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1. PURPOSE
1.1. This is Chapter 1 of the ACCC® Conductor Installation Guidelines, covering general
installation subjects. The Guidelines consist of nine chapters, each written to stand alone to
address specific installation subjects. Taken together, the nine chapters comprise the entire
Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Required Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Terminations, Sagging, and Suspending
1.1.9. Chapter 9 — Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines,
recommendations and requirements necessary to safely and successfully install the ACCC®
composite-core bare overhead conductor and accessories. This document is an overview
and guideline covering what to do but not necessarily how to do it. It is not intended to
serve as a more intensive training manual or act as a substitute for proper training, required
personnel skill sets, or industry experience.
2. SCOPE
2.1. This guideline applies to equipment and techniques required to successfully install all sizes
of ACCC® conductor.
2.2. This guideline includes additional equipment and techniques that are required for Ultra-
Low Sag (ULS) ACCC® conductor sizes.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-O (where O stands for fully annealed) or
Aluminum 1350-O Z-wire trapezoidal wire.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalent
4.3. The remaining Chapters of the Installation Guidelines
5.3. The composite carbon core of ACCC® is much stronger than conventional steel core, and is
quite flexible, but not as flexible as equivalent steel core. Bending beyond a minimum
bending diameter will fracture the ACCC® core instead of yielding like conventional steel
core. This one difference accounts for almost all installation issues and drives nearly all of
the elements of the installation guidelines.
6.2.2. Pulling the conductor over a fence, pipe, wall, or other obstacle that presents a
bending diameter smaller than the minimum allowable
6.2.3. Hoisting a section of conductor or placing a side force on the conductor using a
hook, chain, rope, or narrow sling. When using a sling, spread the straps.
6.2.4. Hanging equipment or personnel from a conductor using a rope, hook, or narrow
strap.
X X
6.2.6. Poor brake operation on the payout reel, resulting in bouncing of the conductor on
the tensioner fairlead.
X X
✓ ✓
X
6.3. Sharp Angles
6.3.1. Any conductor stringing angle which is greater than 30 degrees, or any situation
that includes severe uplift or down pull must use a larger block, tandem sheave
blocks or multiple roller sheaves. Even with large sheaves, the extended contact
area between the sheave and the outer layer of aluminum strands will tend to
loosen the strands, especially at higher tension levels. To avoid loosening, always
use a larger block or tandem sheaves for sharp angles.
REVISION HISTORY
1. PURPOSE
1.1. This is Chapter 2 of the ACCC® Conductor Installation Guidelines, covering safety during
installation. The Guidelines consist of nine chapters, each written to stand alone to address
specific installation subjects. Taken together, the nine chapters comprise the entire
Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Required Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Sagging, Terminations, and Suspensions
1.1.9. Chapter 9 — Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines,
recommendations and requirements necessary to safely and successfully install the ACCC®
composite-core bare overhead conductor and accessories. This document is an overview
and guideline covering what to do but not necessarily how to do it. It is not intended to
serve as a more intensive training manual or act as a substitute for proper training, required
personnel skill sets, or industry experience.
2. SCOPE
2.1. It is far beyond the scope of these guidelines to present the required safety practices for
working high voltage transmission lines. Some extensive and effective safety procedures
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-O (where O stands for fully annealed) or
Aluminum 1350-O Z-wire trapezoidal wire.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors
or IEC or other governing body equivalent.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalents.
4.3. The remaining Chapters of the Installation Guidelines
6. GROUNDING
6.1. Disclaimer: Although the wording and pictures below are industry standards, it is always
the responsibility of the employer to create their own grounding program to protect their
employees and equipment.
6.2. CTC recommends equal potential grounding practices per OSHA 1910.269 or local
equivalent.
6.3. Grounds shall be sized to interrupt the maximum fault current that could be seen on the
installed conductor. Ground clamps with smooth inside surfaces are preferred to avoid
damage to the annealed aluminum. Serrated surface ground clamps may be used if
indentations are not created in the aluminum conductor wire surfaces.
6.4. During installation, grounds must be placed on ACCC® conductors, just as they would be
utilized on other transmission and distribution conductors. CONDUCTOR GROUNDS
MUST BE PLACED DIRECTLY ON THE ALUMINUM STRANDS. The composite core
is non-conductive.
6.5. Rolling Grounds should be in good condition, make good contact, and roll smoothly,
reference OSHA 1926.950. Rolling grounds should be used in addition to grounding mats
and NOT IN PLACE of equal potential grounding practices. Rolling grounds should be
placed in front of the puller and tensioner, not between the payout reel and tensioner.
6.6. De-energizing circuits, grounding including equal-potential grounding shall comply with
OSHA 1926.961, OSHA 1926.962, OSHA 1910.269 and/or country specific safety
requirements relating to de-energizing and grounding transmission and distribution lines.
6.7. Protecting workers on the ground. The employer may use several methods, including equal
potential zones, insulating equipment, and restricted work areas, to protect employees on
the ground from hazardous differences in electrical potential.
6.8. An equal potential zone will protect workers within it from hazardous step and touch
potentials. Equal potential zones will not, however, protect employees located either
wholly or partially outside the protected area. The employer can establish an equal
potential zone for workers on the ground, with respect to a grounded object, through the
use of a metal mats connected to the grounded object. The employer can use a grounding
grid to equalize the voltage within the grid or bond conductive objects and between the
objects and between object and ground. (Bonding an object outside the work area can
increase the touch potential to that object, however.)
6.8.1. Insulating equipment, such as rubber gloves, can protect employees handling
grounded equipment and conductors from hazardous touch potentials. The
insulating equipment must be rated for the highest voltage that can be impressed
on the grounded objects under fault conditions (rather than for the full system
voltage.)
6.8.2. Employees should be restricted from any step or touch potential not involved in the
stringing, deadending, or clipping processes. The employer must ensure that
employees on the ground in the vicinity of transmission structures are at a distance
where step voltages would be insufficient to cause injury. Employees must not
handle grounded conductors or equipment likely to become energized to hazardous
voltages unless the employees are within an equal potential zone or protected by
insulating equipment.
6.9. Live lines nearby can induce voltage and current into the conductor, especially parallel live
lines, and this is common when re-conductoring. ALWAYS follow recommended
grounding procedures.
6.10. Grounds shall never be removed without approval from the designated individual holding
the line clearance.
Appendix A — MSDS
REVISION HISTORY
1. PURPOSE
1.1. This is Chapter 3 of the ACCC® Conductor Installation Guidelines, covering installation
training. The Guidelines consist of nine chapters, each written to stand alone to address
specific installation subjects. Taken together, the nine chapters comprise the entire
Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Required Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Terminations, Sagging, and Suspending
1.1.9. Chapter 9 — Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines,
recommendations and requirements necessary to safely and successfully install ACCC®
composite-core bare overhead conductor and accessories. This document is an overview
and guideline covering what to do but not necessarily how to do it. It is not intended to
serve as a more intensive training manual or act as a substitute for proper training, required
personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully install all
sizes of ACCC® conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-
Low Sag (ULS) ACCC® conductor sizes.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-O (where O stands for fully annealed) or
Aluminum 1350-O Z-wire trapezoidal wire.
3.2. ULS – Ultra Low Sag. Conductor that has a stronger core and is used for heavy ice
conditions along with long spans across rivers, etc.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalent.
4.3. The remaining Chapters of the Installation Guidelines
4.4. CTC Installation Training Slides and accompanying Script (F-750-066)
5. TRAINING
5.1. CTC provides an ACCC® specific Installation Training course which consists of
approximately 2 to 4 hours classroom instruction, hands-on deadend / splice assembly
instruction, and up to 6 days of on-the-job training, for all new projects with previously
untrained crews.
5.2. Attendance by installation supervisor(s) should be mandatory. CTC strongly recommends
that all line personnel, safety inspectors, and construction crew(s) attend the ACCC®
Installation Training Course prior to the start of installation. Should a change in crew
supervision occur during the course of construction, ACCC® installation training should be
repeated before that crew starts work.
5.3. Improper installation equipment or methods could result in line damage or failure and are
not covered by the CTC Warranty.
5.4. An appropriate classroom equipped with digital projector is needed for the classroom
instruction portions of the ACCC® Training Course.
5.5. A language interpreter may be needed for presentation of training, both classroom and
hands-on.
5.6. The training course concludes with a written test. Graduates are issued an ACCC®
Installation Training Course Diploma.
REVISION HISTORY
1. PURPOSE
1.1. This is Chapter 4 of the ACCC® Conductor Installation Guidelines, covering ACCC®
conductor reel handling and storage. The Guidelines consist of nine chapters, each written
to stand alone to address specific installation subjects. Taken together, the nine chapters
comprise the entire Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Required Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Terminations, Sagging, and Suspending
1.1.9. Chapter 9 — Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines, and
requirements necessary to safely and successfully install the ACCC® overhead conductor
and accessories. This document is an overview and guideline covering what to do but not
necessarily how to do it. It is not intended to serve as a training manual or act as a
substitute for proper training, required personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully install all
sizes of ACCC® conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-
Low Sag (ULS) ACCC® conductor sizes.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-O (where O stands for fully annealed) or
Aluminum 1350-O Z-wire trapezoidal wire.
3.2. Terminology differs around the world when referring to the parts of a reel:
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalents.
4.3. The remaining Chapters of the Installation Guidelines
4.4. ACCC® Product Specification WI-750-023
4.5. ACCC® Conductor Reel Specification F-750-032
4.6. NEMA WC26-2008 Binational Wire and Cable Packaging Standard
6.4. Reels are constructed so that they must be supported either by the reel flanges from below
or on an axle (mandrel) through the arbor hole. When an axle through the arbor hole is used
to lift reels, a spreader bar must be employed to prevent damage to the reel flanges, or
conductor, or both, by inward force on the reel flange.
A spreader bar with slings or chains rigged vertically to each end of an adequately sized
axle through the arbor hole is the preferred method of hoisting. If a spreader bar is not
available at least 3 – 4 meter (15’) steel or nylon slings or lifting chains must be used to
prevent damage to the top of the reel flange
6.5. Returnable metal reels may be supported by a singletree arrangement that clamps to the
flange and is lifted from above.
6.6. Reels may be placed on flat ground or floor. Always chock the reel flanges (never chock
under the conductor itself or it’s protective lagging) to prevent rolling.
6.7. At no time shall a loaded reel be laid on its side either during handling, loading, unloading
or storage.
X X
7.2. Identification tags and other markings should be retained on all packages until the
conductor is to be used. Identification tags should be protected from weather to retain
information.
7.3. The reels are delivered from the factory with a protective wrapping which could include
wood lagging and/or fiber board held down with steel bands over the outermost layer of
conductor. The outermost protective covering should be left on the reels if stored for an
extended period of time.
REVISION HISTORY
1. PURPOSE
1.1. This is Chapter 5 of the ACCC® Conductor Installation Guidelines, covering installation site
considerations and set-ups. The Guidelines consist of nine chapters, each written to stand alone to
address specific installation subjects. Taken together, the nine chapters comprise the entire
Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Required Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Sagging, Terminations, and Suspending
1.1.9. Chapter 9 — Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project managers
and planners, field inspectors, utility personnel and linemen with guidelines, recommendations and
requirements necessary to safely and successfully install the ACCC® composite-core bare overhead
conductor and accessories. This document is an overview and guideline covering what to do but
not necessarily how to do it. It is not intended to serve as a more intensive training manual or act as
a substitute for proper training, required personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully install all sizes of
ACCC® conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-Low Sag
(ULS) ACCC® conductor sizes.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-O (where O stands for fully annealed) or
Aluminum 1350-O Z-wire trapezoidal wire.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalents.
4.3. The remaining Chapters of the Installation Guidelines
5. SITE CONSIDERATIONS
5.1. Setup areas
5.1.1. Setup areas, where conductor reel handling equipment will be placed, must allow for
access for the delivery, unloading and handling of new reels of conductor, and for the
loading and handling of take-up reels. Additional detail regarding storage and handling of
conductor reels is found in Chapter 4.
5.1.2. Setup areas must allow for access by and proper placement of payout reel stands and
tensioners. The tensioner should be positioned at least three (3) times the height of the first
structure back from the first structure. The payout reel must be at least 50’ (15 meters)
away from the tensioner. See 6.1.
5.1.3. With proper use of sheaves, the tensioner and / or payout reel equipment may be offset to
avoid obstacles or take advantage of better setup areas.
5.1.4. Tensioners and payout reel stands must be prevented from shifting or movement during
use. In some soil conditions, this can be done with screw anchors or dug-in “dead man”
anchor. In some cases, concrete weighting may be used. Often, large trucks or heavy
equipment is used for anchoring.
5.1.5. For bundled conductor projects, conductor bundles should be pulled simultaneously.
Allow for extra sets of payout reels, tensioners, and pullers at setup areas. Additional
detail regarding bundled conductor considerations is found in Chapters 7 and 8.
5.1.6. Clearance distances from existing electric power lines shall be respected and maintained:
Voltage Minimum Clearance Minimum Clearance
(nominal, kV, alternating current) Distance (feet) Distance (meters)
up to 50 10 3
over 50 to 200 15 5
over 200 to 350 20 6.5
over 350 to 500 25 8
over 500 to 750 35 11
over 750 to 1,000 45 14
over 1,000 * *
* (as established by the utility owner/operator or registered professional engineer who is a
qualified person with respect to electrical power transmission and distribution).
Note: The value that follows "to" is up to and includes that value. For example, over 50 to 200
means up to and including 200kV.
Note: This table from OSHA 1906.1408
5.1.7. Live lines nearby can induce voltage and current into the conductor, especially parallel
live lines, and this is common when re-conductoring. ALWAYS follow recommended
grounding procedures.
6. SET-UPS
6.1. Payout Reel / Tensioner Set-up
6.1.1. Minimum Required Distance between Tensioner and First Structure: The tensioner
must be placed three times the height of the first structure back from the structure.
6.2.2. The tensioner Feed Sheave shall be the same or greater diameter as the first and last
structure sheaves.
6.2.3. The Tensioner Feed Sheave may also be used, if properly positioned and mounted, to
facilitate alignment differences between payout reel, tensioner, and first structure.
6.2.4. For bundled applications, use individual sheaves between each payout reel and the
tensioner to allow for slight differences in payout speeds or tensions and differences in
payout stand placements and conductor path adjustments.
X ✓
©2017 CTC Global- For use with ACCC® Conductor only
ACCC® Conductor Installation Guidelines
Chapter 5 – Site Considerations & Set-ups
WI-750-074 Rev C Page 7 of 9
6.3.3. Assure that contact between the sheave and the structure itself does not restrict the
alignment between the sheave groove and conductor path.
X
6.4. Restricted Area Alternatives
6.4.1. The purpose of the 3:1 rule (paragraph 6.1.1) is to keep the angle of the conductor over the
first sheave under about 20° and to provide sufficient length for the conductor to absorb
the opening of strands that tends to occur when any helical wound conductor passes over a
sheave under tension. When set-up areas are restricted and the 3:1 rule cannot be achieved,
the alternatives are, in order of preference:
6.4.2. Use a larger sheave at the first structure.
6.4.3. Use a tandem sheave block at the first structure.
6.4.4. Reduce the height of the first structure sheave.
6.4.5. Move the set-up area for tensioner / payout reel to the other direction side and pull that
reel in from the other direction.
6.4.6. Skip that set-up area: pull back-to-back reels instead (usually last choice).
6.4.7. The choice of alternatives is best made by experienced personnel based on site conditions.
In all cases, watch for strand opening at the tensioner and each sheave. If opening is
observed, reduce stringing tension if possible.
6.5. Back-to-Back Reel Pulls
6.5.1. Reels of ACCC conductor may be pulled back-to-back for a variety of reasons including
to avoid difficult setup areas. Two reels to four reels may be pulled back-to-back,
sometimes more, please check with CTC Field Service. As a guideline, pulls should not
be more than 20 spans. See Chapter 7 for specific guidelines for pulling multiple reels.
B April, 2016
1. PURPOSE
1.1. This is Chapter 6 of the ACCC® Conductor Installation Guidelines, covering required tools
and equipment. The Guidelines consist of nine chapters, each written to stand alone to
address specific installation subjects. Taken together, the nine chapters comprise the entire
Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
2. SCOPE
2.1. These guidelines apply to specific equipment and techniques required to successfully install
all sizes of ACCC® Conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-
Low Sag (ULS) and Ultra-High Strength (AZR™) (Ice Load) ACCC® Conductor types
and bundled conductor installations.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-0 (where 0 stands for fully annealed) or
AT3 Aluminum Zirconium alloy in trapezoidal or Z-trapezoidal wire configurations.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524Ô Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalent.
4.3. The remaining Chapters of the Installation Guidelines
5.4.4. Metal Reel Stands are equipped with a mandrel that supports the weight of the reel
and arm(s) with drive pins that fit into matching holes in reel flanges and effect the
rotational control of the reel. Wooden reels can be used with metal reel stands as
long as there is a hole in the side of the reel to anchor the wooden reel with the pin
that controls the reel.
5.4.5. Whether stands are designed for metal or wooden reels, rotational control is
typically provided by either disc brakes or hydraulic motor. Hydraulic motor
braking is strongly preferred for ACCC® Conductor installation. If disc brakes are
used, the brakes must be in excellent condition and fully capable of quickly and
smoothly stopping a full reel rotating at payout speed.
5.5. Tensioner
5.5.1. Tensioner bull wheels must be a minimum diameter as specified in Appendix B,
measured at the bottom of the grooves of the bull wheel.
5.5.2. Only multi-groove tensioners and a minimum of four grooves should be used. The
number of grooves in the bullwheel shall be sufficient to prevent conductor
slipping and to maintain good tension control.
5.5.3. Tensioner bull wheel groove radius should be minimum .55 times conductor
diameter to help control strand opening.
5.5.4. Tensioner bull wheel grove material shall be hard enough to avoid friction on outer
layer of strands sufficient to cause strand loosening or birdcage.
5.5.5. See Section 6.1 for bundled applications.
5.6. Tensioner Fairlead
5.6.1. Poor tension control of the conductor feeding the tensioner will cause the
conductor to bounce or pull tight on the rollers of the tensioner fairlead. This will
damage the conductor core. Poor tension control at the fairlead is always caused
by poor control of the brake on the payout reel stand, due either to poor condition
or under capacity brake, or brake operation error. This has been the most common
installation error in the history of ACCC®. It is critical to a) maintain good control
of payout reel braking and b) correctly set-up the tensioner fairlead.
5.6.2. A curved, multi-roller (banana) fairlead on the input side of the tensioner is highly
recommended for use with ACCC®Conductor. Pictured below is Tesmec/Condux,
fairlead part number AYU077.
5.9.2. Wedge Type Clamps are suitable alternative. Must be rated for the loads and use
inserts correctly sized for the conductor diameter. Do not use wedge grips for
pulling conductor. Use only for applying sagging tensions.
5.9.3. Tension grips and clamps should be inspected for rough surfaces and rough edges
which may scratch or gouge the soft aluminum surface strands of ACCC®. Rough
edges or surfaces must be corrected with fine tooth file or sandpaper.
5.11.2. Chain Hoist. Ensure that the hoist rating exceeds the loads.
X ✓ ✓
5.12. Puller
5.12.1. Ensure that pulling machine rating exceeds the calculated loads.
5.13. Swivels
5.13.1. Pulling swivels must be in good condition, rotate freely, and be rated for the
pulling tensions.
5.14.1.3. Fine Tooth (32 TPI or more) Hacksaw. In all cases, the final cut of
ACCC® core MUST be made with a fine tooth hacksaw!
5.14.1.4. Metal File – Smooth tooth, to remove flashing from deadend or splice
crimping process.
When odd numbers of sub conductors are strung, the center one could follow the pulling
line in the center sheave. However, this is usually not desirable because of the material of
the groove or because of contaminants deposited in this groove by the pulling line, or
because of both.
Offset-type bundle conductor travelers are used that balance the load by properly spacing
the even and odd number(s) of conductors on each side of the pulling force. These travelers
are directional and should be color-coded. Care should be taken to ensure their proper
orientation.
6.5. Running Board or Balance Board
A special device called a “running board” or “balance board” (or “gator”) distributes the
pulling force from a single pilot line to the conductors evenly, establishes the spacing, and
prevents the conductor bundle from twisting during pulling with a heavy “tail” which keeps
the board level as it travels between structures. These should be used when pulling multiple
conductors.
Multi-sheave bundle conductor type travelers and running boards must be designed to
complement each other and work in unison. Running boards should have their safe working
load displayed.
6.6. Puller
Pullers and winches must be capable of the required pulling forces. In bundled applications
this is the sum of all the conductors plus the pulling line. Note: pulling force will increase
approximately 2% at each block, for each subconductor.
Notes:
1) Diameters above are WORKING diameters, measured at bottom of groove
2) One working size diameter smaller is allowed for sheaves in intermediate or tangent structures unless large belly or total angle > 20°
3) For total conductor angle > 35° contact CTC Global Field Service (fieldservice@ctcglobal.com)
F-750-069-D
Compression Die Chart
REVISION HISTORY
REV
CHANGE REQUEST # DATE
.
A 121515-1
1. PURPOSE
1.1. This is Chapter 7 of the ACCC® Conductor Installation Guidelines, covering ACCC
Conductor stringing or pulling. The Guidelines consist of nine chapters, each written to
stand alone to address specific installation subjects. Taken together, the chapters comprise
the entire Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Tools and Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Terminations, Sagging, and Suspending
1.1.9. Chapter 9 — Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines,
considerations, and requirements necessary to safely and successfully install the ACCC
composite-core bare overhead conductor and accessories. This document is an overview
and guideline covering what to do but not necessarily how to do it. It is not intended to
serve as a more intensive training manual or act as a substitute for proper training, required
personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully install all
sizes of ACCC® Conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-
Low Sag (ULS) and Ultra-High Strength (AZR™) (Ice Load) ACCC® Conductor types
and bundled conductor installations.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-0 (where 0 stands for fully annealed) or
AT3 Aluminum Zirconium alloy in trapezoidal or Z-trapezoidal wire configurations.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524Ô Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalents.
4.3. The remaining Chapters of the Installation Guidelines
7.4. ALWAYS anchor the far end of the wire mesh sock. Preferred anchor method is two bands
using the banding tool and appropriate banding (see Chapter 6). Alternatively, two screw-
type radiator hose clamps may be used. NEVER anchor the sock anywhere except on the
END furthest from the eye.
7.5. Tape the anchor. It is CRITICAL that the anchoring installed above is completely covered
by plastic electrical tape to protect the lining on the blocks and assure smooth travel
through blocks.
7.6. Tape between the eye and end of the sock, to prevent the core retainer (bug) from coming
out of the sock and to protect the lining on the blocks and assure smooth travel through
blocks.
7.7. When removing the sock after use, all of the protective tape MUST also be removed from
the sock. The tape will retain moisture and cause rusting which will weaken the sock and
may cause it to fail.
7.8. There may be occasions when it is necessary or desirable to pull a long (single) span with a
deadend attached. Never pull a deadend through a sheave. Always be very careful of
creating sharp angles in the conductor where it exits the deadend.
to assist the tensioner in supplying stringing tension. The payout reel braking system must
be in good operating condition. It is NEVER acceptable to use or operate a payout reel that
does not have a working brake system.
9.2. Correct operation of the payout reel brake is critical to maintain even, light tension between
the reel and the tensioner. Brake tension should be set just high enough to prevent over-run
when the pulling stops. Never use the payout reel brake to supply stringing tension, that is
the job of the tensioner machine.
9.3. If the brake tension is too high the conductor may begin to wedge into the underlying
layers on the reel which will damage the conductor and may damage the core.
9.4. As the reel empties, the moment arm available to overcome the brake drag is reduced, and
therefore the tension rises. This may cause the conductor to wedge
into the underlying layers on the reel which may damage the
conductor core. Hydraulic braking systems automatically avoid this
condition. For other braking systems, it is important to periodically
adjust the brake as the conductor is payed out.
be coming out of the right side of the tensioner. If conductor is left hand lay, this is
reversed.
10.1.3. Incorrect tensioner feed (in = right, out = left) will cause loosening of the strands on
the tensioner and could result in bird-caging.
10.1.4. The material and finish of the grooves must be maintained properly so it will not
damage the surface of the conductor. Lined grooves are recommended for all
conductors, but are particularly important for non-specular finished conductors.
Groove material must be relatively hard. Soft groove material will promote loosening
of strands and birdcaging as it proceeds through the bull wheels. When a semi-
conducting elastomer is used for lining the grooves, it must not be relied upon for
grounding.
10.1.5. The tensioner should be threaded with conductor using a rope around the bull wheels.
Install a core retainer (bug) on the conductor per Section 6, install the pulling sock per
Section 7 and attach the sock to an approved swivel. The swivel is then attached to the
rope. The rope then pulls the conductor through the tensioner bull wheels. See Section
11 below.
10.2. As the puller advances conductor through the pull, it is the tensioner which controls the
tension on the pull and the sag or “bellies” in the spans of the pull.
10.3. Constant, open, priority communication between puller operation and tensioner operation is
required to coordinate stops, starts, and speed of the pull.
10.4. Tensioner and puller operation is critical and must be accomplished by experienced
operators, familiar with all of the controls of the tensioner and the puller.
10.5. Never use the tensioner “emergency” stop function for normal stoppages in the pulling
process. The sudden emergency stop can over-tension the conductor.
10.6. Synchronized Tensioner-Payout Reel Stand Operation.
10.6.1. Tensioner / Payout Reel Stand equipment may be equipped with hydraulic
synchronization. Synchronized operation is strongly preferred for ACCC installation.
In this case, the tensioner operator also operates the braking functions of the payout
reel and is responsible for smooth operation of the payout reel as above. It is critical
that the tensioner operator takes out the belly of the conductor between the reel and the
tensioner before the pull begins.
11.3. If the old conductor has ANY splices, they must first be cut out and replaced with two
socks (wire mesh grips) connected with a swivel or a double sock.
11.4. If the old conductor has is rusted or has broken strands, then a pulling (pilot wire) line must
be used. The condition of static wire may be used to help evaluate the condition of the
existing conductor.
12.2. Never use manually operated block and tackle or rope hoists to lift ACCC Conductor. The
bouncing of the conductor created by the start/stop such method can damage the conductor
where acceptable bending would normally exist. Use a capstan hoist to pull the conductor
up smoothly.
X ✓
13. STRUCTURE SHEAVES
13.1. Sheaves sizes are always required to respect minimum working diameters, see Appendix B.
13.3. The sheaves in a tandem set must have their axles rigidly mounted together such that the
sheave flanges are close and the sheaves relatively fixed.
13.4. Tandem sheaves must be mounted to allow free movement of the tandem set in the plane of
the pull. If the sheaves are not allowed to pivot as a pair, they cannot share the load and
halve the angle as intended.
Where structures introduce changes in line or right-of-way angles, sheaves will not be
vertical. Rig sheaves to stay in the plane of the conductor path.
14. PULLER
14.1. If there is room, use the same 3:1 ratio for distance from the tower to the height of the
tower, as was used for the tensioner set-up. In this case ACCC Conductor may be pulled
through the last sheave if it is minimum working diameter or greater.
14.2. An alternate set-up is to use “square rigging” wherein a sheave is used at the arm where the
conductor is being pulled, another where the arm is attached, another at the square of the
structure and one at the bottom of the structure. Do not pull ACCC Conductor through any
of these sheaves.
17. BIRDCAGE
17.1. Loosening and opening of the conductor strands, commonly called “birdcage” is not a
failure, is difficult to avoid in some special situations, and can usually be corrected.
17.2. There are three causes (or “sources”) of birdcage or strand loosening. In all cases, the
loosening normally appears not at the source, but where the strands are constrained near the
source. If the nearest constraint is far enough away (about 15m in the case of ACCC
Conductor), the strands have room to distribute the displacement and the loosening is not
noticeable.
17.3. The first cause is displacement of the aluminum in each strand as a result of compression of
the conductor, either in a grip or installation of a compression sleeve – deadends and
splices for example. These can usually be avoided by making successive compressions
away from the constraint.
17.4. A second cause is also displacement of the aluminum in each strand which can occur if the
conductor passes over a sheave with an incorrect groove size, under tension. Sheave
groove radius should be 0.53 to 0.55 times the conductor diameter.
17.5. A third cause occurs if there is key-stoning of the top layer of conductor. This may allow
relative movement between the layers, effectively allowing displacement of the top layer.
Keystone is normally a defect in the stranding of the conductor.
17.6. If loosening occurs, it often takes care of itself when the constraint is removed, allowing
the displacement to re-distribute over a longer length of conductor and become
unnoticeable.
17.7. The re-distribution can be assisted if necessary, by applying pulling force after the
constraint has been removed. Tapping the conductor with a rubber hose can supply
vibration which facilitates the re-distribution.
17.8. Never strike the conductor with wood or hammer in an effort to address a bird cage
condition. Never attempt to realign strands with screwdriver or other tools.
17.9. Extreme birdcage, when the loosening causes severe plastic deformation of the strands,
cannot be corrected and must be replaced.
20.1. When line design calls for multiple conductors per phase, additional considerations for
stringing and pulling are required.
20.2. All of the guidelines for single conductor pulling apply to bundled pulling. This section
identifies additional concerns, requirement, and special equipment.
20.3. All conductors in the phase bundle may be pulled in simultaneously using a single pilot
line. Because the cost of pulling line failure is multiplied by the number of conductors,
new pilot line is required. Size the pilot line for the cumulative loads of the individual
conductors and remember to add 2% to the total pulling tension for each structure.
20.4. If sub-conductors in a bundle must be pulled in separately, or in groups less than the entire
bundle, the “alternate” sagging procedures (Chapter 8, Section 9.5) must be used.
20.5. Site considerations and set-ups have additional consideration for bundled applications. See
Chapter 5.
20.6. Pulling multiple conductors simultaneously requires some specialized equipment. See
Chapter 6.
20.7. Pulling multiple conductors simultaneously requires some specialized methods:
20.7.1. Tensions of the individual sub-conductors in the bundle must be adjusted to provide
for the same belly or sag between sub-conductors during the pull.
Tensions of the individual sub-conductors in the bundle must be adjusted to keep the
running board horizontal and level, except when the running board approaches a
structure that introduces an angle in the right-of-way. The sheave block at such a
structure should be rigged to match the plane of the conductor path – it will not be
perfectly vertical. As the running board approaches any sheave block, the stringing
speed should be slowed. For angles, the tension of sub-conductors should be adjusted
such that the angle of the running board matches the angle of the sheave block before
the running board enters the block.
20.7.2. Pulling at constant speed is critical for a smooth stringing operation. 5 km/h (3.1 mph)
is the maximum recommend pulling speed.
20.8. Sagging ACCC bundled conductors must be done correctly to achieve desired sag
performance. See and follow the Guidelines in Chapter 8 for Bundled Conductors.
22. REWINDING
22.1. If conditions arise that excess ACCC Conductor must be rewound on its reel, the conductor
can be rewound either manually or hydraulically and shall have medium-light back tension
applied at all times. The conductor MUST NOT be allowed to cross over itself during the
rewinding process. When tension is applied to such cross-overs, the core may be damaged.
22.1.The conductor MUST NOT be allowed to rub or scrape on the reel flanges during
rewinding. This will damage the soft aluminum surface of the conductor and may deform
the strands.
23.SPECIAL CONDITIONS
23.1. Weather
23.1.1. No special considerations exist for ACCC Conductor installation with respect to any
other conductor installation, due to weather conditions.
23.2. Live Lines
23.2.1. No special considerations exist for ACCC Conductor installation with respect to any
other conductor installation, when working live. CTC recommends strict adherence to
the procedures for working energized lines found in IEEE-516.
23.3. Long Spans, Crossings
23.3.1. It is especially important to respect minimum sheave diameter requirements for long
spans. For long spans, use a pilot line (hard line). See Section 19.
23.4. Mountains, Swamps, Inaccessible Terrain
23.4.1. Where structures are inaccessible for a variety of reasons, transport of materials may
require special measures including helicopter, off-road vehicles, work animals, or even
by foot in some extreme cases.
23.4.2. Where tensioned stringing equipment cannot be optimally located, long pulls and
pulling through dead-end structures (paragraph 18) may be considered, or manual
stringing techniques (paragraph 21) may be employed.
23.4.3. CTC offers ACCC® Stringing Plan Review Service℠ for help with planning for
successful installation of ACCC Conductor in exceptional, challenging, and difficult
applications. Please contact Fieldservice@ctcglobal.com
23.5. Mountains, Large elevation changes
23.5.1. Where a single pull includes large elevation changes, the stringing tenstion is
increased by the net weight of the conductor in the vertical change. This must be
accounted for when selecting and sizing equipment and tooling. Respect equipment
and tooling load ratings and use new and/or test all equipment which will be exposed
to tension loads.
23.5.2. This increased stringing tension must not exceed the final sag tension or sag behaviour
will be affected.
23.5.3. It is generally preferable to pull from high to low when possible because better tension
control can be achieved from the tensioner machine and because tension loads on the
pulling wire or line are minimized versus pulling uphill.
23.6. Please contact CTC for advice regarding special conditions not covered in the installation
guidelines: Fieldservice@ctcglobal.com
Notes:
1) Diameters above are WORKING diameters, measured at bottom of groove
2) One working size diameter smaller is allowed for sheaves in intermediate or tangent structures unless large belly or total angle > 20°
3) For total conductor angle > 35° contact CTC Global Field Service (fieldservice@ctcglobal.com)
REVISION HISTORY
1. PURPOSE
1.1. This is Chapter 8 of the ACCC® Conductor Installation Guidelines, covering ACCC®
Conductor sagging, suspensions, terminations, and ancillary hardware. The chapter also
covers sagging of bundled conductors. The Guidelines consist of nine chapters, each
written to stand alone to address specific installation subjects. Taken together, the chapters
comprise the entire Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Tools and Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Terminations, Sagging, and Suspending
1.1.9. Chapter 9 — Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines,
recommendations and requirements necessary to safely and successfully install the ACCC®
composite-core bare overhead conductor and accessories. This document is an overview
and guideline covering what to do but not necessarily how to do it. It is not intended to
serve as a more intensive training manual or act as a substitute for proper training, required
personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to specific equipment and techniques required to successfully install
all sizes of ACCC® Conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-
Low Sag (ULS) and Ultra-High Strength (AZR™) (Ice Load) ACCC® Conductor types
and bundled conductor installations.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-0 (where 0 stands for fully annealed) or
AT3 Aluminum Zirconium alloy in trapezoidal or Z-trapezoidal wire configurations.
3.2. Initial Sag occurs when new conductor is pulled, deadended and connected.
3.3. Initial Sag Tension is the target “Initial” tension from the design sag charts.
3.4. Final Sag occurs when the conductor is at or above its thermal kneepoint. Thermal
kneepoint is the temperature at which all of the tension load is on the ACCC® core, and the
aluminum strands share of the tension load is zero.
3.5. Ruling Span is the calculated span length that will have the same changes in conductor
tension due to changes of temperature and conductor loading as will be found in a series of
spans of varying lengths between deadends.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524Ô Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalents.
4.3. IEEE Standard 516Ô Guide for Maintenance Methods on Energized Power Lines
4.4. The remaining Chapters of the Installation Guidelines
5. SAGGING
5.1. This guideline assumes that the user is familiar with industry standard sagging techniques.
5.2. There is nothing unique about sagging procedures for ACCC® Conductor versus any other
bare conductor, however the annealed aluminum causes ACCC® Conductor to be more
sensitive to over-tension and creep time with respect to sag. Follow the recommendations
below to achieve expected sag performance.
5.3. Any of the four common methods of sagging may be used: line of sight, transit, stopwatch,
or dynamometer.
5.4. Sagging Procedure:
5.4.1. Assemble and connect the soft-side deadend.
5.4.2. Apply tension, at least 90% of initial sag tension, but DO NOT EXCEED initial sag
tension.
5.4.3. Allow the conductor to remain at this tension for at least 10 hours or overnight. If
sagging must be done same day, subtract 5° C (9° F) from the conductor temperature
in the sagging chart.
5.4.4. Apply sag chart tension and mark the conductor for deadending
5.4.5. Assemble hard-side deadend and connect to insulator linkage. It is recommended that
hard siding be done in the air and not lowered to the ground.
6. INSTALL GRIPS
6.1. NEVER use wire mesh or “sock” grips for sagging, only parallel jaw or wedge type
grips.
6.2. The free end of the conductor MUST be supported during installation of grip and deadend
hardware. This may be done with small ropes.
6.3. Grips are heavy and awkward, especially for larger size conductors. The free end of the
conductor MUST be controlled to prevent over-bending and possible damage of the core.
Good working platforms (hook ladders, bucket trucks, baker boards) should be provided
for personnel for these operations.
6.4. The grip should be attached 4-5 meters (12 – 15’) from the end of the insulator to provide
working room to install the deadend hardware. Install a split rubber hose over the
conductor to protect the aluminum from the rigging. Use small ropes to fasten the free end
of the conductor to the rigging.
6.5. Set the grip. It is permissible to “set” a grip after placement on the conductor and after
taking a small amount of tension on the grip, then sharply strike it’s lever arm with a
hammer once or twice.
8. TERMINATIONS
8.1. Dead-Ends
Installing ACCC® Conductor deadends is very similar to installing deadends for any common
bare overhead conductor with two exceptions:
8.1.1. Conductor, Grip, and Deadend Handling. The weight of the deadend and/or conductor
is sufficient to damage the ACCC®core at the point where it exits the grip. The
deadend must be supported in line with the conductor during installation and
subsequent handling.
but DO NOT EXCEED initial sag chart tension. All conductors in a phase bundle
must be brought up to this tension within a few minutes of one another.
9.4.6. Allow the conductors to remain at this tension for at least 10 hours or overnight. If
sagging must be done same day, subtract 5° C (9° F) from the ambient temperature
from the sagging chart.
9.4.7. Apply sag chart tension and mark the conductor for deadending. All conductors in a
phase bundle must be brought to the target tension and marked as closely as possible
at the same time…all within maximum 15 minutes of each other.
9.4.8. Suspension (clipping) of bundled conductors must be done together for all the
conductors in the bundle.
9.5. Bundled Sagging Procedure – Alternate
9.5.1. This alternate procedure should be used when sub conductors have not been strung
simultaneously or brought up to the target sag within 15 minutes of each other.
9.5.2. This alternate procedure includes leaving conductors in sheaves for extended
periods. Risk of high wind lifting the conductors out of their sheave grooves exists
which may damage conductor or core. Do not use this alternate procedure when
high wind conditions exist or are forecast.
9.5.3. Turnbuckles or sagging links are required for final sag tension adjustment.
9.5.4. Assemble and connect the soft-side deadends.
9.5.5. Place the conductor in sheaves at each tower which are positioned at the bundle’s
final horizontal spacing and location to provide proper wire length in the clipped-in
position.
When multiple conductors are strung in bundled conductor type travelers, reduced
horizontal spacing between grooves can result in conductor oscillation, even in a
very light crosswind, too severe to permit satisfactory sagging.
9.5.6. Apply tension to all sub-conductors, AT LEAST 90% of initial sag chart tension, but
DO NOT EXCEED initial sag chart tension.
9.5.7. Allow the conductor to remain at this tension for AT LEAST 72 hours after initial sag
chart (90% or greater) is applied to the LAST sub-conductor pulled.
9.5.8. Apply sag chart tension or sag and mark one conductor for deadending.
9.5.9. Match the sag (not tension) of the remaining sub-conductors to the first one.
9.5.10. Assemble the hard-side deadends and connect
9.5.11. Make final adjustments to match sag of all subconductors with the turnbuckles or
sagging links.
9.5.12. Suspension (clipping) of bundled conductors must be done together for all the
conductors in the bundle.
See IEEE-524 2004, Annex E for calculations and further detailed information.
Consider CTC’s ACCC® Stringing Plan Review Service℠ for technical installation
assistance. Contact us at fieldservices@ctcglobal.com.
REVISION HISTORY
A 121515-1
Added paragraph 10.2
B Added Section 10.5, “Sagging Bundles” 3/1/2016
1. PURPOSE
1.1. This is Chapter 9 of the ACCC® Conductor Installation Guidelines, covering ACCC®
maintenance and repair. The Guidelines consist of nine chapters, each written to stand
alone to address specific installation subjects. Taken together, nine ten chapters comprise
the entire Installation Guidelines:
1.1.1. Chapter 1 — General Installation Guidelines
1.1.2. Chapter 2 — Safety
1.1.3. Chapter 3 — Training
1.1.4. Chapter 4 — Reel Handling and Storage
1.1.5. Chapter 5 — Site Considerations and Set-ups
1.1.6. Chapter 6 — Required Equipment
1.1.7. Chapter 7 — Stringing / Pulling
1.1.8. Chapter 8 — Sagging, Terminations, and Suspensions
1.1.9. Chapter 9 — Maintenance & Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines,
recommendations and requirements necessary to safely and successfully install and repair
ACCC® composite-core bare overhead conductor and accessories. This document is an
overview and guideline covering what to do but not necessarily how to do it. It is not
intended to serve as a more intensive training manual or act as a substitute for proper
training, required personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully maintain and
repair all sizes of ACCC® conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-
Low Sag (ULS) ACCC® conductor sizes.
3. DEFINITIONS
3.1. ACCC® is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-O (where O stands for fully annealed) or
Aluminum 1350-O Z-wire trapezoidal wire.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalents.
4.3. The remaining Chapters of the Installation Guidelines
5. MAINTENANCE
5.1. Once installed, maintenance of ACCC® conductor consists simply of periodic inspection
for environmental damage, structure degradation, broken insulators, vegetation
encroachment, or other issues, and then repair of such damage, exactly as any other bare
overhead conductor.
5.2. Conductor Trolleys
5.2.1. There are no special requirements for the use of conductor trolleys on undamaged
conductor. If aluminum strand damage is observed and the condition of the core is
suspected to have been compromised, then a conductor trolley must not be used for
access and an alternative source of access should be used to allow further detailed
investigation.
6. REPAIR METHODS
6.1. All conductor damage should be inspected carefully and an accurate count of the number of
damaged strands to correctly identify the most appropriate repair.
6.2. If aluminum strand damage is observed and the condition of the core is suspected to have
been compromised, then a conductor trolley must not be used for access. Alternative
method of access should be used to allow further detailed investigation.
6.3. There are three methods of repair techniques for repairing damage to ACCC® conductor
that are available:
6.3.1. Pre-formed Helical Repair Sleeve (96” armor rod)
6.3.2. Compression Repair Sleeve
6.3.3. Mid-span Splice (ACCC® Splice)
6.4. Conventional methods are used to repair ACCC® conductor strands. Aluminum Repair
Methods:
Number of Damaged Helical Preform Compression
Aluminum Strands Repair (96”) Repair Mid Span Joint
1 Outer Layer Strands X X --
2 Outer Layer Strands -- X --
3+ Outer Layer Strands -- -- X
Any Inner Layer Strands -- -- X
6.5. Example One: Aluminum strand damage only. Use appropriate repair method from table
above.
6.6. Example Two: Conductor is damaged and core is damaged in a single area. Remove
damaged core area and install a mid-span splice.
6.7. Example Three: Conductor is damaged and core is damaged over a larger area than can be
replaced by a single splice. Using splices, replace 50’ to 100’ (15 to 30 m) of conductor
per each phase that is damaged. Keep splices at least 50’ (15 m) away from any structure.
6.8. Example Four: Conductor is damaged mid-span and also at one structure at the armor rod
suspension. Using splices, replace all damaged conductor, keeping splices at least 50’ (15
m) from any structure.
6.9. Example Five: Conductor is damaged and core is damaged in a dead-end span. Add a
section of conductor with a splice and add a new dead-end.
7. REPAIR GUIDELINES
7.1. Never install a splice any closer than 50’ (15 m) from a structure.
7.2. Repairs must always be made with materials and components which are rated for ACCC®
operating temperatures (180° C).
7.3. The minimum distance from a repair sleeve to another fitting on the conductor shall be
1.2m, this includes other repair sleeves. (If the repair sleeve is moved closer to the
deadend, the conductor strands may loosen and open and remain open).
7.4. A spacer damper of the appropriate size should be fitted 2 - 8 m from the repair sleeve to
prevent sub-conductor clashing near the repair.
7.5. ACCC® splices or dead-ends cannot be installed via live line maintenance because of the
mechanical way that the splice or dead-end fasten the core.
REVISION HISTORY
A 8 May 2012
B 10 May 2012
C 31 July 2013