“Forever Strong Belt Splice”

INTRODUCTION

• To make conveyor belting endless, Kia-Kaha splice is proffered over hot and cold vulcanising as well as mechanical fasteners.

• The speed and simplicity of the Kia-Kaha Splice installation represents major advantages over the vulcanisation process.

• On most belt width and thicknesses, the spice can be completed under an hour and by an in-house crew with portable, easy-to-use tools. Saves time and money by ensuring a quick start up.

• In the event that an unexpected splice is required, it is thus not necessary to wait for professional assistance.

• Kia-Kaha spices can be done in restrictive environments, with no special regard for space, temperature, moisture or contaminants. • • With shorter overlaps, Kia-Kaha splicing offers reduced belt wastage which will significantly reduce cost.

• With visibility of the splice condition, Kia-Kaha offers early detection of joint failure, resulting in planned repairs that suit the production of the company.

INTRODUCTION - CONTINUES

• Unlike several types of mechanical fasteners, the Kia-Kaha splice maintains a continuous smooth surface on the belt face and back.

• The smooth endless band does not let any material seepage through, resulting in less downtime for spillage cleaning.

• It also travels well over the idlers and the pulleys without causing any additional wear on the pulleys or idlers, again a saving in downtime to replace parts.

• No matter the belt conditions, Kia-Kaha splice is a good choice for both new and older, worn belts.

• The belt strength remains intact as only the top and bottom rubber is removed, while the belt’s vital carcass fabric is left intact.

• Another benefit is that no electricity is required for installation.

• An old Kia-Kaha splice can be dismantled as an entire entity and be reused.

ADVANTAGES OF A KIA-KAHA SPLICE

•Convenient mounting due to different size of the upper and lower parts.•Belt splicing by means of Kia-Kaha splice can substitute other types of splicing like mechanical, cold and vulcanized splicing.•High erection speed•Conveyor is ready for operation straight after splicing.•Splicing execution is very simple and doesn’t demand any special highly-qualified preparation.•Fasteners don’t overlap the belt (are flush with the belt) and as a result such splicing doesn’t damage expensive pulleys, trippers, etc.•Such splicing makes it possible to use the splice during its entire working time.•Maintainability and long working life.•Process doesn’t demand any special accommodation or equipment.•If in the process of operation one of the parts is broken, then it’s easily substituted and this prolongs the working time of the entire splice.•Doesn’t demand purchasing expensive equipment.•Instalment is executed easier and quicker than producing splice by hot or cold methods that reduces the standing time and increases the productivity.

SPLICE SELECTION AND OPERATION

• Identifying the correct splice for the application is essential to ensure maximum splice life and performance. Good Bearing & Belting will provide the necessary technical assistance.

• The Kia-Kaha splice sandwiches the Carcass of the belt and is secured to the belt with a staggered pattern of screws covered in rubber.

• The screws penetrate the belt without damaging or weakening the belt carcass because they slip between the load-bearing carcass fibres.

• The Kia-Kaha splice is installed to provide maximum resistance and distribute splice tension evenly across the width of the belt.

• Kia-Kaha spice can be used with a minimum pulley diameter of 230mm.

• The Kia-Kaha splice installation tools are easily transported to the job site and offer splice installers versatility in installation methods.

• The Kia-Kaha splice sits flush with the belt’s top and bottom covers, eliminating interference with the tight-fitting scrapers, skirt boards and other conveyor components.

• Countersinking strengthens the joint by positioning the Kia-Kaha splice closer to the belt’s load bearing carcass fibres.

CONCLUSION

While vulcanised joints are longer lasting that metal fasteners, even a hot vulcanised joint cannot produce a tensile strength at the joint equivalent to the belt strength itself. The normal practice adopted for calculation of the tensile strength at the joint is approximately ¾ (75%) of belt strength, for example a Class 1000 strength belt will equal 750kn/m tensile strength joint. The Kia-Kaha splice on the other hand eliminates the decrease in strength in the belt at the joint. Therefore no more weak points in your belt.

• The KIA-KAHA splice is cheaper, stronger, faster and easier to install than any other joining method currently on the market.

• The tensile strength at the joint is equal to the belt strength.

•The KIA-KAHA splice can be prepared to suit numerous applications including heat & fibre-, abrasion-, chemical- and oil resistant belts.

REQUIRED TOOL LIST

Stripping PliersCordless Drill

Drill Bit

Working Board

Belt Knife

Splice Template

APPROVED DISTRIBUTORS •North West Province Lebola Mining and Engineering Supplies CC Nico Cell: 071 422 5533 Email: nico@lebola.co.za Schalk Tel: 014 592 0125 Email: Schalk@lebola.co.za C & E Engineering Robert Cell: 083 355 5909 Email: roberts@ceengineering.co.za

•Mpumalanga TMRS Eastern Limb Baksteen Cell: 082 855 4433 Email: Baksteen.tmrs@gmail.com Le Roi Cell: 083 409 8671 Email: lero.tmrs@gmail.com EMS Belting Phillip Cell: 013 752 8277 Email: emsbelt@lantic.net

•Gauteng NS Tec Mike Cell: 076 264 9030 Email: nstrading@telkomsa.net

•KZN Samco Pumps Joffre Cell: 082 427 5046 Email: Joffre@samcopumps.com Johan Cell: 060 769 6826 Email: Johan@samcopumps.com

•Limpopo and Mpumalanga Klevan Mining Christiaan Cell: 082 721 9298 Email: fox.klevan@gmail.com

•Africa Region ELB Equipment Vincent Tel: 011 306 0777 Email: elb@elbquip.co.za

INSTALLATIONS AND RECOMMENDATIONS

Kia-Kaha belt splice has already been installed at various sites and plants and has proven it’s slogan “ forever strong”

Installations has been done at the following plants:

Belt Repair doneat Raumix

1050mm Belt Splice done at Atoll

750mm Splice done at

GW Wearne

PO Box 7018, Petit, 1512 Reg. No. 72/01181/07 Tel (011) 965-1351 (1771) Gauteng, R.S.A Vat No. 4610128151

15 February 2016 TO WHOM IT MAY CONCERN,

Recommendation of KIA KAHA Brand Splicer Kit for: GOOD BEARING & BELTING

Good Bearings and Belting installed a demonstration Kia Kaha Splicer Kit in our crusher conveying plant system in September 2015. We function on a 24 hour basis and this splice has held up well and is performing to our satisfaction. We see the benefit as our on site technicians can also install this splice without requiring the necessary equipment and expertise needed for the traditional cold/hot splice.

Regards,

Mr. M Balambanos

BELT INSTALLATION

1. The conveyor belt drum should be brought to the point of installation and mounted on a suitable shaft, so that the drum can be rotated to unroll and thread the belt on to the conveyor.

2. When mounting the drum, care should be taken to ensure that the belt leads off the top of the roll if it is being pulled on to the carrying idlers, but off the bottom of the roll if it is being pulled on to the return idlers.

3. I f the new belt is being installed to replace the old belt, the best procedure is to use the old belt to pull min the new belt.

4. When the new belt is pulled in completely, the end of the old belt can now be unfastened and the new belt tensioned and spiced.

5. If the belt is being installed on a new conveyor, a rope or cable should be attached by means of a clamp to the belt end. The clamp can be made from 5.0mm or 10.0mm thick plates, 100mm intervals about 50mm back from the belt end. The rope or cable is ten attached to this clamp by welding an eye to the plate. The rope or cable may be attached to a truck, tractor or other means of providing traction.

6. When installing a new belt, great care has to be taken to see that the belt doen not rub or catch on sharp corners or rough edges of the steel work.

PREPARATION OF THE BELT FOR SPLICING

1. Once the belt has been positioned on the conveyor structure, it must be tensioned using clamps in order to reduce the stretch in the belt after the splice has been competed and the clamps have been removed. Additional care should be taken to provide extra tension on the clamps if the splicing is done on top of the slope.

2. If the system is fitted with a gravity take-up, it will be necessary to apply tension and lift the weight to the position where it is expected to float when the belt is running empty. When the belt system is fitted with a fixed screw take-up device, the pulley must be moved to the off position so that the belt is at its shortest endless length when spliced.

3. Often it is convenient to position a flat wooden board under the splicing area.

4. After cutting the belt end square, mark the true centre line of the belt to be used as a datum line for all other measurements. Belt edges should never be used for reference.

5. At right angles to the belt centre line, mark a base line to denote the limit of the splice length. To allow for subsequent trimming of the outer end of the splice, it is suggested that the base line should be drawn 50mm further than the total splice length. This base x line should be marked on the face cover for the leading end and on the back cover for the trailing end.

PREPARATION OF THE BELT FOR SPLICING - Continues

6. Mark the bias length along the belt edge from one edge of the base line. Join this marked point to the other end of the base line to provide for the splice line. Mark a line parallel to this 25mm inward and strip off the cover rubber in this 25mm width. Now re-mark the splice line on the outer ply and remove another 25mm wide strip of cover rubber outward the splice line. This will ensure that the splice line is still visible when the two strips of cover rubber have been removed. The second strip is removed to ensure the use of the single ply cutting knife.

7. Now cut through the first ply along the splice line using the single ply cutting knife. Adequate care should be taken not to cut deeper than required and destroy the fabric, which is to remain as part of the splice.

8. Remove the first ply and cover rubber outwards of the splice line, preferably in thin strips.

9. Mark bias + step length along the belt edge from the base line and draw the step line. Now cut the second ply again, taking care not to cut deeper than intended.

10.Mark the other steps from the base line in the same way now.

11.Cut through the last ply and cover rubber at the end of the splice to make the last step 12mm longer than the normal step length.

PREPARATION OF THE BELT FOR SPLICING - Continues

12.Remove cover rubber for a strip of 38mm width on the reverse side of the belt.

13.Repeat the stripping down operation for the reverse side on the other end, commencing from marking the bias length along the belt edge from the base line.

14.In preparation of the steps for splice, measurements are always taken from the base line across the belt. The edge of each step must be measured from this base line and not from the edge of the previous step.

15.Lay out the belt end and fit the other end to it. Make sure that the splice is properly aligned.

16.When the splice is perfectly matched, turn back one half and fit the bottom half of the splice fragments that is aligned with a plate template, roll back one half and fit top fragments. The holes will align perfectly now.

17.Take screws and tighten top to bottom with cordless drill.

18.Start from the two outer sides, take template out and fit other screws.

PRECAUTIONS TO BE TAKEN WHILE SPLICING

Great care should be taken in the use of the ply cutting knife in order not to cut deeper than intended.

CONCLUSIONWhile vulcanised joints are longer lasting than metal fasteners, even a

vulcanised joint cannot produce a tensile strength at the joint equivalent to the belt strength itself. While it can produce a tensile strength close to the belt strength, the normal practice adopted for calculation of the tensile strength at the joint is approximately 1 ply less i.e., for a belting of full thickness tensile strength of 630 KN/metre, incorporating 4 plies, the joint strength is calculated as 472.5 KN/metre, even though the actual strength may be more than this. However, this drop in the tensile strength at the joint would not affect the belt performance. If belt selection take into account a minimum factor of safety of 1:5 at the spliced joint, under maximum tensile loading (starting/stopping tension) for operating safety of multi-ply textile reinforced belting. Also, please note that the efficiency of a vulcanised joint depends a lot on the capability of the equipment used, the workmanship and the quality of the compounds used, apart from the quality of the belt itself.

The KIA-KAHA splice is an easier and faster way to complete a permanent joint to a conveyor belt. The tensile strength at the joint is equivalent to the belt strength.

The cover rubber compounds are mixed accordantly to belt applications and specifications.