Conveyor Belt Splicing Guide: Mechanical Fasteners & Methods | Texas Belting and Supply
Conveyor
Belt
Splicing
Complete guide to mechanical and vulcanized splicing methods, fastener system selection, and installation best practices for maintenance engineers and reliability teams.
What is Belt Splicing?
Conveyor belt splicing is the process of joining the two ends of a conveyor belt to create a continuous loop. Whether you're commissioning a new conveyor, repairing a damaged belt, or replacing a worn section, the quality of the splice directly determines belt life, system efficiency, and downtime frequency.
There are two primary categories of belt splicing: mechanical fastening and vulcanized splicing. Within mechanical fastening, Texas Belting and Supply stocks four distinct fastener systems — Plategrip™, Riv-Nail™, Staplegrip™, and Steelgrip™ — each engineered for specific belt types, operating tensions, and application environments.
Selecting the correct splice method and fastener system is critical. An undersized fastener will fail prematurely; an oversized one may damage belt carcass or create issues at pulleys. This guide walks through every major variable to help you make the right call for your application.
Key Selection Factors
- Belt thickness (determines fastener size)
- Belt PIW rating (pounds per inch of width)
- Minimum pulley diameter on the conveyor
- Belt material (rubber, PVC, urethane, fabric)
- Operating environment (abrasion, corrosion, chemicals)
- Frequency of splice opening and re-splicing
- Available tools and installation resources
- Belt width (determines fastener quantity needed)
- Whether magnetic separation is involved
Splicing Methods
Mechanical
Fasteners
Mechanical splicing uses metal fasteners driven into both ends of the belt and connected by a hinge pin, allowing the joint to flex around pulleys. This is the most common field-repair and new-installation method due to its speed and practicality.
Texas Belting stocks four mechanical fastener systems covering belts from 1/16" to 3/4" thick and PIW ratings from 150 to 1,500. The correct system depends primarily on belt thickness and minimum pulley diameter.
- Fast installation — no curing time required
- Field-repairable with basic tooling
- Re-splicing possible at loading/delivery points
- No heat or special equipment needed (most systems)
- Ideal for frequent belt replacement or adjustment
- Works on all rubber, PVC, and fabric belt types
- Available for belts up to 84" wide
Vulcanized
Splicing
Vulcanized splicing fuses belt ends using heat and pressure to create a seamless joint that is nearly indistinguishable from the parent belt. This method yields the strongest possible splice — often equal to 100% of belt rating — but requires specialized equipment and curing time.
Hot vulcanization requires a vulcanizing press, while cold vulcanization uses chemical bonding agents. Both are significantly more time-intensive than mechanical splicing and are typically performed by trained technicians.
- Maximum splice strength — up to 100% belt rating
- No protrusion above belt surface
- Ideal for high-speed or high-tension applications
- Smooth, seamless joint for delicate products
- Preferred for steel-cord and heavy-duty belting
- Eliminates any risk of fastener pullout
- Requires longer downtime for installation
Mechanical Fastener Systems
Broad, heavy-toothed plates designed for high-tensile and PVC belting. Teeth overlap plate edges for extra holding on thin belts. Passes smoothly over pulleys, allowing natural troughing action on both sides. Available in standard and hinged configurations.
- Belt Thickness3/16" – 15/16"
- Max PIW620 PIW
- Min Pulley12" (std) / 6" (hinged)
- Sizes1, 140, 190, 1¼, 1½, 2, 2¼, 2½, 3
- Packaging25-set boxes or 100-set buckets
A compression fastener using pilot nails that divide rather than cut belt fabric, allowing rivets to slide between fill and warp yarns for maximum pullout resistance. Engineered for synthetic high-strength belts used in mining, agriculture, and heavy industry.
- Belt Thickness1/8" – 3/4"
- Max PIW1,500 PIW
- Min Pulley5" (R-2) to 18" (R-8)
- SizesR-2 through R-8
- MaterialsSteel, RS, RC, RLC stainless, Durgard
Hinged plates held in compression with high-tensile stainless steel oval staples clinched 90° to the belt pull direction — making it virtually impossible for staples to open under load. Designed for modern lightweight, high-strength belts on slider bed or troughing conveyors.
- Belt Thickness1/16" – 1/4"
- Min Pulley2" (Size 62) – 4" (Size 187)
- Sizes62, 125, 187
- InstallationHammer & punch or SG-25XP pneumatic gun
- MaterialsSteel or Stainless Steel
Time-tested wire-hook lacing with a continuous common bar that distributes tension evenly across the full belt width. Steel points pierce the belt carcass without cutting longitudinal strength members. Installation requires only a hammer and gauge pin — no additional tooling needed.
- Belt Thickness1/16" – 3/8"
- Min Pulley1" (Size 00) – 9" (Size 45)
- Sizes00, 1A, 7, 15, 20, 27, 35, 45
- InstallationHammer and gauge pin only
- MaterialsGalvanized, Carbon Steel, Stainless
Plategrip™ System Detail
Plategrip fasteners feature broader, heavier teeth that overlap the edges of the plates, providing extra holding power especially on thin belts. They pass smoothly over conveyor pulleys, allowing natural troughing of belts and smooth operation on both sides — through trippers and scrapers, as well as over crowned or takeup pulleys.
All 100-set buckets of solid plate fasteners have pre-assembled bolts and bottom plates utilizing a patented system with a special thin metal washer to clinch the bolt during installation. This design is superior to plastic or nylon washers, which can slide along bolt threads and loosen over time.
Splice angle: A 90° splice is generally used where pulley diameter and belt thickness correspond to the specification chart. The 45° splice should be used where pulley diameters are smaller than the recommended minimum — it reduces flexing behind the fastener and has the same strength as the corresponding 90° splice.
| Plategrip Size | Belt Thickness | Min Pulley | Max PIW |
|---|---|---|---|
| 1 | 3/16"–7/16" | 12" | 150 |
| 140 | 3/16"–7/16" | 14" | 225 |
| 190 | 5/16"–9/16" | 18" | 375 |
| 1¼ | 3/8"–1/2" | 14" | 150 |
| 1½ | 7/16"–11/16" | 18" | 300 |
| 2 | 9/16"–13/16" | 30" | 440 |
| 2¼ | 9/16"–13/16" | 36" | 620 |
| 2½ | 3/4"–1" | 42" | 450 |
| 3 | ≥15/16" | 48" | 560 |
The Hinged Plategrip is a compression-type fastener secured by bolts, providing tremendous holding power with good troughing action while remaining readily separable after easy installation. It is ideally suited for applications where loading and delivery points frequently change — such as mine, pit, quarry, and construction sites.
X375: Minimum 6" pulley diameter, belt 1/4"–13/32" thick, rated to 200 PIW. Available in steel matched sets from 12" to 60" belt width, plus stainless and Durgard options.
X550: Minimum 9" pulley diameter, belt 1/4"–5/8" thick, rated to 300 PIW. Available in steel matched sets from 16" to 72" belt width. Each matched set includes one complete joint with hinge pin, nuts, bolts, and filler tubing.
| Size | Belt Thickness | Min Pulley | Max PIW |
|---|---|---|---|
| X375 | 1/4"–13/32" | 6" | 200 |
| X550 | 1/4"–5/8" | 9" | 300 |
Hinge pins are available in nylon-covered steel cable (NC) — the standard for long wear — as well as bare steel cable (SC), bare stainless steel cable (SSC), and nylon-covered stainless (NCS). Order by specifying pin type and belt width. Example: NC-36 for a 36" belt with nylon-covered steel cable.
Riv-Nail™ System Detail
The Riv-Nail is a compression rivet-hinge fastener engineered for synthetic high-strength belt fabrics used in mining, agriculture, wood products, and construction. Unlike bolt-type fasteners that require pre-punched holes, Riv-Nail pilot nails divide belt fabric rather than cutting it — allowing rivets to slide between fill and warp yarns for superior pull-out resistance.
A design pattern of 2–8 Riv-Nails per fastener creates maximum compression. Each Riv-Nail assembly consists of a semi-tubular rivet and a pilot nail; upon completion of the splice, the rivet and pilot nail separate, leaving the rivet clinched and compressed within the fastener plates.
Available sizes: R-2 through R-8, fitting belts from 1/8" to 3/4" thick, rated from 330 to 1,500 PIW. Fastener strips are cross-scored to break by hand to any belt width. All fastener strips sold one set per carton; hinge pins and rivets sold separately.
| Fastener Size | Belt Thickness | Min Pulley | Max PIW |
|---|---|---|---|
| R-2 | 1/8"–3/8" | 5" | 330 |
| R-3 | 3/16"–3/8" | 6" | 330 |
| TR-4 | 7/32"–7/16" | 9" | 400 |
| R-5 | 7/32"–7/16" | 9" | 450 |
| R-5½ | 3/8"–19/32" | 12" | 800 |
| R-6 | 13/32"–3/4" | 18" | 1,000 |
| R-8 | 13/32"–3/4" | 18" | 1,500 |
| Belt Width | R-2 Count | R-3 Count | TR-4 Count | R-5, R-5½, R-6 | R-8 Count |
|---|---|---|---|---|---|
| 18" | 40 | 60 | 80 | 100 | — |
| 24" | 52 | 78 | 104 | 130 | — |
| 30" | 64 | 96 | 128 | 160 | — |
| 36" | 80 | 120 | 160 | 200 | — |
| 48" | 108 | 162 | 216 | 270 | 432 |
| 60" | 136 | 204 | 272 | 340 | 544 |
| 72" | 164 | 246 | 328 | 410 | 656 |
| 84" | 192 | 288 | 384 | 480 | 768 |
Rivet Size Selection
Rivets are selected based on belt thickness. They are available in steel (zinc dichromate gold — moderate corrosion resistance) and stainless steel (silver or copper color-coded). Stainless rivets should be used with RC and RS series stainless fastener strips in corrosive environments.
| Rivet Size | Belt Thickness |
|---|---|
| 0 | 1/8"–3/16" |
| 1 | 3/16"–1/4" |
| 2 | 1/4"–5/16" |
| A/B | 9/32"–13/32" |
| C | 13/32"–15/32" |
| D | 17/32"–19/32" |
| E–I | 19/32"–29/32" |
Hinge Pin Selection
Hinge pins are selected based on fastener size, belt width, and application. Bare cable or armored cable pins are used when pins must be frequently withdrawn, or when conveyed materials are highly abrasive. Nylon-coated or nylon-armored pins are used when pins remain in place permanently — the fastener loops bite into the cover and lock the pin, preventing migration.
Available styles for R-2 through R-5: SC (bare steel), SSC (bare stainless), NC (nylon steel), AC (armored steel), NAC (nylon-armored), NCS (nylon stainless). For R-5½ through R-8: SC6, AC6, SAC6, NAC6, and heavy-duty SAC6-SP options.
Staplegrip™ System Detail
Staplegrip is designed for modern lightweight, high-strength belting used on slider bed and troughing conveyor applications. Hinged plates are held in compression by high-tensile stainless steel oval-shaped staples clinched 90° to the direction of belt pull — making it virtually impossible for staples to open under load.
The oval staple design reduces the possibility of fabric damage compared to rectangular staples used by other brands. Staplegrip is available in two configurations: Traditional lacing (pre-loaded staples installed with a field lacing tool and hammer) and Preset lacing (staples pre-set into strips, used with hammer driver fixtures).
For the highest productivity, the SG-25XP pneumatic staple gun system drives each staple with uniform force and clinches to 80–90% of maximum with the initial stroke. After all staples are driven, a single hammer blow completes the clinch — all without turning the belt over. Field tests confirm longer splice life with the professional system. Available for belt widths 12" to 72".
| Size | Belt Thickness | Min Pulley | Application |
|---|---|---|---|
| 62 | 1/16"–1/8" | 2" | Ultra-thin belts, small pulleys |
| 125 | 1/8"–3/16" | 3" | Standard lightweight applications |
| 187 | 3/16"–1/4" | 4" | Thicker light belts, higher tension |
All sizes available in traditional steel, traditional stainless, Durgard steel, preset steel, and preset stainless configurations. Packaged 4 sets per box (10 sets for smallest widths). Each set includes lacing, hinge pins, and installation instructions.
Steelgrip™ System Detail
Steelgrip wire-hook lacing combines toughness with extreme ease of installation. The common bar design creates a continuous lacing strip across the full belt width, distributing tension evenly across every hook rather than concentrating it at individual fastener points. This uniform load distribution is a key advantage over plate-style fasteners on lightweight belts.
The special steel points pierce the belt carcass without cutting longitudinal strength members, preserving belt integrity. The lacing is cross-scored so it can be easily broken by hand to fit any belt width exactly. Installation requires only a hammer and gauge pin — no drilling, punching, or specialized tooling necessary. Each standard box includes lacing, gauge pin, hinge pins, and instructions.
For flat conveyor belt applications, Steelgrip long-length lacing is available in most popular lengths up to 60", with special continuous strips also available. Available in steel (galvanized for sizes 00–7, carbon steel for sizes 15–45) and stainless steel (nickel-chrome, excellent for food and sanitary applications).
| Size | Belt Thickness | Min Pulley | Material Standard |
|---|---|---|---|
| 00 | 1/16" | 1" | Galvanized |
| 1A | 1/16"–3/32" | 1½" | Galvanized |
| 7 | 3/32"–9/64" | 2" | Galvanized |
| 15 | 1/8"–5/32" | 2½" | Carbon Steel |
| 20 | 5/32"–3/16" | 3" | Carbon Steel |
| 27 | 1/4"–9/32" | 5" | Carbon Steel |
| 35 | 9/32"–5/16" | 7" | Carbon Steel |
| 45 | 5/16"–3/8" | 9" | Carbon Steel |
Fastener Material Options
The most common and economical belt fastener material, suitable for the vast majority of applications. Steel fasteners use special grades of high-strength steel annealed for extra durability — yielding 25–35% greater tensile strength than standard grades. R-2 through R-6 sizes use galvanized coated steel. Galvanizing provides moderate moisture resistance; not recommended for highly corrosive environments. Standard for most dry, moderate-duty applications.
Recommended for applications where corrosion or chemical exposure is a major concern. Stainless steel fasteners offer superior resistance to abrasions, acids, chemicals, and magnetic attraction compared to standard steel. Texas Belting stocks three stainless grades: RS (most non-magnetic, available for R-2, R-3, TR-4, R-5); RC (high-chrome with nickel, for acidic conditions and magnet belts); and RLC (low-chrome, enhanced wear/corrosion over standard steel, for R-5, R-5½, R-6). All stainless rivets use 430 SS.
A special heat-treated steel with abrasion-resistant characteristics that provide several times the service life of standard steel in highly abrasive applications. Durgard is available for Plategrip, Hinged Plategrip, Riv-Nail, and Staplegrip systems. Not recommended for corrosive environments — Durgard is specifically formulated for abrasive conditions such as aggregate conveying, quarry operations, and bulk material handling where fastener wear from the material stream is the primary concern.
Application Selection Guide
Use Riv-Nail R-5 through R-8 for heavy mining belts requiring high PIW ratings. Hinged Plategrip X550 or X375 for frequently relocated conveyors at mine faces. Durgard material for abrasive aggregate.
Use Staplegrip 62 or 125 for lightweight agricultural belts with small pulleys. Steelgrip 15 or 20 for flat transmission belts. Stainless steel fasteners where washdown or fertilizer contact occurs.
Use Steelgrip stainless (nickel-chrome) — excellent resistance to fatty acids and washdown chemicals. RS or RC series Riv-Nail stainless for heavier food processing belts. Non-magnetic RS grade for magnetic separation applications.
Use Hinged Plategrip X375 or X550 for portable conveyors requiring frequent splice separation. Riv-Nail R-3 or TR-4 for construction equipment belt replacements. Steel is acceptable in most construction environments.
Use Steelgrip flat power transmission lacing — available in 6" to 12" lengths for transmission belt applications. Sizes 00 through 45 cover belts from 1/16" to 3/8" thick with minimum pulleys as small as 1".
Use Staplegrip 62 or 125 for slider bed conveyor applications. The smooth, low-profile splice operates cleanly over slider beds without snagging packages. Pneumatic SG-25XP gun installation recommended for production environments.
Use Riv-Nail R-6 or R-8 for belts rated 800–1,500 PIW. Plategrip size 2¼ for high-tensile PVC belts to 620 PIW. Vulcanized splicing should be evaluated for belts exceeding 1,500 PIW or where seamless joints are critical.
Use RC or RLC stainless Riv-Nail for high-chrome resistance to acidic conditions. Stainless Plategrip (complete stainless sets or stainless top plates with steel bottoms) for moderate corrosion. Avoid Durgard and standard steel.
Use Steelgrip size 00 or 1A for belts as thin as 1/16" with pulleys as small as 1". Staplegrip 62 for thin belts needing a hinged plate splice. Both systems require only basic hand tools and are ideal for decentralized maintenance.
System Comparison Chart
| System | Type | Belt Thickness | Min Pulley | Max PIW | Installation | Best For | Materials |
|---|---|---|---|---|---|---|---|
| Plategrip™ | Bolt plate | 3/16"–15/16" | 12" | 620 | Bolt wrench | High-tensile, PVC belts | Steel, SS, Durgard |
| Hinged Plategrip™ X375 | Hinged bolt plate | 1/4"–13/32" | 6" | 200 | Bolt wrench | Portable conveyors, frequent splice | Steel, SS, Durgard |
| Hinged Plategrip™ X550 | Hinged bolt plate | 1/4"–5/8" | 9" | 300 | Bolt wrench | Mobile, mine applications | Steel, SS, Durgard |
| Riv-Nail™ R-2 | Rivet-hinge | 1/8"–3/8" | 5" | 330 | Hammer / air driver | Agriculture, light mining | Steel (galv), RS stainless |
| Riv-Nail™ R-5/TR-4 | Rivet-hinge | 7/32"–7/16" | 9" | 450 | Hammer / air driver | General industrial, 2–3 ply | Steel, RS, RLC, Durgard |
| Riv-Nail™ R-6 | Rivet-hinge | 13/32"–3/4" | 18" | 1,000 | Hammer / air driver | Heavy industrial, mining | Steel, RLC, RC stainless |
| Riv-Nail™ R-8 | Rivet-hinge | 13/32"–3/4" | 18" | 1,500 | Hammer / air driver | Highest-tension applications | RC stainless |
| Staplegrip™ 62 | Staple plate | 1/16"–1/8" | 2" | — | Hammer / pneumatic gun | Ultra-light belts, package handling | Steel, Stainless, Durgard |
| Staplegrip™ 125/187 | Staple plate | 1/8"–1/4" | 3"–4" | — | Hammer / pneumatic gun | Light conveyor belts | Steel, Stainless, Durgard |
| Steelgrip™ (00–1A) | Wire-hook lacing | 1/16"–3/32" | 1"–1½" | — | Hammer & gauge pin | Very thin belts, tiny pulleys | Galvanized, Stainless |
| Steelgrip™ (15–45) | Wire-hook lacing | 1/8"–3/8" | 2½"–9" | — | Hammer & gauge pin | Flat transmission & conveyor belts | Carbon Steel, Stainless |
Mechanical Splice Installation
Cut both belt ends cleanly and squarely using a belt cutter or skiver. A 90° splice is standard; use a 45° cut when pulleys are smaller than the minimum recommended diameter. Clean cuts improve fastener seating and splice longevity.
Confirm the correct fastener size by measuring belt thickness and checking minimum pulley diameter. For Plategrip, pre-assemble bottom plates. For Riv-Nail, select the correct rivet size to match belt thickness. Break Staplegrip or Steelgrip strips to exact belt width.
Use Grip-Tite™ belt clamps to pull and hold belt ends together with proper tension alignment. Clamps are available for belt widths from 20" to 96" and provide up to 3 tons of holding force — essential for maintaining alignment during installation.
For Plategrip: use template to position fasteners, punch or bore bolt holes, insert bolts, and torque nuts. For Riv-Nail: use multi-tool or single-driver with hammer or air/electric driver. For Staplegrip: use field lacing tool or SG-25XP pneumatic gun. For Steelgrip: hammer and gauge pin only.
Insert the appropriate hinge pin through the interlocked fastener loops. For permanent installations use nylon-coated pins; for frequently removed splices use bare cable. Inspect all fasteners for proper seating, then verify the splice runs cleanly over all pulleys and scrapers before returning the conveyor to service.
Frequently Asked Questions
Need Help Selecting
the Right Splice?
Texas Belting's technical team has decades of experience matching fastener systems to specific belt types, conveyor configurations, and operating environments. Contact us with your belt specs and we'll recommend the right system.