GENERAL STAGES FOR BELT SPLICING.

1.0 Identification of damaged area.

 Rema tip top artisans do the daily inspections in the plant and mark areas where
they see will need to be attended or a section of the conveyor that needs replace-
ment.
 A report is made and presented to the mechanical foreman during the maintenance
planning meeting.
 The foreman will make decision based on the severity of the damaged portion, start-
ing with the most critical one.
 In case of breakdowns the plant operators may just report to Rema tip top and these
can be done directly without waiting for the mechanical foreman’s approval.

2.0 Healthy and safety.

 All electrical and mechanical equipment and tools are to be inspected and
tagged/colour coded prior to use.
 Pre-task risk assessment should be carried out and make sure the belt is isolated be-
fore starting any work on the conveyor.
 A permit to work should be issued prior to work.

3.0 Belt installation.

 Rigging and installation is done by the mine.

 Rema tip top artisans identify the carrying side of the conveyor (which is the top side
of the conveyor) fasten the new conveyor to the old conveyor.
 The belt is run on maintenance mode on short intervals continually checking the
stands holding the new roll of belt if they still secure.
 The beltsman in conjunction with the electrical and mechanical foremen will identify
a splicing workstation where sufficient supply of water and electricity of 220V and
380V is available.

4.0 Setting up vulcanising and platform.

 Release belt tension.
 Belt is clamped and secured using belt clamps and tick toques.
 All idlers and brackets are removed from the working area.
 Timber boards are used to ensure that the top surface of the conveyor is level to the
surface of the platen.

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 GENERAL STAGES FOR BELT SPLICING.

5.0 Belt stripping and bonding.

 Belt is marked with a 900 line across using a builder’s square.
 A bias line is marked calculated based on the belt with.
 All markings are joined using a chalk line.
 Strip the cover rubbers and make all the necessary steps in case of a fabric conveyor.
 Buff the stripped areas with a variable speed angle polish with speed not exceeding
3000rpm.
 Clean the buffing dust with a banister brush.
 Apply first coat of adhesive and leave to dry for 30min.
 Apply second coat and wait for 15min or just tack at the back of the palm then bond
the joint.

6.0 Pressuring and curing.

 Put up the top platens and beams then tighten the bolts.
 Pressurise using an electric water pump, up to 10bars.
 Check if the pressure bags are not leaking before energising.
 Set the curing time by calculating the thickness of belt by 3 (3minutes per mm).
 Temperatures will automatically heat up to 1500C before starting the curing count
down time.
 Keep on monitoring the pressure and thermo gauges till the end.

7.0 Cooling and dismantling.

 When the curing time is done cool down to 600C.
 Dismantle the vulcanising press and take it back to workshop.
 Take back the removed idlers.

8.0 Commissioning.
 Belt is re-tensioned and run to see if the splice is ok for complete two revolutions.

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