ACCC Installation Guidelines PDF

ACCC-TW Conductor Installation
Guidelines

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A Division of Composite Technology Corporation

1. PURPOSE

1.1.The purpose of this document is to provide experienced transmission engineers, field
inspectors, utility personnel and linemen with guidelines, recommendations and
requirements necessary to safely install the ACCC-TW composite-core bare overhead
conductor. This document is intended to provide an overview of the differences in
installation techniques between the composite-core ACCC-TW conductor and
conventional steel-core conductor, but is not intended to serve as a more intensive training
manual or act as a substitute for required personnel skill sets or industry experience.

2. SCOPE

2.1.These guidelines apply to equipment and techniques required to install ACCC conductor.

3. TRAINING

3.1.CTC strongly recommends that all linemen, safety inspectors and construction crew attend
a CTC sponsored training seminar prior to or in conjunction with the pre-construction
meeting, at a time and place agreed to by all parties. Attendance by all Installation
Supervisors is mandatory prior to the start of construction. Should a change in crew occur
during the course of construction, CTC should be notified as soon as possible so that
additional field training and support can be provided in a timely manner. Improper
installation techniques are not covered by the CTC Warrantee Program and could result in
premature line failure.

4. ASSOCIATED DOCUMENTS

4.1.IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors.

5. DEFINITIONS

5.1.ACCC/TW is defined as Aluminum Conductor Composite Core Trapezoidal Wire.

6. RESPONSIBILITY

6.1.It is the responsibility of the Utilitys Project Engineer and the Prime Contractors
Supervisors and Field Inspectors to ensure a safe installation by following the instructions
provided in this guideline, as well as customary safe installation practices.

7. TOOLS, GAGES, FIXTURES

7.1.All equipment shall be maintained in accordance with applicable safety standards.

ACCC Cable Installation Guidelines

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7.2.Only sheaves identified herein as correct for each conductor size shall be used.

8. SAFETY REQUIREMENTS

8.1.All safety requirements associated with the operation of approved equipment shall be
followed.

8.2.Electrical grounds shall be placed on all equipment and cable per OSHA Regulation
1910.269 and 1926.950.

8.3.CONDUCTOR GROUNDS MUST BE PLACED DIRECTLY ON THE ALUMINUM
STRANDS AS THE COMPOSITE CORE IS ESSENTIALLY NON-CONDUCTIVE.

9. SHIPPING

9.1.Aluminum conductors are shipped in sturdy, carefully designed containers or reels that
safe-guard the conductor from damage in transit, storage, and at the point of installation.
The conductor is carefully inspected during all stages of fabrication; packaging is
inspected prior to shipment, and only properly packaged material is delivered to the
carrier. All reels will be steel, with a 36 diameter drum (D) or larger and have a 5.25
arbor hole for reels with flanges 90 and larger, and 3.25 arbor holes for reels with flanges
78 or smaller.

9.2.Reels should be properly controlled during the loading, unloading, and staging process,
and cannot be dropped or allowed to roll freely down ramps to the ground.

9.3.Cranes or other equipment of adequate capacity should be used to avoid damage or result
in a safety hazard.

9.4.It is important that reels of ACCC cable are not lifted by placing the forks of the forklift
directly under the drum area of the reel which would allow the forks to come in direct
contact with the conductor or its wrapping material.

9.5.Lift reel by approaching from the side and placing forks under flanges. The trapezoidal
strands of the conductor are annealed, and are subject to damage.

9.6.Reels may also be lifted using fork truck approaching from side of reel so the weight is
lifted on reel flanges or through the center of the reel.

9.7.A spreader bar with slings or chains attached directly to the reel is the preferred method of
lifting a reel.

9.8.At no time should the reel be laid on its side for transport or unloading or storage.


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9.9.Do not field rewind the conductor to another reel as damage to the aluminum strands may
occur.

9.10.At the end of the pull, if there is surplus conductor left on the reel, it is important that the
end of the conductor is carefully secured back to the side of the reel to prevent the
conductor end from whipping loose.

10. Storage

10.1.If the conductor is to be stored for an extended period of time before use, the reel
containing the conductor should be kept off of the ground and otherwise protected from
possible damage.

10.2.Identification tags and other markings should be retained on all packages until such time
as the conductor is to be used.

10.3.For future identification purposes, it is good practice to retain and track the reel tag
information corresponding to the section of line in which the conductor is used. Key reel
tag information includes, but not limited to the manufacturing date of the ACCC/TW
conductor, the ACCC/TW manufacturing lot number, the length of conductor on the reel,
and the CTC core component number.

10.4.The reels come from the factory with a pressboard type reel wrap, held down with bands
over the outermost layer of conductor. It is recommended that the cover be left on the
reels if they are going to be stored for an extended period of time.

11. STRINGING CONDUCTOR

11.1. Conductor reels should be loaded into their pay-out cradles prior to the removal of
lagging or protective wrapping. When the conductor is loaded onto the payout cradles, the
reel shall be situated such that the conductor is pulled off the top side of the reel towards
the bull-wheel tensioner. After the removal of the covering, all reels must be examined for
nails or other sharp objects that may damage the conductor as it is unreeled.

11.2. A reel brake mechanism must be utilized at all times to avoid spring action or
uncoiling. Adequate back-tension must be applied at all times during the pulling
operation to prevent the conductor from unraveling, binding, or jumping out of
alignment with tensioning or stringing equipment.

11.3. Tensioner bull wheels must be a minimum of 40X the diameter of the conductor
being strung measured at the bottom of the grooves of the bull wheel sheaves.

11.4. Conductor must be continuously inspected as it is fed into the stringing equipment for dirt,
bits of foreign material, nicks, or abrasions in the conductor.


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11.5. Precautions should be taken to keep pulling lines and stringing sheaves free from dirt and
foreign debris that would cling to the conductor as it passes through the sheaves.

11.6. The conductor must not be pulled across the ground or underlying structure (such as a
fence) as that could damage the soft aluminum strands causing electrical discharge or
corona when energized.

11.7. It is a good practice to retain the reel tags and document the section of line where the
specific reels of conductor are used.

11.8. It is recommended that the protective outer wrap that is removed from the reels be placed
on the ground to protect the conductor during set up and splicing operations.

11.9. At splices and dead-ends, all die marks, flashes, and the body of the aluminum sleeve
should be cleaned up with files and sanding medium in order to avoid corona.

11.10.Should the conductor unintentionally come in contact with the ground, any dirt or debris
build up should be cleaned off.

11.11. Always use Neoprene or Urethane lined dollies, sheaves, rollers, blocks, etc. as sized in
accordance with Table 1 when stringing conductor. With exception for use for a rolling
ground sheave, unlined metal sheaves must never be used. This is to avoid scratching
the surface of the aluminum strand wires.

11.12. MINIMUM STRINGING SHEAVE DIAMETER- The minimum stringing sheave
diameter(s) shall be as per Table 1.

11.13. Never bend the conductor less than the recommended minimum bend diameter (see
Table 1). During handling and installation, the radius of curvature for any bend
made in the conductor must never be less than the value that is listed in Table 1.


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Table 1 - Sheave Sizes Required

Conductor
Diameter
(O.D.)

Conductor
Name
Minimum
Bending
Radius
of
Curvature
(inches)
First and Last
Structure
Minimum
Sheave
Diameter
(inches)*
Intermediate
Structure
Minimum
Sheave
Diameter
(inches)*
All Angle or
Elevation
Changes
Minimum
Sheave
Diameter
(inches)*

0.563 Penguin 4 10 10 10

0.720 Linnet 6.5 14 12 14

0.858 Hawk 9 20 16 20

0.927 Dove 10.5 22 20 22

0.990 Grosbeak 11.5 28 20 28

1.196 Cardinal 13.5 28 22 28

1.345 Bittern 13.5 28 28 28

1.108 Drake 16 35 28 35

1.504 Lapwing 17 35 28 35

1.602 Chukar 18 42 35 42

1.762 Bluebird 19.5 42 42 42

* The diameter indicated is the bottom of the groove diameter where the conductor rolls over.
It is not to be confused with the dimension of the overall sheave roller wheel.


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11.14. Excessive Bend Angles If, at any time during the installation process the ACCC cable
is bent at a sharp angle in excess of the bending radius that is shown in Table 1, AND if
this portion of the conductor is going to be put up under tension or non-tension, this
section of conductor must be cut out and a full splice installed. The sharp bend may have
inadvertently damaged some of the fibers in the pultruded core material. Sharp angles
can be avoided by proper sheave placement, sheave size, and attention to control of the
back tension and brake applied on the payout reel. The pultruded core fibers provide
the backbone strength component for the conductor. If they become damaged the
strength of the conductor may be compromised.

11.15. It is critical that a minimum of a 3 to 1 distance to height ratio be used between
the bull-wheel tensioner and the stringing sheave on the first structure and between
the puller and stringing sheave on the last structure. This is to avoid bending the
conductor at a severe angle during the installation of the conductor. The tensioner
must be right hand lay, meaning the conductor coming off of the wire reel goes into the left
side of the tensioner, and the conductor going to the first structure will be coming out of the
right side of the tensioner. The let off trailer, the tensioner, and the stringing sheaves must
all be in good alignment. It is unadvisable to have a change in angle direction immediately
at the first structure.


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The formula to calculate the tension required to pull in the conductors is based on the
rolling efficiency of the conductor stringing blocks.

The formula for calculating the stringing tension for pulling in the conductor is

=
n
E D
L W
T
1
8
max
2

Where

Tmax =pulling tension (assume level pull)
W =weight of the cable (lb/ft)
L =span length (ft)
D =sag length (ft) (while pulling in the conductor)
E =% roller resistance efficiency (expressed as a decimal)
=0.98 for the large stringing sheaves used for ACCC/TW
n =number of rollers

11.16.Maximum Pulling Force: The maximum pulling force applied to the conductor string
should not exceed 10% of the rated strength of the ACCC conductor. For example a
HAWK ACCC/TW conductor with a rated strength of 23200 lb the maximum pulling force
excerpted on the conductor pair should not exceed 2320 lb force during the installation of
the conductor.

11.17. Only multi-groove tensioners should be used.

11.18. V-groove tensioners cannot be used for the back-tensioning of ACCC cable.

11.19.Longest Length - While it is possible to string in multiple reels of the ACCC/TW
conductor, attention must be paid to the maximum stringing tension limit requirement.
Conductor ends may be joined together using a double pulling sock arrangement.

11.20.Support of Stringing Blocks at Angles - For angle changes greater than 15 degrees, the
stringing block should be externally supported (example - tied off) to allow the ACCC/TW
conductor to roll along the bottom of the groove. When the stringing block is not
supported, the conductor may not track evenly through the stringing block and may impart
uneven contact point pressure. This uneven contact pressure may result in movement of
and subsequent deformation to the aluminum strand wires along the conductor.

11.21.Pulls with Angle Changes - Angle changes are defined as directional changes where
you have a change in line elevation and/or line angle direction. It is recommended that
no installation be made in one continuous pull which contains more than 45 degrees in
total angle change. For pulls with more than 45 degrees in accumulated angle changes,


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the pull should be broken up into separate pulls.

The vertical angle change of the conductor running from the bull-wheel to the first structure
and the vertical transition from the last structure to the pulling unit is not be included in the
45 degree total angle calculation. Larger stringing blocks should always be used at any
angle change.

11.22. Pulling Grips Standard Kellem grips, also known as sock splices, basket grips, or wire
mesh can be used to pull ACCC cable.

11.23.Swivels When pulling in the conductor, a swivel shall be used between the pulling
cable and the pulling sock that is attached to the conductor.

11.24.Sagging Grips There are two basic types of grips used to attach onto the ACCC/TW
conductor for the conductor sagging operation. One type is a clam-shell type that bolts
closed over the top of the conductor. These are known as pocket book or come along
type grips. The other type of grip is a pliers type of grip that pinches down onto the
surface of the conductor. These are known as a Chicago Grips or Klein Grips. Either
type of grip may be used to grip the conductor when tensioning the conductor. When the
Chicago type of grip is used, it is important that it is the long body version. These grips
must also be sized properly to match the conductor diameter in order to minimize strand
distortion and maximize gripping power.

11.25.Consult with the grip manufacturer for the correct sizing and the recommended
installation procedure.

11.26.All of the conductor grips must be clean, properly sized, and load tested prior to use to
ensure that they will exceed the intended maximum installation tension(s).

11.27.It may be necessary to use tandem grips for certain high tension applications.

11.28.Tandem grips do not provide double the gripping power.

11.29.Consult with the equipment manufacturer as to the rating system they apply for tandem
grips.

11.30.Dead-ends and Splices Specially designed compression fittings are used for all dead-
ends and splices. See Sections 12 and 13 below. Because the aluminum strands are
annealed TW, installation of compression dead-ends and splices may cause conductor
distortion and minor birdcaging. These can usually be corrected by reshaping with a small
wood block or piece or rubber pipe. Installation techniques should be modified to minimize
the potential for birdcaging to form. It is suggested that any grounding clamps be safely
attached as far downstream from the dead-end as possible in order to allow for maximum
travel of the extruded trapezoidal strands. A distance of 20 feet has shown success.


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11.31.J umper Connections J umper connections are made up using a compression type
jumper fitting. To minimize the formation of birdcaging in the aluminum strand wires
between the jumper ends, a modified compression technique may be used. See Sections
12 and 13 for more information.

12. DEAD-END INSTRUCTIONS
12.1.The ACCC FCI Burndy cable dead-end assembly kit includes the following: Threaded
internal collet housing, collet assembly, threaded eyebolt, aluminum filler sleeve, outer
aluminum housing compression sleeve, Penetrox A13, and sanding medium.
12.2.Remove prescribed amount of aluminum stranding from core. This is best done with a
circumciser due to the fact that the core cannot be nicked or damaged in any way. The
exposed end of the core needs to be cut very cleanly. This is best done with a hacksaw.
12.3.Lightly sand the exposed core with sanding medium provided in the kit.
12.4.Clean and remove any dirt or particulate matter off of the exposed core with clean cloth
lightly dampened with a suitable solvent.
12.5.Slide the inner sleeve over the conductor with the tapered end facing the end of the
conductor. Slide it down about three feet.
12.6.Slide the outer sleeve over the conductor with the pad two feet from the cut end of the
conductor.
12.7.Slide the collet housing, wrench flats toward the aluminum strands onto the core, and butt
it against the aluminum strands.
12.8.Install the collet, narrow end towards the housing, onto the core leaving inch of the core
exposed from the wide end of the collet.
12.9.Install the eye and hand tighten before fully tightening with a wrench to 85 ft lbs of torque.
12.10.Thoroughly wire brush the top layer of the aluminum strands and apply the
Penetrox A13 along the brushed length of the aluminum strands. Rebrush the
surface allowing the Penetrox inhibitor to penetrate the spaces between the strands.
12.11.Slide the aluminum outer sleeve towards the eye.
12.12.Liberally apply the Penetrox A13 to the outer diameter of the aluminum inner sleeve and
slide the inner sleeve into the outer sleeve all the way to the stop point.
12.13.Crimp using a 60 ton press with the prescribed die size (see Table 2). The crimps need
to overlap in the area marked on the aluminum outer sleeve. The direction of the crimping
must always start at the steel eyebolt of the fitting and crimp out towards the span length
of the conductor. You must never back press dead-end fittings.
12.14.Use a file to remove any burrs or flashing that result from the crimping.

Table 2 Compression Dead-End


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Installation Tooling
(not included)
Y60BHU or Y60BHU-D
Hydraulic HYPRESS
ACCC kcmil
Exposed Core
length mm (ln)
Dead-End
Die Set
Terminal Die
Index
Linnet 431 190 mm (7.5 in) L727 717
Hawk 611 190 mm (7.5 in) L727 720
Dove 713 190 mm (7.5 in) L727 722
Grosbeak 816 190 mm (7.5 in) L727 724
Drake 1020 280 mm (11 in) L735 725
Cardinal 1222 280 mm (11 in) L735 727
Bittern 1572 280 mm (11 in) L735 728
13. SPLICE INSTALLATION INSTRUCTIONS:
13.1.The ACCC cable splice assembly kit includes the following: Two threaded internal collet
housings, two collets, splice coupling, collet retainer, two aluminum inner sleeves, outer
aluminum sleeve, Penetrox A13 and sanding medium.
13.2.Remove prescribed amount of aluminum stranding from core. (See table) This is best
done with a circumciser do to the fact that the core can not be nicked or damaged in any
way. The exposed end of the core needs to be cut very cleanly. This is best done with a
hacksaw. Failure to follow these instructions could result in a failed connection.
13.3.Lightly sand the exposed core with the sanding medium provided in the kit.
13.4.Clean and remove any dirt or particulate matter off of the exposed core with clean cloth
and suitable solvent.
13.5.With the tapered end of the inner sleeves facing the end of the conductor, slide them over
each conductor about three feet.
13.6.Slide the outer sleeve over one side of the aluminum conductor with the end of the tube
about two feet from the cut end of the conductor.
13.7.Slide the collet housing with the wrench flats toward the aluminum strands onto the core
and butt it against the aluminum strands.
13.8.Install the collet with the narrow end towards the housing onto the core, leaving inch of
the core exposed from the wide end of the collet.
13.9.Install the coupling on one side and the collet retainer on the other side and hand tighten.
Complete the tightening with wrenches to 85 ft lbs of torque. Ensure that approximately
one inch of the core at the narrow end of the collets is visible.
13.10.Turn the pre-assembled coupling to release. Bring the two sides together and hand
tighten. Complete tightening with the wrenches.


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13.11.Thoroughly wire brush the aluminum strands and apply the Penetrox A13 along
the brushed length of the aluminum strands. Rebrush the surface allowing the
Penetrox inhibitor to penetrate the spaces between the strands. Slide the aluminum
outer sleeve towards the eye.
13.12.Liberally apply Penetrox A13 to the outer diameter of the aluminum inner sleeves, and
slide the inner sleeves into the outer sleeve all the way to the stop point.
13.13.Crimp using a 60 ton press with the prescribed die size (see Table 3). The crimps need
to overlap in the area marked on the aluminum outer sleeve. The direction of crimping
must always start at the center of the splice assembly and crimp out towards the span
length of the conductor. You must never back press splice fittings.
Table 3 Compression Splice

ACCC kcmil
Exposed Core length
mm (in)
Installation Tooling
(not included)
Y60BHU or Y60BHU-D
Hydraulic HYPRESS
Splice Die Set
Linnet 431 190 mm (7.5 in) L727
Hawk 611 190 mm (7.5 in) L727
Dove 713 190 mm (7.5 in) L727
Grossbeak 816 190 mm (7.5 in) L727
Drake 1020 280 mm (11 in) L735
Cardinal 1222 280 mm (11 in) L735
Bittern 1572 280 mm (11 in) L735
14. JUMPER INSTALLATION INSTRUCTIONS:
14.1.To reduce the potential of forming birdcaging in the aluminum strand wires between the
two bolted jumper fitting ends, one end is crimped in the normal fashion while the other
end is back pressed. J umper connections are designed only for non-tension applications
and must never be put under a mechanical tension load.
14.2.The ends of the ACCC conductor are cut flush with the core left in place.
14.3.Thoroughly wire brush the top layer of aluminum strands with Penetrox A13 along the
brushed length of the aluminum strands. Rebrush the surface with additional Penetrox
allowing the inhibitor to penetrate the spaces between the strands.
14.4.For the first end of the jumper, slide the conductor into the barrel of the jumper.
14.5.Crimp using a 60 ton press with the prescribed die size (see Table 2). The crimps need to
overlap in the area marked on the aluminum jumper. The direction of the crimping must
always start at the four bolt connector end of the fitting and crimp out towards the exposed
conductor.
14.6.For the second end of the jumper, slide the conductor into the barrel of the jumper and,
using a marker pen, mark the conductor where it sticks out of the fitting. Pull the


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conductor back 1 inch. Crimp using a 60 ton press with the prescribed die size (see Table
2). The crimps need to overlap in the area marked on the aluminum jumper. The direction
of crimping is reversed and will start at the conductor end of the fitting and crimp down
towards the four bolt pad. This technique is known as back pressing. Back pressing
must never be used for deadends or conductor splices where a mechanical load tension is
going to be applied on the conductor.
Connector Notes:
Compression fittings are used for dead-ends and splices. (See ACCC Cable Dead-end and Splice
Installation Guidelines.) Because the aluminum strands are annealed TW, installation of
compression dead-ends or splices may cause conductor distortion and minor birdcaging. These
can often be repaired satisfactorily by reshaping with a small wooden block or a piece of rubber
hose. Installation techniques can also be modified to minimize the potential for birdcaging to form.
It is suggested that the location of any grips (20 hoists) and/or grounding clamps be safely
attached as far downstream from the end of the dead-end as possible in order to allow for
maximum travel of the extruded trapezoidal aluminum strands. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN A POOR CONNECTION.
15. ANCILLARY HARDWARE:
15.1.For assistance with appropriate ancillary hardware selection, such as dampers,
suspension clamps, and armor-rod, please contact CTCs engineering department or your
preferred hardware supplier.

15. CONDUCTOR SAGGING:
15.2.ACCC cable is sagged the same as conventional ACSR (Aluminum Conductor Steel
Reinforced).
15.3.Standard sight, return wave, transit, and dynometer methods are applicable for sagging
the ACCC conductor.


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16. LEGAL NOTICES:

PLEASE READ THESE LEGAL NOTICES CAREFULLY.

Disclaimer: This guide provides suggestions for methods, equipment and tools that have been
found practical based on field testing of CTC Brand ACCC cable and accessories. ACCC
cable requires some specific shipping, handling, storage and installation procedures. Unlike
traditional ACSR cables that have a steel core, ACCC cable consists of a composite core strength
member surrounded by one or more layers of conductor. Due to the structure of the ACCC cable,
the ACCC cable cannot be handled in accordance with some of the techniques used to install
other overhead transmission line conductors. These guidelines are meant to provide procedures
that will help provide a high quality, trouble-free installation so that the ACCC cable, once installed,
will perform its intended function. Failure to follow these guidelines may cause a hazardous
condition or result in premature line failure.

The information contained herein or related hereto is intended for evaluation by technically skilled
persons, with any use thereof to be at their independent discretion and risk. Such information is
believed to be reliable, but the accuracy or completeness thereof is not guaranteed. The user
assumes all risks and liability whatsoever in connection with such use.

WARNING: A potential for electrical shock exists when using cables energized with electrical
power. Use appropriate safety procedures.

COMPOSITE TECHNOLOGY CORPORATION SHALL NOT BE LIABLE TO THE USER OR ANY
OTHER PERSON UNDER ANY LEGAL THEORY, INCLUDING BUT NOT LIMITED TO
NEGLIGENCE OR STRICT LIABILITY, FOR ANY INJ URY OR FOR ANY DIRECT, INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES SUSTAINED OR INCURRED BY REASON OF
THE USE OF ANY OF COMPOSITE TECHNOLGY CORPORATIONS PRODUCTS.

Trademarks and Copyrights

2006 by Composite Technology Corporation. All rights reserved. CTC and ACCC are
trademarks of Composite Technology Corporation. Any use of Composite Technology
Corporations copyrights or trademarks require written approval from Composite Technology
Corporation. Such permission may be obtained from Composite Technology Corporations
headquarters in Irvine, California.

Additional Information

Composite Technology Corporation reserves the right to make changes in specifications or other
information contained in this document without prior notice. Composite Technology Corporation is
not responsible for typographical errors contained herein.

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