1、 Collection of SANS standards in electronic format (PDF) 1. Copyright This standard is available to staff members of companies that have subscribed to the complete collection of SANS standards in accordance with a formal copyright agreement. This document may reside on a CENTRAL FILE SERVER or INTRA
2、NET SYSTEM only. Unless specific permission has been granted, this document MAY NOT be sent or given to staff members from other companies or organizations. Doing so would constitute a VIOLATION of SABS copyright rules. 2. Indemnity The South African Bureau of Standards accepts no liability for any
3、damage whatsoever than may result from the use of this material or the information contain therein, irrespective of the cause and quantum thereof. ISBN 978-0-626-23132-3 SANS 485:2009Edition 1SOUTH AFRICAN NATIONAL STANDARD Conveyor belting Splicing of steel cord reinforced conveyor belting Publishe
4、d by SABS Standards Division 1 Dr Lategan Road Groenkloof Private Bag X191 Pretoria 0001Tel: +27 12 428 7911 Fax: +27 12 344 1568 www.sabs.co.za SABS SANS 485:2009 Edition 1 Table of changes Change No. Date Scope Foreword This South African standard was approved by National Committee SABS SC 45A, Ru
5、bber and rubber products Conveyor belts, in accordance with procedures of the SABS Standards Division, in compliance with annex 3 of the WTO/TBT agreement. This document was published in August 2009. Annexes A, B, C, D, E, F and G form an integral part of this standard. SANS 485:2009 Edition 1 1 Con
6、tents Page Foreword 1 Scope 3 2 Normative references . 3 3 Definitions . 3 4 Requirements. 5 4.1 General . 5 4.2 Spicing layout 5 4.3 Number of stages per class of belt . 9 4.4 Workmanship 9 4.5 Splicing materials 9 4.6 Press apparatus 10 4.7 Environmental conditions 11 5 Method of constructing a sp
7、lice of steel cord and reinforced conveyor belting. 11 5.1 General . 11 5.2 Layout . 11 5.3 Practices not permitted . 11 5.4 Situations where splicing is not permitted . 12 6 Safety, health and environmental issues 12 6.1 Safety 12 6.2 Health 12 6.3 Environment 13 7 Rejection criteria . 13 8 Methods
8、 of test . 13 8.1 Conditions of test 13 8.2 Compliance documentation . 13 8.3 Full load cycle test 14 8.4 Raw materials . 14 8.5 Fire retardant belting . 14 8.6 Cord pull out test . 14 8.7 Hardness testing . 15 8.8 Testing for floppy edges 16 9 Marking . 16 9.1 Marking of the belt 16 9.2 Template fo
9、r marking 16 9.3 Prohibited practice 17 10 Reports . 17 10.1 Job card pack 17 10.2 Job card pack components . 17 SANS 485:2009 Edition 1 2 Contents (concluded) Page Annex A (normative) Quality verification for the splicing of steel cord reinforced conveyor belting . 18 Annex B (normative) Vulcanisin
10、g press platen bias 18 Annex C (normative) Minimum splicing tools . 20 Annex D (normative) Quality control of raw materials . 21 Annex E (normative) Sample quality plan . 22 Annex F (normative) Raw materials 25 Annex G (normative) Sample quality assurance agreement . 26 Bibliography 28 SANS 485:2009
11、 Edition 1 3 Conveyor belting Splicing of steel cord reinforced conveyor belting 1 Scope This standard specifies the requirements for the splicing of steel cord reinforced conveyor belting. This standard covers the splicing of belts of similar cord configuration as well as belts of different cord co
12、nfiguration. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. Information o
13、n currently valid national and international standards can be obtained from the SABS Standards Division. SANS 1366, Steel cord reinforced conveyor belting. 3 Definitions For the purposes of this document the following definitions apply. 3.1 acceptable acceptable to the authority administering this s
14、tandard, or to the parties concluding the purchase contract, as relevant 3.2 bias oblique angle to the centre line of the belt, which matches the bias of the vulcanising press platen (see annex B) 3.3 bonder rubber unvulcanised rubber compound that fills the gaps and voids between cords 3.4 butt gap
15、 distance between two aligned cord ends (see figure 2) 3.5 carcass combination of cords and bonder rubber SANS 485:2009 Edition 1 4 3.6 cord steel tension carry member 3.7 cord diameter nominal diameter as specified in the parent belt (as specified in SANS 1366) 3.8 cord pitch nominal distance betwe
16、en cord centres 3.9 cord pull out test sample sample required for determining the cord pull out force and is commonly known as an H-block sample 3.10 cord spacing internal distance between two adjacent cords in the overlapping zone of the splice 3.11 cover rubber compound that has specific propertie
17、s and thickness related to the required application 3.12 floppy edge where the length along the edge is greater than the length of the centre of the belt in the splice area (see figure 6) 3.13 owner owner of the conveyor system or his designated representative 3.14 ramp time time taken to attain vul
18、canisation temperature 3.15 release agent material used to prevent adhesion between the newly vulcanised compound and the press platen 3.16 splice where the two ends of a belt are joined together 3.17 stage as shown in figures 1, 2 and 3 3.18 step length shortest distance at which cords overlap 3.19
19、 transition zone zone in which the cords are deflected from the cord pitch in the parent belt to the cord pitch in the splice (see figure 1) SANS 485:2009 Edition 1 5 4 Requirements 4.1 General In order for a splice to comply with this standard, the following requirements and the requirements in 4.2
20、 to 4.7 (inclusive) shall be complied with: a) There shall be one single cure across the full width of the belt. b) Belts shall always be aligned along the centre line. c) Splice shall be cleaned, including removal of release agent and trimming of flash rubber. d) Any evidence of moisture ingress or
21、 cord damage shall be recorded and brought to the immediate attention of the responsible owner or official before any further splice construction. e) The cover hardness of the vulcanised splice shall comply with the compound manufacturers nominal Shore A hardness specification (see figure 5). f) Edg
22、e bars shall be made of aluminium, steel or copper and shall be of a thickness of between 1,0 mm and 1,5 mm less than the parent belt thickness as measured at the edge of the belt. g) Urethane or cellulose sponges, clean and dry brushes and new clean cotton cloths shall be used during cleaning and p
23、reparation of splice surfaces. h) Cable cutters only shall be used; no angle grinders or bolt cutters. Cords shall only be cut using a sharp cable cutter so that the end of the cords shall not be distorted or crushed (see annex C). 4.2 Splicing layout 4.2.1 The splice shall be constructed in accorda
24、nce with a splice layout diagram as agreed to by the belt manufacturer or owner. If opposing belts contain an unequal number of cords then the splicing constructor shall use the layout diagram for this purpose, as supplied by the manufacturer of the new belting. 4.2.2 A splice shall be designed to r
25、eturn the highest possible strength. Thus all the cords from both belt ends shall be used in the splice. 4.2.3 The minimum cord spacing shall be one-third of the cord diameter or 2 mm whichever is greater. This spacing together with the total number of cords will dictate the type of splice pattern.
26、The types of splice pattern are as follows: a) Stage 1: Centre cord(s) butted. Lay cords alternately from each belt end, starting with the trailing end, working from centre outwards (see figure 1). SANS 485:2009 Edition 1 6 Figure 1 Common splice pattern stage 1 b) Stage 2: Centre cord(s) butted. La
27、y cords alternately from each belt end, starting with the trailing end, working from centre outwards. Butt every second cord from each end in the centre of the splice (see figure 2). Figure 2 Common splice pattern stage 2 SANS 485:2009 Edition 1 7 c) Stage 3: Centre cord(s) butted. Lay cords alterna
28、tely from each belt end, starting with the trailing end, working from centre outwards. Butt every second and third from each side at one third of splice length (see figure 3). NOTE 1 A stage 3 splice is used for high strength belts or where the cord spacing precludes lower stage splice layout (or bo
29、th). NOTE 2 Higher stage splices are necessary where cord spacing is insufficient to allow a stage 3 splice. The layout of higher stage splices should be obtained from the belting manufacturer. Figure 3 Common splice pattern stage 3 4.2.4 The splicing of belts with different cord counts, for example
30、, 107 cords matched to 114 cords is given in figure 4. SANS 485:2009 Edition 1 8 Figure 4 Example of a splice pattern SANS 485:2009 Edition 1 9 4.3 Number of stages per class of belt The number of stages per class of belt shall be in accordance with table 1. Table 1 Class of belt and stages 1 2 3 4
31、5 Minimum step length Butt gaps Transition zone Class Number of stages mm, min. mm, min. mm, min. St500 1 550 - 50 St630 1 550 - 50 St800 1 550 - 50 St1000 1 700 - 75 St1250 1 700 - 75 St1400 1 850 - 100 St1600 1 850 - 100 St2000 2 550 25 125 St2500 2 700 25 125 St3150 2 900 25 150 St4000 * * * * St
32、5000 * * * * St6300 * * * * * Obtain information from the belt manufacturer. 4.4 Workmanship The splice, including edges, shall be substantially rectangular in cross-section and free from defects that would impair its long-term serviceability. Differences in belt thickness and worn belts shall be de
33、alt with in a manner to ensure uniform pressure across the splice during vulcanisation. 4.5 Splicing materials 4.5.1 All materials shall be used within the shelf life as specified by the raw materials manufacturer. 4.5.2 Only one batch per material type shall be allowed. 4.5.3 Storage conditions of
34、all materials shall be as defined by the raw materials manufacturer. 4.5.4 Bonder rubber shall be compatible with the rubber of the parent belt. Compatibility shall be determined by an H-block test. 4.5.5 Splicing materials shall be compatible with the parent belt in all aspects. 4.5.6 Top cover rub
35、ber shall be compatible with the existing top cover of the parent belt and shall have the same or better properties than those specified in SANS 1366. SANS 485:2009 Edition 1 10 4.5.7 Bottom cover rubber shall be compatible with the existing bottom cover of the parent belt and shall have the same or
36、 better properties than those specified in SANS 1366. 4.5.8 Bonding solution (solution of the bonder rubber in an acceptable solvent) shall be compatible with the bonder rubber in the parent belt and the bonding solution used in the splice shall be the same as that used in the H-block test. 4.5.9 An
37、 adhesion test shall be performed to determine compatibility of splicing materials with the parent belt. 4.5.10 The splicing construction company shall ensure that raw materials used in the construction of the splice are capable of producing a splice that will not fail. Properties of raw materials s
38、hall be within the material manufacturers specification, and shall show no degree of curing, and shall be free of contamination. Proof of compatibility of all raw materials to the parent belt shall be verified. Proof of product compatibility shall be made available to the owner as part of the qualit
39、y control documentation (see annex A) before commencing the splice construction. 4.5.11 Any corrosion or evidence of poor cord to rubber bonding shall be recorded and brought to the immediate attention of the responsible owner or official before any further splice construction. 4.5.12 Minimum thickn
40、ess of the bonder rubber shall be one-third of the cord diameter or 2 mm, whichever is the greater. 4.5.13 All splicing materials shall be according to specifications and within the recommended shelf life. 4.5.14 Release agents An acceptable release agent is one of the following: a) release cloth; b
41、) silicon paper; c) teflon sheeting; or d) teflon coated glass cloth. The release agent used shall be such that the finished splice has a similar surface finish when compared with the parent belt. 4.6 Press apparatus 4.6.1 Vulcanising press, that is capable of achieving the required temperature rang
42、e and ramp time as specified by the supplier of the raw materials. 4.6.2 Platen, of minimum combined length that shall exceed the splice length by 150 mm on the leading and trailing ends. The width of the platen shall accommodate the width of the belt plus a minimum of 50 mm per edge bar. Specific p
43、laten pressure on the surface of the belt shall be uniform and automatically controlled to 1400 kPa 70 kPa. 4.6.3 Metal clamping plates, which shall extend across the full width of the press and shall extend a minimum of 150 mm beyond the leading and trailing ends of the press. SANS 485:2009 Edition
44、 1 11 4.6.4 Electronic operation and control, with automatic pre-set temperature controller accurate to 1C. 4.6.5 Thermocouples, with a minimum of one per platen. 4.6.6 Temperature range, the press shall be capable of achieving the required temperature range as specified by the supplier of the raw m
45、aterials. 4.6.7 Ramp time, the press shall be capable of achieving the required ramp time as specified by the supplier of the raw materials. 4.7 Environmental conditions The work area shall comply with the following conditions: a) Dry. b) Dust and pollutant free. c) Luminance shall be a minimum of 4
46、00 lux. d) Be well ventilated for chemical use so as to prevent exposure to toxic fumes by personnel working in the area. Personnel should also position themselves such that they are not exposed to toxic fumes and take precautions to prevent contact with toxic materials. e) Ambient temperature above
47、 the dew point. f) Humidity of no more than 70 % as measured on a hygrometer (see annex C). g) Compliant with conditions as laid out in clause 6. NOTE Ideally a permanent belt splicing station should be available. 5 Method of constructing a splice of steel cord and reinforced conveyor belting 5.1 Ge
48、neral The properties of the parent belt shall be pre-determined and that information shall be supplied by the owner to the splice constructor in order to ensure compatibility of the raw materials with the parent belt. 5.2 Layout The splice shall be constructed in accordance with the requirements as
49、set out in figures 1, 2, 3 and 4 and table 1. 5.3 Practices not permitted The following practices are not permitted: a) multi-section curing; b) repairs on the vulcanised splice; SANS 485:2009 Edition 1 12 c) the use of cotton waste and paper towels for the application of solvents and solutions; d) incorrect storage of splice materials; e) the use of conveyor belting in place of edge bars; f) post vulcanisation cutting of the edges; and g) the use of any chlorinated solvent is prohibited. 5.4 Situations where splicing is not permitted Splicing is not permitted in
