The impact of fiber friction, yarn twist, and splicing air pressure on mechanical and structural properties of spliced portion have been reported in the present paper. The mechanical properties include the tensile and bending related properties and, in the structural properties, the diameter and packing density of the splices are studied. A three variable three level facto­rial design approach proposed by Box and Behnken has been used to design the experiment. The results indicate that there is a strong correlation between retained spliced strength (RSS) and retained splice elongation (RSE) with all the experimental variables. It has been observed that RSS increases with the increase in splice air pressure and after certain level it drops, whereas it consistently increases with the increase in yarn twist. The RSE increases with the increase in both fiber friction and yarn twist. It has also been observed that the yarn twist and splicing air pressure have significant influence on splice diameter, percent increase in diameter and retained packing coefficient, but the fiber friction has negligible influence on these parame­ters. Yarn twist and splicing air pressure has a strong correlation with splice flexural rigidity, where as poor correlation with retained flexural rigidity.