Procedure for Transport, Handling and Installation of Electric Cables

Issue 02, October 2009

Please note. This is not a treatise on cable installation. It is supplementary information intended
to enhance engineers, technicians, electricians and cable installation personnels knowledge of
cable installation.
Cognisance must also be taken of Installation practices specified in BS 7671, IEC 60364 and
other International Standards for Electrical Installations.
We hope users find this information useful and invite and constructive (or corrective) criticism.

Cable Drums
a) Cable drums should be clearly marked or labeled with the following information:
1. Manufacturers name or trade mark.
2. Rated voltage, rated area, number of cores and specification.
3. Length of the cable in meters.
4. Year of manufacture.
5. Gross mass in kilograms.
6. The instruction NOT TO BE LAID FLAT.
7. Serial number or other identification.
8. On each flange an arrow with the words ROLL THIS WAY.
9. Mark of the Standards authority (if applicable).
b) Both ends of the cable on the drum should be sealed and the inner end fixed to the
flange of the cable drum to prevent loose coiling. The outer end is fixed to the flange as
well, for the same reason.
c) Drum protective closure should be maintained until cable is utilised.
d) Cable drums should stand on firm, well drained surfaces.
e) It is recommended that periodically the drum is rotated.

Page 1 of 14

Cable transportation
a) Preparation
i. The truck must be suitable for the drum size and weight.
ii. Do not overload trucks
iii. Cable ends must be sealed, secured and protected.
iv. Use special cable trailers for depot to site transportation where possible. (See
below). Cables should not be removed from the cable drum and transported
independently to the installation site.

b) Loading
i. Check drums for correct cable and size, serial number, mass and any
form of possible damage.
ii. Select correct forklift or crane.
iii. Select correct slings and spindle and check their condition.
iv. If a crane is to be used, ensure that a spreader is incorporated to prevent damage to
drum flanges.
v. If the drum is to be rolled, observe correct rolling direction by referring to arrows on
the drum flanges.
vi. Ensure the drum bolts are tight.
vii. Ensure that the truck surface is clear of obstructions, nails, etc.
viii. Do Not drop drums onto truck loading bed.
c) Securing
i. Secure drums to the truck bed to prevent sliding and rolling, using adequate steel
chains and chocks.
ii. Always try and pack drums flange to flange.
iii. Do not lay cable flat.
iv. Stop the vehicle at periods during transportation and check that the load is secure.
d) Off Loading
i. Check the drums for any trace of damage. Damaged drums to be reported before off
loading.

Page 2 of 14

ii.
iii.
iv.
v.
vi.
vii.
viii.

Select correct spindle slings for the drum size and mass and ensure that they are in
good order. Ensure that a spreader is used.
Do not drop the drums. Lower gently onto a firm and relatively level surface.
Off load drums in such a way that they are easily accessible.
If using a forklift, ensure that it is of adequate size relative to the task at hand.
Ensure the forklift forks lateral spacing is correct.
Take care that the protruding forks do not damage other equipment or drums.
There are two methods of rolling drums off loading beds if cranes are not available.
(see below).
Method 1: Hole excavated (Maximum slope 1 in 10) to receive truck.

Method 2: Ramp construction (Maximum slope 1 in 4).

Drum stop

Cable Storage
a. Indoors
i.

Stack flange to flange and preferably not one on top of the other. Do not lay the
cable drum flat.
ii. Stack so that drums are easily accessible.
iii. Observe fire precaution rules.
iv. Cable ends must be sealed at all times.
v. If drums are expected to be stored for a long time they should be specially treated,
or, if applicable, use pesticides at regular intervals in the storage area to avoid
termite and rodent attack on wooden drums.
vi. Despatch on a first in first out basis.
b. Outdoors
i. Drums should be stored on a hard surface at a slight angle and the area should have a
drainage system.
ii. Drums should be released on a first in first out basis.
iii. Cable ends must be sealed at all times.
iv. Stack flange to flange, but if this is not possible, limit vertical stacking practice to
smaller drums only. Do not store the cable drum flat.
v. Stack in such a way that drums are easily accessible.
vi. In areas having a hot climate, drums should be stored under a shade and should be
protected from direct sunlight.
Page 3 of 14

vii.
viii.
ix.
x.

Observe fire protection rules.

Cables must be identifiable at all times.
Cable racks are ideal for storage but take care not to overload.
If drums are expected to be stored for a long time they should be specially treated,
or, if applicable, use pesticides at regular intervals in the storage area to avoid
termite and rodent attack on wooden drums.

Mechanical Forces on Cables during Installation

All cables have a maximum pulling force which should not be exceeded during installation.
The cable construction imposes the limitation on the pull-in force (F). When a cable stocking
(Pulling Sock) is used the maximum force can be related to the overall cable diameter in mm
as follows :Steel Wire Armoured cables
Steel Tape Armoured or Unarmoured Cables
Control and Communication Cables

F = 0.94 * D4 * 10-6 kN
F = 0.39 * D4 * 10-6 kN
F = 0.26 * D4 * 10-6 kN

Attempts should be made to limit the pulling force required to a minimum to avoid
stretching in the outer layers of the cable. This is particularly relevant when installing cables
at high ambient temperatures when thermoplastic bedding and sheathing materials may be
softer than usual, and thus having reduced tensile properties.
An increase in the pulling force is permissible when the cable is laid by means of a pulling
eye attachment to the conductors. As a rule of thumb, the following forces may be applied
to a conductor :Copper conductor
Aluminum conductor

4.9 * 10-2 kN/mm2

2.94 * 10-2 kN/mm2

Page 4 of 14

Then, for example, the maximum force that should be applied via a pulling eye to a 70mm2
3 core copper cable is :70 * 3 * 4.9 * 10-2 = 10.29kN
Generally when cables are installed using well-oiled rollers and jacks, the following forces
can be expected :Straight route
2 - 90 bends

15 20% of cable weight

20 40% of cable weight

Cables laid in open trenches should be left slightly snaked so that any longitudinal
expansion or contraction can be accommodated. Similarly when cables are installed in
cleats or on hangers a slight sag between fixing points is recommended.
Pulling cables Through Pipes or Ducts
When a cable is pulled through a pipe, friction between the cable serving and the pipe
material increases the longitudinal force requirements. Representative values for the coefficient of friction () between the more common cable servings and pipe materials are
given in the table below.
Serving Material
PVC
PVC
PVC
PVC
Bitumenised
Hessian
or Jute

Pipe Material
Asbestos
Metal (Steel)
Pitch Fibre
PVC
Asbestos
Metal (Steel)
Pitch Fibre
PVC

Co-efficient of friction ()
0.65
0.48
0.55
0.35
0.97
0.76
0.86
0.55

For Cables with servings of PE or LSF material, use the same Co-efficient of friction as PVC

This information can readily be used to determine the maximum length of cable that can be
pulled through a given pipe without exceeding the maximum permissible pulling force. Take
for example the 70mm2 3 core cable previously quoted, is this is a low voltage cable with a
PVC sheath and it is desired to know the maximum length of PVC pipe it can be pulled
through then :Maximum pulling force
For PVC to PVC

But force

=
=
=
=

Page 5 of 14

10.29kN (by pulling eye)

0.35
* Reactive force
* Cable weight

Mass of cable that can be pulled

=
=

* Cable mass/102
10.29/0.35 * 102

= 2998 kg

(1kN = 102kg)
The mass of a 70mm2 3 core copper PVC insulated and wire Armoured cable is 3.6kg/m.
Thus the maximum length of this cable that can be pulled through a PVC pipe is :2998/3.6
=
832 metres
If there are any bends in the route then these will create additional loading and reduce the
length of cable that can be installed.
In certain instances when long runs in pipes or ducts are encountered it may be beneficial
to grease the cable with petroleum jelly or some other non aggressive compound to
facilitate pulling-in.
Considerable damage can be done to cable servings at the mouth of a pipe and precautions
should be exercised at such points. (The potential for damage is increased when a cable is
installed in hot conditions, as materials may soften due to the heat and the tensile strength
of the serving material is thus reduced). Fitting of a rubber grommet, or a Bellmouth*, at
the mouth to the pipe will reduce the potential for serving damage.
*

A Bellmouth (in separable hinged halves) will guide the cable into the duct, avoiding
potential damage at the ducts entrance edges.

Preparation for cable laying

a. Planning
When planning a cable route there are several factors to be considered, amongst the
most important are :i. Ground Thermal resistivity (TR) tests.
ii. Position of joint bays
Page 6 of 14

iii.

Provision to indicate on the as laid drawings, the serial or drum number of the
cable installed.

iv.

Suitability of the cable type to the installation. e.g. LSF cables are not
recommended for use in installations in direct sunlight* (Cables with LSF properties
are usually used in buildings or confined spaces where smoke and fumes in a fire
situation could endanger human life), or, buried direct in soil ( LSF properties serve
no purpose in the ground, the additional cost is therefore wastage). * LSF materials
have lower mechanical strength than conventional materials, and therefore extreme caution must
be exercised when installing this type of cable. Twisting or over bending the cable during
installation could result in increased forces being exerted within the cable that could cause cracking
or splitting of the outer sheath. This is particularly important when installing this type of cable in
areas with hot climates.

v.

Correct derating factors for cable current ratings for multiple circuits, differing soil
or ambient temperatures, depth of burial, etc. ( Variation of installation conditions along a
route - When the heat dissipation differs in one part of a route to another, the current carrying
capacity shall be determined so as to be appropriate for the part of the route having the most
adverse conditions).

b. Drum Handling
i. Always use the best hoisting equipment available.
ii. Do not drop drums of cable onto the ground as this can damage the drum as well
as the cable.
iii. It is most important that a minimum of rolling the drums on the ground be allowed
and then only in the direction of the arrows indicated on the drum.
iv. When rolling a drum of cable, to change direction use 2 steel plates with grease
between them, and by standing one flange on these plates the cable drum may
then be swiveled in the desired direction.
v. Position the drum prior to cable-pulling so that the cable is pulled from the top of
the drum.
vi. Note that a drum of power cable can weigh in excess of 10 tons, so make sure that
adequate cable drum jacks are used, that the spindle is strong enough to hold the
drum and that the jacks stand on firm ground and that they hold the spindle
horizontal.
vii. Site the drum at the most convenient place for cable-pulling, usually at the start of
a reasonably straight section near the commencement of the trench work.
viii. Allow for drum braking.

Page 7 of 14

c. Ground Thermal resistivity

i. This often governs the rating of a power cable buried directly, as does the
temperature of the soil. Losses for cables running at the maximum temperature at
which the dielectric system can faithfully operate for a maximum life of, say 30
years, are considerable, ranging from 15 W/m for normal distribution cables. Cable
conductor temperature and the soil surrounding the cable must be able to
dissipate this heat effectively or thermal instability (runaway) will result. For
example an XLPE insulated 11kV cable with the conductors running at 90C could
end up with a surface temperature close to 80C resulting in drying-out of the soil.
Depth of burial plays an important factor here and has been set at 800mm. Most
MV cable current ratings are calculated with ground temperatures at 25C at
depths of burial of 800mm.
LV cables are normally buried at 500mm. Soil thermal resistivity (the ability of the
soil to conduct or dissipate heat) is usually 1.2K.m/W. For variances in these
temperatures or thermal resistivity of the soil, contact the cable supplier for the
relative derating factors.
ii. The actual soil thermal resistivity along with the proposed route should be
measured as different soil compositions along the route will have different rates of
heat dissipation and could result in hot spots.
iii. To overcome this, bedding and backfill soils may have to be imported. Bedding
should be a layer of well compacted sifted soil. If the soil taken from the trench is
suitable, break it up and sift it through a sieve of maximum mesh size 12mm, then
ram it well down to provide a stone free bed on which to lay the cable. Where the
route lies in an area of made-up or aggressive ground containing rock, sharp
stones, clinker, slag, ash, bricks, etc., do not use this soil even if the particles are
small enough to pass through a 12mm sieve. For such sections, import loamy soil
for use as bedding and covering. Sand that consists of spherical particles, obtained
from a river bed or sea shore, is not suitable as its thermal resistivity is very high.

d. Positioning of Joint Bays

Ensure that there is sufficient working space, consider passing traffic and other
obstructions. If it is not possible to position the joint bay at standard cable length
distances, remember that the cable can be ordered in specific lengths. Consider
drainage for large bays and try to construct the bays prior to cable pulling to prevent
any damage to the cable at a later stage.

Page 8 of 14

e. Recording Cable drum Serial Numbers on As Laid Drawings

In the unlikely event of a cable failure in the future, quoting the drum serial number will
assist the cable manufacturer in his quality control, as this serial number is related to
the manufacturing and raw material management in the factory.

f. Preparing for cable Laying

The following VITAL ACTIONS must be observed prior to a cable pull.
i. Cable rollers must be placed between 2 and 4m apart in the
trench (Depending on cable size).
ii. Ensure that rollers can rotate freely. Grease or apply graphite
lubricants if required.
iii. Check that skid plates, or corner rollers, are secure and in
position.
iv. Ensure that each member of the pulling gang knows exactly what he is to do and
that communication signals between members are clear.
v. The trench floor must be clear of stones and other obstructions and the cable
bedding is correctly dispersed.
vi. Cable covers are available at convenient points.
vii. Any objects that may fall into the trench and damage the cable during the pull
and prior to backfilling have been removed. Similarly for cables installed on cable
ladders care should be taken that no sharp edges or protrusions are present that
can damage the cable.
viii. If the ambient temperature is below 10C, or has been for 24 hours, the cable on
the drum will have to be covered with a tarpaulin and heated with suitable
lamps or heaters for at least 24 hours under close supervision. Ensure that
sufficient ventilation exists, and pay the cable off the drum slowly and carefully.
Similarly, if the ambient temperature is above 45C, the cable drum should be
shielded from the sun prior to and during paying the cable off the drum.
ix.
Place the drum at a convenient point, prior to the pull, on strong jacks and on
sound footing (as mentioned earlier) with the arrow on the drum flanges
POINTING IN THE OPPOSITE DIRECTION to the rotation when the cable is being
pulled. The cable, on the jacks, should be at an angle of about 10 - 15 to the line
of the trench.

Page 9 of 14

x.
xi.
xii.

xiii.
xiv.

xv.

xvi.

Before pulling, cut the inner end of the cable free. Failure to do this will cause
buckling of the cable.
The cable must be payed off from the top of the drum, but take care not to bend
it too sharply.
Cable pulling stockings should be examined and placed over the nose of the
cable with care. The pulling rope or wire must be attached to the stocking in
such a way that the cable cap will not be damaged during the pull. The use of
swivels is recommended to prevent twisting of the stocking. The use of rope or
slings attached directly to the cable for the pull-in is not recommended.
Permissible mechanical forces are indicate in the section titled Mechanical
Forces on Cables during Installation. A dynamometer should be attached in line
with the pulling rope to indicate the pulling force exerted on the cable.
Bending radius of cables should not be less than what the cable manufacturer
recommends. Usually a minimum of 15 * the cable overall diameter is used.
One man should remain at the drum and brake the drum in order to maintain
the correct tension on the cable during the pull. If the drum is allowed to
continue turning when cable pulling has ceased, there is a danger of the cable
kinking or twisting.
Avoid twisting the cable, as it can result in bird caging of the armour wires and
subsequent damage to the outer serving of the cable. This is particularly
important if the cable is to be installed by the flaking (Figure of 8) method where
twisting within the cable is more prevalent, especially in areas with hot climates,
as the heat can soften the sheathing material resulting in lower tear resistance of
the material. If the flaking method is used, the radius of bend should be as large
as the available space allows, but never less than the supplier specified radius,
and the number of layers at cross-over points must not be excessive.

Cables should be pulled to their final position in a continuous manner.

Page 10 of 14

xvii.

Cables should be snaked on either side of each joint position to relieve the
joints of any thermo mechanical stresses.

xviii.

If a winch is being used to pull the cables and unavoidable sharp bends are
encountered, a snatch block could be used to assist the pulling tension at the
bend.

g. Sealing of cable Ends

Once the cable pull is completed, the nose end of the cable is carefully lifted off the
rollers and placed on the bottom of the trench, leaving enough slack to terminate the
cable and observing the minimum bending radius. Immediately after cutting, the cable
must be suitably sealed on both ends of the cut to prevent the ingress of moisture.
Examine the nose cap, and if any damage has occurred to it during pulling, the seal
should be replaced.
h. Bond Pulling
These techniques are applied when heavy cables are to be laid, or the trench undergoes
many changes in direction, or very long lengths of cable have to be laid, or a
combination of these.
As in the previously mentioned methods of cable pulling, the trench would have been
prepared with cable rollers, corner rollers and skid plates. Snatch blocks would have
been anchored to the sides of the trench at bends and a winch placed at the far end of
the section. At the near end a mobile bond carrier is placed conveniently adjacent to the
cable drum, ensuring that its braking system is adequate and that it has rewinding
facilities. A steel rope, more than twice the length of the cable to be pulled, is wound
onto the bond carrier drum and its end fed over the rollers and through the snatch
blocks and then secured to the drum of the winch.
Page 11 of 14

The cable end is manhandled onto the first rollers and tied to the steel rope (see below)
at intervals of about 2 meters. Start the winch and as the nose arrives at the snatch
block untie it from the steel cable, take it around the corner roller and retie on the
straight.

Once the nose has reached the winch end, and allowing the necessary slack, the cable
can be untied, the steel rope rewound onto the bond carrier. Further preparation for
backfilling may then be commenced.

i.

Backfilling and Reinstatement

Once the cables have been laid, and before commencing with backfilling, carry out a
visual inspection of the installation to ensure that :a) The cables are properly bedded.
b) Spacing between cables is correct, if there is more than one in the trench.
c) Cable entrances at ducts are suitably protected against possibility of vermin gaining
entrance.
d) Laying and pulling equipment has been removed.
e) That there is no obvious damage to the cable sheaths. (Up to 90% of the service
failures experienced in any cable system can be avoided if appropriate action is
taken at this stage).
Before jointing is commenced, most of the cable trench should be backfilled. Tip sifted
soil, or specially selected sand, into the trench and rake it smooth to cover
the cable to a depth of 150mm, then ram it well down by means of hand
compacting tools. DO NOT use mechanical compactors at this stage.
Backfill and consolidate all of the trench with the exception of the joint bays
in this way. Where necessary, lay suitable cover tiles to cover the whole
area in which the cables are buried.

Page 12 of 14

Above this backfill layer, the trench soil, if suitable, can be replaced and
consolidated, in layers of 150mm. A Mechanical compactor can be used at
this stage.
If a marker tape is required, install it at a depth of about 200mm below
the ground surface.

j.

Clamping or Strapping of cables on Racks or cable ladders

Similarly to cables installed for burial, once the cables have been laid on the racks or
cable ladders, carry out an inspection of the installation to ensure that :a) Spacing between cables and configuration is correct, if there is more than one
cable on the rack.
b) Laying and pulling equipment has been removed.
c) That there is no obvious damage to the cable sheaths. (Up to 90% of the service
failures experienced in any cable system can be avoided if appropriate action is
taken at this stage).
d) Where cable clamps are fitted, they have adequate cushioning material between
the clamp and the cable surface.
e) Where cable straps are fitted, that they are not excessively tight and do not have
sharp edges that may stress the cable serving material.

Available with Neoprene inserts

Page 13 of 14

We trust this basic procedure will assist you with your cable
installations.

References :Power Cables and their applications by Lothar Heinhold

Electric Cables handbook by Mc Alistair
BS 7671:2008 Requirements for Electrical Installations.
IEC 60364 Electrical Installations of buildings.
BS 8512:2008 Code of practice for the storage, handling, installation and disposal of
cables on wooden drums
SANS 0198 Code of practice for the selection, handling and installation of power
cables

Page 14 of 14