Professional Documents
Culture Documents
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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.
X
6.2.4. Hanging equipment or personnel from a conductor using a rope, hook, or narrow
strap.
6.2.6. Poor brake operation on the payout reel, resulting in bouncing of the conductor on
the tensioner fairlead.
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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
F-824-006-E
ACCC Safety Data Sheet
Safety Data Sheet SDS NO. 061306001
May be used to comply with OSHAs Hazard Communication Standards,
29 CFR 1910, 1200, Standard must be consulted for specific requirements.
IDENTITY (As Used on Label and List) Note: Blank spaces are not permitted. If any item is not applicable, or no
ACCC Cable Core Information is available, the space must be marked as indicated that.
Section I
Manufactures Name Emergency Telephone Number
CTC Global Corporation Infotrac 800-535-5053
Address (Number, Street, City, State, and Zip Code) Telephone Number for Information
2026 McGaw Ave 949-428-8500
Irvine, CA 92714
Date Prepared
08/18/14
Signature of Preparer (optional)
None EstablishedN/E
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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
F-824-006-E
ACCC Safety Data Sheet
Safety Data Sheet SDS NO. 061306001
May be used to comply with OSHAs Hazard Communication Standards,
29 CFR 1910, 1200, Standard must be consulted for specific requirements.
IDENTITY (As Used on Label and List) Note: Blank spaces are not permitted. If any item is not applicable, or no
ACCC Cable Core Information is available, the space must be marked as indicated that.
Section I
Manufactures Name Emergency Telephone Number
CTC Global Corporation Infotrac 800-535-5053
Address (Number, Street, City, State, and Zip Code) Telephone Number for Information
2026 McGaw Ave 949-428-8500
Irvine, CA 92714
Date Prepared
08/18/14
Signature of Preparer (optional)
None EstablishedN/E
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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 (F-750-066) and Sign-In Roster (F-750-277)
5. TRAINING
5.1. CTC offers an ACCC specific Installation Training course which consists of
approximately day classroom instruction and day hands-on instruction.
5.2. 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.
Attendance by installation supervisor(s) should be mandatory. Should a change in crew
occur during the course of construction, ACCC installation training must be completed
before that crew starts work.
5.3. Improper installation techniques are not covered by the CTC Warranty and could result in
line damage or failure.
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. CTC training is available in English and Spanish only at this time.
5.6. CTC offers a separate Maintenance and Repair Training course for ACCC.
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 Z-wire trapezoidal wire.
3.2. Terminology differs around the world when referring to the parts of a reel:
Transverse Flange
Flange Transverse
Drum or Hub Hub, Drum, or Barrel
Arbor Boss
Size Convention:
Size Convention:
flange x transverse x drum dia.
flange x hub dia. x transverse
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
5.3. New conductor reels should be inspected and verified against the above requirements.
5.4. New conductor reels are marked with manufacturers name and location, date of
manufacture, and a reel identification number that provides manufacturing traceability.
This information should be recorded as the reels are installed.
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
6.4. Returnable metal reels may be supported by a singletree arrangement that clamps to the
flange and is lifted from above.
6.5. Reels may be placed on flat ground or floor. Always chock the reel flanges (never chock
under the conductor itself or its protective lagging) to prevent rolling.
6.6. At no time shall a loaded reel be laid on its side either during handling, loading, unloading
or storage.
wooden flanges and center drum should never be used for long-term, outdoor, or damp
conditions storage. ACCC should never be submerged or allowed to remain wet during
storage. ACCC core can absorb moisture. This does not affect the tensile strength of the
core and has no effect on installed conductor, but it can increase the allowable bending
diameter which may subject the conductor core to increased risk during installation.
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.
Transverse Flange
Flange Transverse
Drum or Hub Hub, Drum, or Barrel
Arbor Boss
Size Convention:
Size Convention:
flange x transverse x drum dia.
flange x hub dia. x transverse
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
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 5 Site Considerations & Set-ups
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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.
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 5 Site Considerations & Set-ups
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 Chapter 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
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 5 Site Considerations & Set-ups
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.
3X
6.1.2. The payout reel must be positioned so that it will rotate in the same direction as the
tensioner bullwheels. The payout reel must always feed the tensioner from the top.
6.1.3. Minimum Required Distance between Reel and Tensioner: 15 meters!
Loosening of the stranding that often occurs between the reel and the bullwheels of
the tensioner is caused to a great extent by coil memory in the conductor. As the
conductor is unwound from the reel and straightens out, the outer strands become
loose, a condition that is particularly noticeable in a large diameter conductor and
can be best observed at the point at which it leaves the reel. As the conductor
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 5 Site Considerations & Set-ups
15m
6.2. Tensioner Feed Sheave
6.2.1. ALWAYS install a minimum working diameter sheave between the payout reel
and the tensioner. Position the sheave to guide the conductor into the CENTER of
the tensioner fairlead. The purpose of the feed sheave is to prevent the conductor
from bending sharply at any of the tensioner fairlead rollers, under any conditions.
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 5 Site Considerations & Set-ups
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.
6.3. First Structure Sheave Set-up
6.3.1. The first structure sheave groove must always be free to align exactly with the
plane of the conductor path, or the conductor will ride up out of the bottom of the
sheave groove which can cause birdcage or damage the aluminum strands.
6.3.2. Pulling tension tends to naturally produce this alignment. However, when the angle
is large, the pulling tension may be too low to produce sufficient alignment. In this
case, use a rope and hoist to create the correct vertical angle of the sheave such that
the conductor will ride in the bottom of the sheave groove.
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 5 Site Considerations & Set-ups
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 may be pulled back to back and
up to three reels if the site conditions dont allow proper access. As a guideline,
pulls should not be more than 20 spans.
6.5.2. Back-to-Back Pulls must always be joined by double-socks (wire mesh grips), with
bugs. Splices must be installed after the conductor is in place. ACCC splices
must never be allowed to run through sheaves.
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 5 Site Considerations & Set-ups
2016 CTC Global- For use with ACCC Conductor only
REVISION HISTORY
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 6 Required Tools and Equipment
WI-750-075 Rev A Page 1 of 18
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
1.1.5. Chapter 5 Site Considerations and Set-ups
1.1.6. Chapter 6 Required Equipment
1.1.7. Chapter 7 Stringing / Pulling
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) 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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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
5.4.4. 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 installation. If disc brakes are used, the
brakes must be in excellent condition and fully capable of quickly stopping a full
reel rotating at payout speed.
5.5. Tensioner
5.5.1. Tensioner bull wheels must be a minimum of 40 times the diameter of the
conductor, measured at the bottom of the grooves of the bull wheel.
For any ACCC conductor utilizing a ULS composite core, the tensioner bull
wheel diameter shall be a minimum of 70 inches (1778 mm).
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 the outer layer of
wires from slipping over the lower layers and to maintain good tension control.
5.5.3. Tensioner bull wheel groove depth should be minimum .55 times conductor
diameter to help control strand opening.
5.6.3. ALWAYS install a minimum working diameter sheave between the payout reel
and the tensioner. Position the sheave to guide the conductor into the CENTER of
the tensioner fairlead. The purpose of the feed sheave is to prevent the conductor
from bending sharply at any of the tensioner fairlead rollers, under any conditions.
5.8.5. Consumables
5.8.5.1. Electrical Tape
5.8.5.2. Banding
5.9. Blocks (Sheaves or Travelers)
5.9.1. Grooves should be inspected before use to avoid surface defects which may
damage the fully annealed aluminum of ACCC. Grooves should be lined with
material (neoprene or urethane) which will help avoid marking the surface of the
conductor.
5.9.2. See Minimum Sheave Size Chart, Appendix B
5.10.2. Chain Hoist. Ensure that the hoist rating exceeds the loads.
5.10.3. Hoist Hooks, Rigging. ACCC conductor can be damaged by using point-contact
hoisting equipment. Forces must be spread using wide hooks or nylon slings.
Slings should be spread to provide for wide contact with the conductor.
X
2016 CTC Global- For use with ACCC Conductor only
ACCC Conductor Installation Guidelines
Chapter 6 Required Tools and Equipment
WI-750-075 Rev A Page 9 of 18
5.11. Puller
5.11.1. Ensure that the rating exceeds the loads.
5.15.1.2. Cable Trimmer cable trimmers must be kept sharp and in good
mechanical condition. Cable trimmers with (correctly selected) cut
depth control bushings are preferred. A cable trimmer that cuts too
deeply can nick or score the conductor core, which will result in failure.
5.15.1.3. Fine Tooth Hacksaw. In all cases, the final cut of ACCC core MUST
be made with a fine tooth hacksaw!
5.15.1.4. Metal File Smooth tooth, to remove flashing from deadend or splice
crimping process.
5.15.3. Caulking Gun for application of AFL filler compound for Alcoa Hardware
5.15.4. Consumables
Hacksaw Blades Fine Tooth
Deadend Body and Splice Body Lubricant or Soap
Sandpaper - 220 Grit
Electrical Tape
Black Permanent Felt Tip Markers
HT Penetrox or Alnox Electrical Joint Compound or equivalent oxidation
inhibitor. MUST be high temperature (200 C) oxidation inhibitor.
o Repels water
o Improves thermal transfer (helps joints run cooler)
o Inhibits oxidation and corrosion
OR AFL (brand) Filler Compound (AFC) or equivalent
o Filler Compound protects the compressed steel barrels from corrosion.
Compressing removes galvanizing from the forging. The filler
compound acts as a barrier to moisture.
o Filler Compound contains aluminum particles, which clean the strands
(removing oxides) while compressing. Compressing forces the
compounds within the strands.
o Filler Compound blocks moisture, which can wick up through the
strands. Compressing forces the compound throughout the conductor
strands.
o Filler Compound aids in the holding strength of the accessory.
o Note: Main reason for accessory failure is inadequate amount of filler
compound in the accessory.
Page 1
Page 2
REVISION HISTORY
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
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
7.3. If the brake tension is too high, the conductor may start to open (birdcage) or the conductor
may begin to wedge into the underlying layers on the reel. Either condition can damage the
conductor.
7.4. 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 off.
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
9. TENSIONER OPERATION
9.1. Threading the Tensioner
9.1.1. The minimum bend diameter of the conductor must be
respected at all times during the threading of the tensioner.
9.1.2. ACCC conductors always have a right-hand direction of lay
for the outer wires, bullwheels should be arranged so that
when facing in the direction of pull, the conductor will enter
the bullwheel on the left and pull off from the right side. This
arrangement is necessary to avoid loosening of the outer layer
of strands as the conductor passes over the bullwheels. The tensioner must be fed
using the right hand lay method, meaning the conductor coming off of the payout
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.
9.1.3. Incorrect tensioner feed (in = right, out = left) will cause loosening of the strands
on the tensioner and could result in bird-caging.
9.1.4. The material and finish of the grooves must be maintained properly so it will not
damage the surface of the conductor. Elastomer lined grooves are recommended
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
X
13. STRUCTURE SHEAVES
13.1. Sheaves sizes are always required to respect minimum working diameters, see Appendix B.
13.2. Smaller interim sheave sizes, per Appendix B, may be considered where stringing sags are
relatively low and stringing path is structure-to-structure only. When in doubt, use a larger
diameter sheave.
13.3. Sharp Pulling Angles
13.3.1. Where there is a severe uplift, down pull, or angles over 20 degrees on the ACCC
conductor, it is critical to use tandem sheaves. For angles over 30 degrees, please
contact CTC Global service department (Fieldservice@ctcglobal.com) for review
and recommendations.
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
13.4. 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.
13.5. 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.
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 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.
16. BIRDCAGE
16.1. 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.
16.2. 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
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
21.SPECIAL CONDITIONS
21.1. Weather
21.1.1. No special considerations exist for ACCC conductor installation with respect to
any other conductor installation, due to weather conditions.
21.2. Live Lines
21.2.1. 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.
21.3. Long Spans, Crossings
21.3.1. It is especially important to respect minimum first and last sheave diameter
requirements for long spans. For long spans, use a pilot line (hard line). See
paragraph 18.
21.4. Please contact CTC for advice regarding special conditions not covered in the installation
guidelines: support@ctcglobal.com
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
Recommended Common Sheave and Tensioner Wheel Sizes for ACCC
Diameter - Inches (millimeters)
Conductor
First and Last Intermediate Direction Change
International Name ASTM Name
Structure Structures* 20 - 30
0.72 (18.288)
Helsinki Pasadena 0.616 (15.646) 24 (610) 22 (560) 24 (610)
Copenhagen Linnet 24 (610) 22 (560) 24 (610)
Reykjavik Oriole 0.741 (18.821) 24 (610) 22 (560) 24 (610)
Glasgow
Waco
0.818 (19.533)
0.77 (19.558)
24 (610)
24 (610)
22 (560)
22 (560)
24 (610)
24 (610)
Casablanca
Monte Carlo
Laredo
0.807 (20.498)
0.818 (20.777)
24 (610)
35 (890)
22 (560)
35 (890)
24 (610)
35 (890)
Lisbon
Oslo
Hawk
Irving
0.0858 (21.793)
0.882 (22.403)
24 (610)
35 (890)
22 (560)
28 (710)
24 (610)
35 (890)
Amsterdam Dove 0.927 (23.546) 28 (710) 24 (610) 28 (710)
Brussels
Stockholm
Grosbeak 0.99 (25.146)
1.039 (26.391)
28 (710)
35 (890)
24 (610)
28 (710)
28 (710)
35 (890)
Lubbock 1.04 (26.416) 28 (710) 28 (710) 28 (710)
Galveston 1.09 (27.686) 28 (710) 28 (710) 28 (710)
Warsaw 1.091 (27.711) 35 (890) 28 (710) 35 (890)
Dublin Drake 1.108 (28.143) 35 (890) 28 (710) 35 (890)
Hamburg Plano 1.127 (28.626) 35 (890) 28 (710) 35 (890)
Kolkata 1.127 (28.626) 35 (890) 28 (710) 35 (890)
Curlew 1.14 (28.956) 42 (1067) 42 (1067) 42 (1067)
Milan Corpus Christi 1.146 (29.108) 35 (890) 28 (710) 35 (890)
Rome Arlington 1.177 (29.896) 35 (890) 28 (710) 35 (890)
Vienna Cardinal 1.198 (30.429) 35 (890) 28 (710) 35 (890)
Budapest Fort Worth 1.24 (31.496) 35 (890) 28 (710) 35 (890)
Prague 1.251 (31.775) 35 (890) 28 (710) 35 (890)
Mumbai 1.251 (31.775) 35 (890) 28 (710) 35 (890)
El Paso 1.252 (31.801) 28 (710) 28 (710) 35 (890)
Munich 1.293 (32.842) 35 (890) 28 (710) 35 (890)
Beaumont 1.294 (32.868) 35 (890) 28 (710) 35 (890)
London San Antonio 1.315 (33.401) 35 (890) 28 (710) 35 (890)
Paris Bittern 1.345 (34.163) 35 (890) 28 (710) 35 (890)
Bordeaux 1.408 (35.76) 42 (1067) 35 (890) 42 (1067)
Antwerp 1.451 (36.855) 35 (890) 28 (710) 35 (890)
Dallas 1.452 (36.881) 35 (890) 28 (710) 35 (890)
Madrid Lapwing 1.504 (38.202) 35 (890) 28 (710) 35 (890)
Berlin 1.504 (38.202) 42 (1067) 42 (1067) 42 (1067)
Houston 1.506 (38.252) 42 (1067) 42 (1067) 42 (1067)
Falcon 1.545 (39.243) 42 (1067) 42 (1067) 42 (1067)
Chukar 1.604 (40.742) 42 (1067) 35 (890) 42 (1067)
Athens 1.762 (44.75) 42 (1067) 42 (1067) 42 (1067)
Bluebird 1.762 (44.755) 42 (1067) 42 (1067) 42 (1067)
ULS Conductors (T = Tandem Sheave Block)
ULS Oslo ULS Irving 0.818 (20.79) T 42 (1067) 42 (1067) T 42 (1067)
ULS Stockholm 0.882 (22.4) T 42 (1067) 42 (1067) T 42 (1067)
ULS Lubbock 0.984 (25) T 42 (1067) 42 (1067) T 42 (1067)
ULS Galveston 0.99 (25.15) T 42 (1067) 42 (1067) T 42 (1067)
ULS Hamburg ULS Plano 1.039 (26.4) T 42 (1067) 42 (1067) T 42 (1067)
ULS Milan ULS Corpus Christi 1.04 (26.42) T 42 (1067) 42 (1067) T 42 (1067)
ULS Prague 1.09 (27.69) T 42 (1067) 42 (1067) T 42 (1067)
ULS El Paso 1.108 (28.14) T 42 (1067) 42 (1067) T 42 (1067)
ULS Bittern 1.127 (28.63) T 42 (1067) 42 (1067) T 42 (1067)
ULS Leipzig 1.14 (28.96) T 42 (1067) 42 (1067) T 42 (1067)
ULS Dublin ULS Drake 1.142 (29.01) T 42 (1067) 42 (1067) T 42 (1067)
ULS Rome ULS Arlington 1.146 (29.11) T 42 (1067) 42 (1067) T 42 (1067)
ULS Antwerp 1.177 (29.9) T 42 (1067) 42 (1067) T 42 (1067)
ULS Dallas 1.251 (31.78) T 42 (1067) 42 (1067) T 42 (1067)
ULS Monte Carlo 1.252 (31.8) T 42 (1067) 42 (1067) T 42 (1067)
ULS 25mm 1.345 (34.16) T 42 (1067) 42 (1067) T 42 (1067)
ULS Curlew 1.451 (36.86) T 42 (1067) 42 (1067) T 42 (1067)
ULS Mahakam 1.452 (36.88) T 42 (1067) 42 (1067) T 42 (1067)
Tensioner Bull Wheels: 60" (1500mm) for all ACCC conductors except ULS; 70" (1800mm) for ACCC ULS conductors.
* Intermediate Structures: for long spans, or where large bellys are anticipated (ex.: making splice on the ground and then let-up), then use First and Last Structure sheave size.
Page 1
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
Page 2
ACCC Conductor Installation Guidelines
Chapter 7 Stringing / Pulling
REVISION HISTORY
A 121515-1
ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
WI-750-077 Rev A Page 1 of 12
1. PURPOSE
1.1. This is Chapter 8 of the ACCC Conductor Installation Guidelines, covering ACCC
sagging, suspensions, terminations, and ancillary hardware. The chapter also covers
bundling. 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 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,
ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
WI-750-077 Rev A Page 2 of 12
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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 Z-wire trapezoidal wire.
3.2. Initial Sag occurs when new conductor is pulled and clipped in.
3.3. Final Sag occurs when conductor has been energized.
3.4. Ruling Span is the assumed uniform, or average span that best represents the actual spans
in any specified section of a line.
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. IEEE Standard 516 Guide for Maintenance Methods on Energized Power Lines
4.4. The remaining Chapters of the Installation Guidelines
5. SAGGING
5.1. There is nothing unique about sagging ACCC versus any other bare conductor. This
guideline assumes that the user is familiar with industry standard sagging techniques.
5.2. Any of the four common methods of sagging may be used: line of sight, transit, stopwatch,
and dynometer (least preferred).
5.3. It is recommended that conductors not be allowed to hang in the stringing blocks more than
24 hours before being pulled to the specified sag. If this time is exceeded, the cable
manufacturer should be consulted to determine if short-term creep correction factors are
required. The total time that the conductors are allowed to remain in the stringing blocks
before being clipped should never be more than 72 hours. If this time is exceeded, damage
ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
WI-750-077 Rev A Page 3 of 12
may occur to the conductors and/or sheaves. Tension should be kept as low as possible
when snubbed-off; the tension should never approach that of the sagging tension value.
Keeping the holding tension low and working within the 24-hour window avoids having to
rely on short-term creep correction curves for subsequent sagging. These curves become
less accurate as time increases.
5.4. Sagging ACCC is most successful when time (overnight) is allowed for initial creep. If
sagging must be done same day, an acceptable alternative is to subtract 5 C (9 F) from
ambient temperature in the sagging calculations.
6. INSTALL GRIPS
6.1. Never use wire mesh or sock grips for sagging.
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, if available.
6.4. The grip should be attached 4-5 meters from the end of the insulator to provide working
room to install the deadend hardware. Install a split rubber hose over the conductor just
where it leaves the grip to protect the aluminum from the grip attachment and use a small
rope to tighten the free end of the conductor to the grip attachment. This rope will help
prevent over-bend and possible damage to the conductor during subsequent operations.
Protect the conductor where the grip and hoist are attached. Use ropes or other means to tie
up the conductor to the hoist and sling to prevent the end of the conductor from falling
which could damage the conductor.
ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
WI-750-077 Rev A Page 4 of 12
8. TERMINATIONS
8.1. Deadending
8.2. Installing ACCC deadends is very similar to installing deadends for any common bare
overhead conductor with two exceptions:
8.2.1. 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.
Similarly, it is possible to damage the ACCC core at the point where it exits the
deadend if too much bending force or weight is allowed there.
8.2.2. Back Pressing. ACCC terminations are pressed from the conductor end toward
the eye end. The usual method of pressing from the eye toward the conductor can
displace the trapezoidal aluminum strands of ACCC and cause a bird-cage.
8.2.3. Step by step instructions for correct installation of ACCC deadends are found in
ACCC training programs, in the Appendices here, and are packaged with each
deadend hardware kit.
8.3. Splicing
8.4. Installing ACCC splices is very similar to installing splices for any common bare
overhead conductor with two exceptions:
8.4.1. Conductor, Grip, and Splice Handling same issues as with deadends above.
ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
WI-750-077 Rev A Page 6 of 12
8.4.2. Pressing Direction. Splices must be pressed from the short side of the conductor
span toward the long side of the conductor span.
8.5. Step by step instructions for correct installation of ACCC splices are found in ACCC
training programs and are packaged with each splice hardware kit.
8.6. Terminal Pads
8.6.1. Installing ACCC terminal pads is identical to installing terminal pads for any
common bare overhead conductor with one exception: ACCC terminal pads are
back-pressed for the same reason as deadends.
8.7. T-Taps
8.7.1. Installing ACCC T-Taps is identical to installing T-Taps for any common bare
overhead conductor with one exception: ACCC T-Taps must be pressed AWAY
from the deadend, for the same reason that deadends are back-pressed.
8.7.2. Avoid placing T-Taps closer than 1meter from a deadend.
9.3. Tandem suspensions and yoke plates must be used where change of direction angles exceed
30 degrees.
ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
WI-750-077 Rev A Page 7 of 12
10.BUNDLED CONDUCTORS
10.1. Considerations for bundled ACCC conductors are identical with any conventional
conductors. When ACCC is used in bundled applications, all conductors in the bundle
should be pulled in together. Synchronized and multiple conductor tensioners and pullers
are typically used. Set-up areas must accommodate a set of equipment for each conductor.
10.4. For sagging, horizontal spacing of sheaves should match the final horizontal spacing.
10.5. Never apply tension above the interim (final before energizing) sag tension. Over-tension
or over-sag will cause the conductors sag behavior to differ which will result in uneven
bundle sagging.
ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
WI-750-077 Rev A Page 8 of 12
6. Wipe outer surface of the core clean and free from oil. Then
rub the core lightly with 220 mesh sanding paper (provided)
until it becomes white and re-wipe the core with a clean cloth.
8. Install the collet (See Fig. 2), narrow end towards the housing,
onto the core leaving 0.25 in (6mm) of the core exposed from
the wide end of the collet (See Fig. 3).
9. Install the eye and hand tighten before fully tightening with a
wrench (85.0 ft-lbs or 115 N-m torque required). Ensure that
approximately 3.0 in (76 mm) of core is exposed between the
aluminum and the collet after tightening (See Fig. 4). The 3
inches occurs when you measure housing plus 2 inches (50
mm). When starting to tighten the dead end eye into the
housing, ensure that the approximate still extends out of
the collet.
10. Wire brush the aluminum strands that will be covered with
outer sleeve and liberally apply oxidation inhibitor (supplied)
along the length of the brushed aluminum strands, then slide
the aluminum outer sleeve towards the eye up to the
painted/machined mark (See Fig. 4).
REVISION HISTORY
A 121515-1
ACCC Conductor Installation Guidelines
Chapter 9 Maintenance and Repair
WI-750-019 Rev D Page 1 of 4
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 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 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 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 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 taken in order 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)
6.5. 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 in the vicinity of 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