sides using cobbler’s knife.
CSG Splicing (Pty) Ltd Email: info@csgsplicing.com Cellphone: 083 383 8533
