Belt Splicing

;

SPLICING AND REPAIR MATERIALS

Conveyor Belt Splices are the weakest point in a belt. Hot Splicing of Conveyor Belts provide jointing solutions that  last the  life  of  the conveyor  belt.

The strength of a splice depends on various factors including, the quality of the rubber materials used, the vulcanizing press and the quality of workmanship.

Rexline Engineering manufactures splicing kits for Fabric and Steel Cord Conveyor Belts suitable for Troughed, Pipe, Cleated and Sidewall Belts.

Our Splicing Kits are manufactured for all specifications of cover grades and tensile strengths.

For Bucket  Elevator Jointing Solutions, please refer our Rexline Bucket Elevator Brochure.

Splicing Kits consist of all the consumables required to carry out a splice including Uncured  Rubber and Vulcanizing Solution. Rexline Splicing kits contain uncured rubber with superior tack. This allows easier assembly resulting in  better splices.

Splicing  Kits  for Fabric Conveyor  Belts

Kits consists of:

  • Cover Rubber – The uncured rubber is available in most  cover grades (OR, FR, CR, HR, SHR & UHR)
  • Skim Rubber – Provides superior bonding between the fabric piles and the cover rubber
  • Hot Vulcanizing Solution
  • Cleaning Solution
  • Silicone Release Paper

Splicing Kits for Steel Cord Conveyor Belts

  • Top & Bottom cover slabs – Slabs include cover rubber and bonder rubber for all cover grades (OR,FR, CR, HR, SHR & UHR).
  • Cover slabs provide better bonding with steel cords.
  • Intercord Strips – These are manufactured to match steel cord spacing and cord diameters.
  • Hot Vulcanizing Solution
  • Cleaning Solution
  • Silicone Release Paper

Storage

Shelf life of Rubber materials in the splicing kit is 6 months when store under 18°C

COLD ADHESIVES

Rexline REXBOND Cold Solution is a two component system used for splicing and repairs of  conveyor belts. It provides quick, strong bonding of Rubber-to-Rubber, Rubber-to Fabric and Rubber-to-Metal.Applications include conveyor belt splices and pulley lagging. It is also used for application of wear and corrosion resistance materials like liners for  chutes, bunkers, tanks, pipes, etc.Rexline REXBOND provides excellent initial and final bonding strengths with an ideal curing time of 6 hours. Bonding strength is increasedwhen used with products having Rexline Bonding Layers.

Rexline Primer and Cleaning Solutions are  also recommended for improved bonding.

Application

Rexline REXBOND is a fast curing, chloroprene based adhesive supplied along with hardener. The hardener is thoroughly mixed with the solution immediately before applying the material.

Bonding Procedure

A minimum of  2  coats  need to  be applied using a clean brush. The first  coat should be allowed to dry completely (at least 1 hour) before applying the second coat.  During application, make sure that there is  no buildup of  material. After  application of the second coat, the surface should be allowed to dry to  a tack. This can be tested  by  using the back of  your hand. The surface should be dry but still have a tacky feeling. If there is  no tack after  a second coat,  an additional coat  may be applied.Surfaces must be tacky when bonded together. After joining the two  surfaces, for conveyor belts, a Rexline Double Acting Roller may be used to apply pressure across the entire surface until the solutions dries.

Preparation of  Surface for Rubber to Rubber Bonding

Both surfaces should first  be cleaned using Rexline Cleaning Solution. For rubber that does not have Rexline Bonding Layers, once dry, the surface should be buffed to a rough finish using a buffing  machine with  a  maximum speed of 2000 rpm and grain size of 36 max. The surface should be removed of any rubber dust and cleaned using Rexline Cleaning Solution. Once cleaned the bonding procedure detailed in our splicing manual may be followed.

Storage

Shelf life of Rexline REXBOND is 1 year when stored under 18° C

Coverage

Area  covered  is approximately 1  square meter per 1  Liter of  solution per coat.

VULCANIZING PRESSES

NIPL Engineering Product (formerly known as Nilos India)
  • Rexline Engineering Vulcanizing Presses offer quality equipment designed for trouble-free operation in the harshest conditions. Our presses are easy to set-up and operate.Our presses are built to provide uniform heating and pressure across the entire splice area, with heating up to 180C and specific pressure up to 14kg/cm2. It’s quick heating and Integrated Cooling Platens enable short splicing cycles cutting downtime.Presses are designed to be used stand-alone or in combination with other Rexline presses. All vulcanizing presses are designed to customer’s requirements for belt widths, splice lengths, combinations, voltages, configurations, etc.

PRESSURE BAG PRESS

NIPL Engineering Product (formerly known as Nilos India)

Control Panel

  • Digital display shows exact temperature reading in each heating plate via PT 100 thermo sensor
  • Automatic temperature and pressure cut-offs allow users to set and forget.
  • Optional Splice Recording stores the temperature, pressure vs time graph.
  • Optional LCD touch screen display or portable device interface.
  • Electronic controller for quick and simple programming of temperature
  • Digital display for set and actual temperatures
  • Manual backup in case of electronic controller failure.
  • Can be provided in three-phase or single phase current

Cross Beams

  • Lightweight Aluminum Alloy provides maximum tensile and bending strength with minimum weight
  • End bolts are designed within the cross beam profile providing higher safety.

HEATING PLATENS

NIPL Engineering Product (formerly known as Nilos India)
  • Quick and Even heating with Heating Mats
  • Regulation via thermo-sensor PT 100
  • Heating plates made of corrosion-resistant aluminium alloy
  • Designed for Rhombic splices(16° 42’; 22°) or rectangular splices(90°)
  • Cooling Channels within the platens provide Quick cooling reducing your splicing time by several hours.
  • Air and/or water cooling available
  • Optimum pressure and temperature distribution
  • Robust, flush fitting electrical connections guarantee safe operation
  • Platens are designed to be used in combination or stand alone. This makes the presses easier to maneuver.

Pressure Bag

  • Rexline Pressure Bags provide uniform pressure distribution
  • Durable and Long lasting with special Aramid Inserts
  • Both Air and Water Bags available
  • Pressure up to 200 psi

SPOT REPAIR PRESS

NIPL Engineering Product (formerly known as Nilos India)

Spot Repair Presses offer a portable solution for belt repairs. Its light weight construction and compact design allow you to repair areas from 300 mm² and higher. Pressure is built up with a motor-driven pump unit or manually with a reciprocating piston hand pump

C-Clamps

Aluminum alloy with torsion-stiff, solid welded construction

Heating Plates

Heating plates with automatic temperature regulation, signal lamp and thermometer

  • Available with either air or water cooling
  • Uniform pressure distribution
  • Easy to transport-can be carried by one person.

FRAME PRESS

NIPL Engineering Product (formerly known as Nilos India)

Rexline Frame Presses are designed for quick and easy operation. Its two piece frame construction is made of lightweight aluminum and is easily transported and setup. Can be used in combination with multiple Rexline Frame Presses to cure larger splice lengths.

Heating Platens

  • Made of lightweight aluminum with integrated air or water

cooling channels

  • Provides uniform heating using Rexline Heating Mats
  • Perfect for splices of up to 21 inches (550mm) and Belt

Widths up to 60 in (1600mm)

Pressure Bag

  • Uniform pressure distribution using Rexline Pressure Bags
    Surface Pressure of up to 100 psi

RIP & EDGE REPAIR PRESS

NIPL Engineering Product (formerly known as Nilos India)

Rexline Rip and Edge Repair Presses lengthen the life of you conveyor belt allowing you to quickly repair longitudinal rips or damaged edges. Pressure is built up with a motor driven pump unit or manually with a reciprocating piston hand pump.

C-Clamps

  • Aluminum alloy construction provides maximum bending resistance with minimum weight
  • Configurations suitable for edge repair up to center longitudinal repairs. Available for belts up to 95 inches (2400mm). Built in protection against hose breakage with the cross beam pressure being maintained in the event of a hose breakage and sudden  pressure drop
  • Uniform Pressure Distribution using Rexline Pressure Bags
  • Air and Water Bags available.

Heating Plates

  • Corrosion-resistant aluminum alloy.
  • Suitable for longitudinal repairs with a minimum width of 200 mm and for any required  length
  • Specially developed heating systems and profile reinforcements guarantee optimum  pressure and temperature distribution
  • Robust, flush fitting electrical connections
  • Thermo-sensor PT 100 in every heating plate
  • Available with either air or water cooling

HYDRAULIC PRESS

NIPL Engineering Product (formerly known as Nilos India)

Heating Platens

  • Regulation via thermo-sensor PT 100
  • Heating plates made of corrosion- resistant aluminum alloy
  • Designed for Rhombic splices(16° 42’;  22°) or rectangular splices(90°)
  • Heating plates combined with hydraulic pressure systems allow splicing even on  partially worn belts
  • Optimum pressure and temperature distribution Air and/or water cooling available Robust, flush fitting electrical connections guarantee safe operation
  • Platens are designed to be used in combination or stand alone. This makes  the presses easier to maneuver.

Pressure is built up with a motor-driven pump unit or manually with a reciprocating piston hand pump.

Control Panel

  • Digital display shows exact temperature reading in each heating  plate via PT 100 thermo-sensor
  • Electronic controller for quick and simple programming of temperature
  • Digital display for set and actual temperatures
  • Manual backup in case of electronic  controller failure.
  • Optional Timer function.
  • Can be provided in three-phase  current or AC

Hydraulic Cross Beams

  • Lightweight Aluminum Alloy with hydraulic pressure system provides maximum tensile and bending strength with minimum weight
  • End bolts are designed within the cross beam profile providing higher safety.
  • Built-in protection against hose breakage. The cross beam pressure is maintained in case a hose breaks or there is a sudden drop in pressure
  • Compact, light metal cylinders provide high-pressure for even surface pressure.
  • Recommended pressure for fabric belts is 100 psi (8 kg/cm2) and 170 psi (12 kg/cm2) for steel cord belts.
  • Quick and simple pressure build-up using a reciprocating piston hand pump or a motor-driven pump unit

Reciprocating Piston Hand Pump

  • Pressure is built up with a motor-driven pump unit or manually with a reciprocating piston hand pump.
  • Pressure is limited to 450 bar (6.5K psi); 700 bar (10Kpsi) available Usable Oil Volume of 10 litres (2.6gallons)
  • Pressure gauge for pressure control

Motor Driven Pump

  • Pressure limited to 450 bar (6,500 psi)
  • Supplied complete with tubular protective frame,  pressure gauge, hose coupling and valves
  • 400 V, 50 Hz (other voltages on request)
  • Rating 1.1 kW