Independent engineering review

What does your steel cord X-ray reveal?

Already have X-ray images or scan video? Get a professional, independent review of your steel cord belt or splice with Andrew Hustrulid, PhD, PE.

Understand the cord layout, identify areas that need closer attention, and assess how the as-constructed splice shares load.

Discuss your X-ray data See the examples

Static X-ray images · X-ray scan video · Splice analysis

Example splice measurements: approximately 640 and 620 mm steps and a 19.4 degree bias angle.
Example measurements from the original X-ray, shown over a cleaned illustration with inferred background detail.

Start with the data you have

Still images or a moving scan.

For belt owners, operators, maintenance teams and engineers seeking an independent interpretation of existing inspection data.

Static X-ray review

Review full-splice images, individual radiographs or image exports. Trace and number visible cords, examine the splice pattern, and estimate step lengths, bias angle and cord gaps where image quality and scale allow.

X-ray video review

Review a moving belt scan across successive frames to follow visible cord paths and locate areas of interest. Coverage, motion and image quality are assessed before deciding which observations and measurements the recording supports.

Original inspection exports give the best starting point. If you only have screenshots or a recording of a display, describe what is available so we can assess its suitability.

Expert splice analysis

From visible cords to an engineering explanation.

01 / Interpret the scan

Map visible cord paths and splice geometry. Identify irregular spacing, cord-end alignment and uncertain regions that need further inspection.

02 / Compare the layout

Compare the as-constructed splice with the supplied design or an agreed reference. Where the data supports it, use finite element analysis (FEA) to evaluate cord tension, rubber shear and the center of tension.

03 / Explain the findings

Review annotated images, measurements and calculations in a written report. A narrated video can help your team follow the analysis. The scope, assumptions and unresolved questions are made clear.

Example 01 · Report & video

One splice. A report and a visual walkthrough.

This published, anonymized case compares an X-ray-based splice layout with an as-designed reference. Explore the complete assessment or watch the one-minute explanation.

Written assessment

Splice X-ray & FEA report

Numbered cords, measured geometry, design comparisons and calculated load sharing, with the assumptions behind the results.

First page of the English example report, with findings and an as-designed versus as-constructed comparison table. Read the report English PDF · 10 pages

Narrated walkthrough

Watch the analysis unfold

Follow the X-ray through cord identification, splice measurements and the comparison of cord tension and rubber shear.

1 minute · Narration and captions in English

All editions

Also published on LinkedIn: example report and narrated video.

Example 02 · Cord tracing from scan video

Full-width splice, including outer cords.

This sidewall-belt example combines two aligned X-ray video frames into a single annotated splice view. Maven's tracing follows the central cord bundle and the separate cord groups at both edges of the recorded image.

Annotated full-width splice X-ray with red End A and blue End B traces, central cords numbered 001 to 061, green center pair 031, and separate left and right outer cord labels.
Red traces identify End A; blue traces identify End B. Center pair 031 is highlighted green. Separate edge IDs distinguish the outer groups from the 61-cord central bundle at each end.

View full-resolution image PNG · 4976 × 3682

Paths across obscured bands are interpolated; partial and uncertain edge traces are marked. The colors identify cord paths, not stress or damage. This example presents a geometric tracing review; no load or strength calculation is shown.

Cable tracing and annotation: Maven Software Inc.
X-ray source: Wuming Zou / DMC, LinkedIn · Aligned video frames at 26.36 s and 28.86 s.

Example 03 · An unusual splice pattern

A much shorter middle step?

This unusual-looking splice raises a question about the geometry shown in the video. Maven traced and numbered 79 cords from each end to make the arrangement easier to examine.

Stitched splice X-ray with 79 red End A cords and 79 blue End B cords, numbered independently at each end. The middle interval appears shorter than the outer intervals.
Red identifies End A and blue identifies End B. Each end is numbered 001–079, including the edge cords. J1–J3 mark joins between the captured scan blocks.

An unusual-looking steel-cord splice—it appears to have three steps, with a much shorter middle step. Is that the actual splice geometry, or an effect of the video capture? It would be interesting to see the original splice drawing.

Read Andrew's comment on LinkedIn

What the source frame shows

Both boundaries of the middle interval are visible within a single video frame at two checked locations. Our stitching did not remove middle rows at those locations. However, the scan advance and completeness are unverified, so the composite cannot establish the physical step lengths.

Single-frame evidence at 31.77 seconds, with a 155-pixel middle interval marked between two cord-tip rows and an enlarged view of the same pixels.
The capture check uses original pixels from one frame. Pixel intervals are not physical measurements.

View numbered splice PNG · 2565 × 6030

A three-step interpretation is plausible; the step count and intended dimensions remain unconfirmed. This observation is not a finding of faulty construction. Cord paths are interpretations of compressed video, particularly where cords touch; colors identify the two belt ends, not stress or damage.

Cable tracing and annotation: Maven Software Inc.
X-ray source: Wuming Zou / DMC, LinkedIn · Selected frames at 31.43–31.97 s.

Request an independent review

Tell us what you have and what you need to understand.

Contact Andrew with a brief description of your X-ray data and the questions you want answered. We can then agree on the review scope, the available evidence and how to transfer the files.

Email Andrew

Andrew I. Hustrulid, PhD, PE
Maven Software Inc.
andrew@hustrulid.com

Useful information to include

  • The scan: still images, a full scan export or the original video; scan date and splice identifier.
  • The belt: width, rating, cord diameter and pitch, and direction of travel, where known.
  • The design: splice drawing, step lengths and construction records, if available.
  • The question: a specific concern, a comparison with an earlier scan, or an independent review of a newly completed splice.

You can start the conversation with incomplete information. We will identify what else is needed for a useful assessment.