ACCC Installation Guidelines 2016

ACCC Conductor Installation Guidelines
Chapter 1 General Guidelines

WI-750-070 Rev A Page 1 of 7
Chapter 1 General Guidelines Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 1
3. DEFINITIONS ..................................................................................................................................... 2
4. ASSOCIATED DOCUMENTS ................................................................................................................ 2
5. ACCC INSTALLATION DIFFERENCES .................................................................................................. 2
6. GENERAL CONDUCTOR HANDLING GUIDELINES ................................................................................ 3
6.3. Sharp Angles .................................................................................................................................................. 5
7. TEN INSTALLATION DONTS .............................................................................................................. 6
7.1. DONT OVER-BEND! ....................................................................................................................................... 6
7.2. ONE Tensioner DON'T ................................................................................................................................... 6
7.3. TWO Payout Reel DON'TS ............................................................................................................................. 6
7.4. THREE Handling and Equipment DON'TS ...................................................................................................... 6
7.5. TWO Pulling / Stringing DONTS .................................................................................................................... 6
7.6. ONE Termination DONT ............................................................................................................................... 6
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.
2016 CTC Global- For use with ACCC Conductor only

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. ACCC INSTALLATION DIFFERENCES

Three unique features of ACCC must be considered for a trouble-free installation:
5.1. The aluminum is softer than conventional conductor (because it conducts electricity better,
and all the conductors rated tensile strength is designed into the ACCC composite core
after the knee point is achieved , not relying on any aluminum for rated tensile strength).
All handling and tools which come in contact with the conductor must avoid gouging or
scratching the aluminum surface, which can create corona effects which can cause damage
and failures at voltages over 138k.
5.2. The individual aluminum strands are trapezoid shaped and fit tightly together to form each
layer of strands. The individual strands can slide axially with respect to one another, but
not as easily as conventional round strands. This makes the conductor more susceptible to
loosening and the condition known as birdcage. While loosening or birdcage conditions
themselves are not a defect or failure, they can and should be avoided and/or corrected. The
ACCC Conductor Installation Guidelines highlight the areas and techniques to avoid
loosening and birdcage in the first place.
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. GENERAL CONDUCTOR HANDLING GUIDELINES

6.1. Never bend ACCC conductor further than its minimum sheave working diameter (see
Chapter 6). It is CRITICAL to AVOID sharp bends in the conductor to prevent core
damage!
6.2. It is not always obvious that a particular handling practice may apply a bending force over
a too-small radius and result in core damage. For instance:
6.2.1. Dropping the conductor on a rock or edge
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.
6.2.5. Applying tension or force (like conductor bouncing or dropping) over an

undersized sheave, block, or roller.

6.2.6. Poor brake operation on the payout reel, resulting in bouncing of the conductor on
the tensioner fairlead.
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.

7. TEN INSTALLATION DONTS

7.1. DONT OVER-BEND!
7.1.1. Dont allow the conductor to contact surfaces that present sharp angles or small
diameters.
7.2. ONE Tensioner DON'T
7.2.1. Dont let ACCC run hard on the end roller of the fairlead. Always use an interim
sheave to feed the conductor into the middle of the tensioner fairlead opening. A
multiple-roller banana fairlead is highly recommended.
7.3. TWO Payout Reel DON'TS
7.3.1. Dont allow the conductor to bounce or jump up and down between the payout reel
and the tensioner. When the conductor is jumping or bouncing, the core can be
damaged.
7.3.2. Dont use a payout reel with insufficient brakes. Poorly maintained or undersized
brakes will cause jumping and bouncing of the conductor between the payout reel
and the tensioner. The payout reel brakes should allow the tensioner to draw new
conductor from the reel smoothly and evenly.
7.4. THREE Handling and Equipment DON'TS
7.4.1. Dont use grips that arent designed for installing ACCC. Use Klein Chicago
long jaw grips or equal, designed for the size conductor being installed. Never use
pocketbook grips!
7.4.2. Don't allow the conductor tail or the deadend to fall or droop unsupported while
handling the conductor. If the tail is not controlled, it will damage the core at the
back of the grip.
7.4.3. Dont hoist the conductor in any manner which causes a sharp bend in the
conductor.
7.5. TWO Pulling / Stringing DONTS
7.5.1. Dont install any ACCC with under-diameter sheaves on the first and last
structure or any angles that are over 30 degrees.
7.5.2. Don't pull in conductor using old conductor if it is rusty. Dont use old conductor
with splices or broken strands for pulling. Always cut splices and any damaged
areas out and replace with Kellum grips before using old conductor for pulling.
When in doubt, pull in a pilot line using the old conductor and pull in ACCC
using the pilot line. Always use a pilot line for long spans and river crossings.
7.6. ONE Termination DONT
7.6.1. Dont allow a sharp bend where the conductor exits the termination hardware.
Hoisting conductor or deadend without paying attention to this area can damage
the core at that point.

REVISION HISTORY
REV. CHANGE REQUEST # DATE
A 121515-1 15 Dec 2015

Chapter 2 Installation Safety
Chapter 2 Installation Safety Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 1
3. DEFINITIONS ..................................................................................................................................... 2
5. ACCC UNIQUE SAFETY CONSIDERATIONS ......................................................................................... 2
6. GROUNDING ..................................................................................................................................... 3
7.1. DONT OVER-BEND! ....................................................................................................................................... 5
Appendix A MSDS ................................................................................................................................... 6
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
1.1.8. Chapter 8 Sagging, Terminations, and Suspensions
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

are found in the referenced documentation. CTC recommends strict adherence to a

comprehensive safety program and compliance with locally applicable regulations and
company policies.
2.2. These guidelines apply to equipment and techniques required to successfully install all
sizes of ACCC conductor.
2.3. These guidelines include additional equipment and techniques that are required for Ultra-
3. DEFINITIONS
or IEC or other governing body equivalent.
1926.950 or ISO 29.240.20 or local country equivalents.
5. ACCC UNIQUE SAFETY CONSIDERATIONS

5.1. ACCC bare core, and to a lesser extent ACCC conductor, presents a striking hazard if
the conductor is bent and then suddenly released.
5.2. The carbon fiber composite core is sheathed in a fiberglass layer. Tiny glass slivers are
produced when the core is cut or broken. Always wear leather work gloves and safety
glasses when cutting or working with the end of ACCC conductor or core.
5.3. The carbon and glass fibers that comprise the composite core have diameters that range
from 7 to 25 microns, and these fibers are embedded in a thermoset resin. Nanotubes or
nanofillers that have diameters in the nanometer range, are not used in the composite
core. When cutting the composite core during installation, the size of the dust particles will
be governed by the cutting device used; a hack saw will generate relatively large dust
particles compared to the diameters of the fibers that make up the core. No nano-dust that
might represent a short-term breathing hazard is created when cutting or sanding down the
core. The dust that is created consists of carbon and glass fibers; only long term exposure to
excessive quantities of dust (more than 100 times the amount of dust from installation
cutting/sanding) may result in detrimental health effects.
5.4. A Material Safety Data Sheet (MSDS) for ACCC composite core is found in Appendix A.

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.


diameters.
damaged.
pocketbook grips!
back of the grip.
conductor.

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)
Section II Hazardous Ingredients/Identity Information

Hazardous Components (Specific Chemical; Common name(s))
None
OSHA PEL ACGIH TLV Other Limits Recommended % (Optional)
N/E N/E N/E N/E
None EstablishedN/E
Section III Physical/Chemical Characteristics

Boiling Point Specific Gravity (H 2 0 = 1)
N/A 2.03 g/cc
Vapor Pressure (mm Hg.) Melting Point
N/A N/A
Vapor Density (AR = 1) Evaporation Rate
N/A (Butyl Acetate = 1) N/A
Solubility in Water
<0.1%
Appearance and Odor
Tan/Brown solid rod
Section IV Fire and Exposition Hazard Area
Flash Point (Method Used) Flammable Limits LEL UEL
> 300 deg C / 570 deg F Estimated Not Established NE NE
Extinguishing Media
Water, Foam, CO2, Dry Chem.
Special Fire Fighting Procedures
Use self contained breathing apparatus
Unusual Fire and Explosion Hazards

Combustion product may be toxic.
Note: Cable on reel under high tension. Fire may burn through cable releasing tension violently.
Section V Reactivity Data

Stability Unstable Conditions to Avoid None
Stable X
Incompatibility (Materials to Avoid)

None known
Page 1

REVISION HISTORY
A 121515-1 15 Dec 2015

Chapter 2 Installation Safety Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 1
3. DEFINITIONS ..................................................................................................................................... 2
5. ACCC UNIQUE SAFETY CONSIDERATIONS ......................................................................................... 2
6. GROUNDING ..................................................................................................................................... 3
7.1. DONT OVER-BEND! ....................................................................................................................................... 5
Appendix A MSDS ................................................................................................................................... 6
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
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

are found in the referenced documentation. CTC recommends strict adherence to a

comprehensive safety program and compliance with locally applicable regulations and
company policies.
3. DEFINITIONS
or IEC or other governing body equivalent.
5. ACCC UNIQUE SAFETY CONSIDERATIONS

5.1. ACCC bare core, and to a lesser extent ACCC conductor, presents a striking hazard if
the conductor is bent and then suddenly released.
5.2. The carbon fiber composite core is sheathed in a fiberglass layer. Tiny glass slivers are
produced when the core is cut or broken. Always wear leather work gloves and safety
glasses when cutting or working with the end of ACCC conductor or core.
5.3. The carbon and glass fibers that comprise the composite core have diameters that range
from 7 to 25 microns, and these fibers are embedded in a thermoset resin. Nanotubes or
nanofillers that have diameters in the nanometer range, are not used in the composite
core. When cutting the composite core during installation, the size of the dust particles will
be governed by the cutting device used; a hack saw will generate relatively large dust
particles compared to the diameters of the fibers that make up the core. No nano-dust that
might represent a short-term breathing hazard is created when cutting or sanding down the
core. The dust that is created consists of carbon and glass fibers; only long term exposure to
excessive quantities of dust (more than 100 times the amount of dust from installation
cutting/sanding) may result in detrimental health effects.
5.4. A Material Safety Data Sheet (MSDS) for ACCC composite core is found in Appendix A.

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.


diameters.
damaged.
pocketbook grips!
back of the grip.
conductor.

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)
Section II Hazardous Ingredients/Identity Information

Hazardous Components (Specific Chemical; Common name(s))
None
OSHA PEL ACGIH TLV Other Limits Recommended % (Optional)
N/E N/E N/E N/E
None EstablishedN/E
Section III Physical/Chemical Characteristics

Boiling Point Specific Gravity (H 2 0 = 1)
N/A 2.03 g/cc
Vapor Pressure (mm Hg.) Melting Point
N/A N/A
Vapor Density (AR = 1) Evaporation Rate
N/A (Butyl Acetate = 1) N/A
Solubility in Water
<0.1%
Appearance and Odor
Tan/Brown solid rod
Section IV Fire and Exposition Hazard Area
Flash Point (Method Used) Flammable Limits LEL UEL
> 300 deg C / 570 deg F Estimated Not Established NE NE
Extinguishing Media
Water, Foam, CO2, Dry Chem.
Special Fire Fighting Procedures
Use self contained breathing apparatus
Unusual Fire and Explosion Hazards

Combustion product may be toxic.
Note: Cable on reel under high tension. Fire may burn through cable releasing tension violently.
Section V Reactivity Data

Stability Unstable Conditions to Avoid None
Stable X
Incompatibility (Materials to Avoid)

None known
Page 1

REVISION HISTORY
A 121515-1 15 Dec 2015

Chapter 3 Training
Chapter 3 Training Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
5. TRAINING ......................................................................................................................................... 2
6. INSTALLATION TRAINING SYLLABUS ................................................................................................. 3
6.1. The 3 DIFFERENCES (Classroom only, practical demonstration) ................................................................... 3
6.2. Conductor Reel Handling (Classroom and Field) ........................................................................................... 3
6.3. Site and Equipment Setup (Classroom only) ................................................................................................. 3
6.4. Conductor Handling (Classroom and Field) ................................................................................................... 3
6.5. Stringing and Sagging (Classroom and Field) ................................................................................................. 3
6.6. Terminations ................................................................................................................................................. 3
6.7. Equipment Requirements (Classroom and Field) .......................................................................................... 4
6.8. The 10 DONTs (Classroom and Field) ........................................................................................................... 4
7.1. DONT OVER-BEND! ....................................................................................................................................... 5
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
recommendations and requirements necessary to safely and successfully install ACCC

Chapter 3 Training
2. SCOPE
3. DEFINITIONS
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.
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors.
1926.950 or ISO 29.240.20 or local country equivalent.
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.

Chapter 3 Training
6. INSTALLATION TRAINING SYLLABUS

6.1. The 3 DIFFERENCES (Classroom only, practical demonstration)
6.2. Conductor Reel Handling (Classroom and Field)
6.2.1. Proper lifting and handling of the new conductor reels
6.2.2. Preparation of new reel for stringing
6.3. Site and Equipment Setup (Classroom only)
6.3.1. Puller
6.3.2. Tensioner
6.3.3. Payout Reel
6.4. Conductor Handling (Classroom and Field)
6.4.1. Installing first and last structure sheaves
6.4.2. Installing tangent structure sheaves along with installing larger or tandem sheaves
on structures with over a 30-degree angle
6.4.3. Pulling the conductor up to the first structure and attaching to old conductor
6.5. Stringing and Sagging (Classroom and Field)
6.5.1. Loading the conductor onto the reel stand
6.5.2. Stringing the conductor through the tensioner
6.5.3. Core Retainer (Bug) Installation
6.5.4. Installing and anchoring wire mesh sock clamp onto conductor, installing swivel
and preparing to pull the conductor
6.5.5. Paying close attention to any bad angles or long spans
6.5.6. Sagging (Cutting Conductor to Length)
6.6. Terminations
6.6.1. Installing Deadends and Splices (Classroom and Field)
6.6.1.1. Threaded Collet Hardware
6.6.1.2. Compression Collet Hardware
6.6.1.3. Sleeve Compression
6.6.2. Installing Conductor Suspensions and Dampners (Classroom and Field)
6.6.3. Installing Terminal Pads and T Taps (Classroom and Field)
6.6.4. Installing Ancillary Hardware

Chapter 3 Training
6.7. Equipment Requirements (Classroom and Field)

6.7.1. Sheave Sizes and Types including special rigging for exceptional stringing
conditions
6.7.2. Core Retainers (Bugs)
6.7.3. Presses and Dies
6.7.4. Clamps
6.7.5. Socks (wire mesh) and Banding
6.8. The 10 DONTs (Classroom and Field)

Chapter 3 Training

diameters.
damaged.
pocketbook grips!
back of the grip.
conductor.

Chapter 3 Training
REVISION HISTORY
A 121515-1 15 Dec 2015

Chapter 4 Reel Handling and Storage
Chapter 4 Reel Handling and Storage Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 1
3. DEFINITIONS ..................................................................................................................................... 2
5. NEW CONDUCTOR REELS .................................................................................................................. 2
6. CONDUCTOR REEL HANDLING ........................................................................................................... 3
7. CONDUCTOR and CONDUCTOR REEL STORAGE ................................................................................. 4
8.1. DONT OVER-BEND! ....................................................................................................................................... 6
Appendix A ACCC Reel Specifications ..................................................................................................... 7
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:
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

3. DEFINITIONS
3.2. Terminology differs around the world when referring to the parts of a reel:
North America Europe

Reel Spool or Bobbin
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
4.4. 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. NEW CONDUCTOR REELS

5.1. ACCC conductors are shipped on industry standard reels with added packaging that
safeguards the conductor during transit, storage, and at the point of installation. The
conductor reels must be verified by the conductor manufacturer against the specification in
Appendix A. The conductor is inspected during all stages of fabrication; packaging is
inspected prior to shipment, and only properly packaged material is delivered to the carrier.
5.2. The conductor is packaged with a protective covering over the top layer of conductor on
the reel to prevent damage during shipping and handling.

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.
6. CONDUCTOR REEL HANDLING

6.1. Reels should be properly controlled during the loading, unloading and staging processes.
6.2. Proper equipment must be available to hoist and handle conductor reels. Cranes or other
equipment of adequate capacity must be used to avoid damage and safety hazards.
6.3. Reels may be handled with forklift equipment of adequate capacity. It is important that
reels of ACCC conductor are not lifted by placing the forks of the forklift under the drum
area of the reel, which would allow the forks to come in direct contact with the conductor
or its wrapping material. Slings, winch lines, nylon straps or any other types of lifting
devices shall never be placed around the conductor to lift the reel. The ACCC conductor
will be damaged if such devices are used.
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.
7. CONDUCTOR and CONDUCTOR REEL STORAGE

7.1. If the conductor is to be stored for an extended period of time before use, the reel shall be
kept off of the ground and otherwise protected from possible damage. Only all-steel reels,
should be used for long-term or outdoor storage. Wood reels or steel spoke reels with

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.
7.4. Storage Temperatures:

7.4.1. Maximum storage temperature: +55C (131F)
7.4.2. Minimum storage temperature: -40C (-40F)


diameters.
damaged.
pocketbook grips!
back of the grip.
conductor.

Appendix A ACCC Reel Specifications

F-750-032D
ACCC Reel Specification Requirements
page 2
ULS CONDUCTORS
Diameter (mm) Spool (mm) Reel (inches)
Conductor
International Weight* Minimum Hub Reference Boss Minimum Reference
Core Conductor Name ASTM Name kg/km Dia. Diameter Drum Dia. Arbor Diameter
8.76 22.40 ULS Oslo ULS Irving 981 1515 130 60 5.25
8.76 26.40 ULS Stockholm 1395 1515 5.25
8.76 26.42 ULS Lubbock 1376 130 60
8.76 27.69 ULS Galveston 1526 130 60
8.76 28.63 ULS Hamburg ULS Plano 1627 1515 130 60 5.25
8.76 29.11 ULS Milan ULS Corpus Christi 1686 1515 130 60 5.25
8.76 31.78 ULS Prague 2031 1515 5.25
8.76 31.80 ULS El Paso 2002 130 60
8.76 34.16 ULS Bittern 2331 130 60
9.53 25.15 ULS Leipzig 1253 1635 5.25
9.53 28.14 ULS Dublin ULS Drake 1583 1635 130 65 5.25
9.53 29.90 ULS Rome ULS Arlington 1774 1635 130 65 5.25
9.78 36.86 ULS Antwerp 2760 1645 5.25
9.78 36.88 ULS Dallas 2761 130 65
10.54 20.79 ULS Monte Carlo 799 1810** 130 72** 5.25
10.54 25.00 ULS 25mm 1216 1810** 5.25
10.54 28.96 ULS Curlew 1610 130 72**
10.54 29.01 ULS Mahakam 1677 1810** 130 5.25
*International weight when applicable, ASTM equivalents typically 1-2% lighter due to aluminum fill factor
Stockholm 2L; Stockholm 3L = 1368 kg/km effective for both core reels and conductor reels
** 1780 mm (70 inches) allowable for 3 months storage or less
Steel Reels are recommended, meeting DIN 46395 or NEMA WC 26, except for drum diameters above
Wooden Reels shall not be used for outdoor storage longer than 3 months
Wooden Reels should meet DIN 46395 or NEMA WC 26 Class 3, except for drum diameters above
Spacers may be used provided the following criteria are met:
Spacer must maintain a uniform roundness and be free of bumps or angles
It is not required for the spacer to be affixed or attached to the reel hub provided the conductor is attached to the reel as normal
Material must be of suitable strength to withstand the load of the conductor without being crushed or deforming
Load bearing capability must be sustained across the entire winding surface from flange to flange
Material shall be weather resistant such that it can be stored outside in rain, snow or ice conditions without degradation
North America Europe

Reel Spool or Bobbin
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
A 121515-1 15 Dec 2015

Chapter 5 Site Considerations & Set-ups


Chapter 5 Site Considerations and Set-ups Table of Contents
1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
5. SITE CONSIDERATIONS ...................................................................................................................... 2
5.1. Setup areas .................................................................................................................................................... 2
5.2. Wire Pull Plan ................................................................................................................................................ 4
6. SET-UPS ............................................................................................................................................ 4
6.1. Payout Reel / Tensioner Set-up ..................................................................................................................... 4
6.2. Tensioner Feed Sheave .................................................................................................................................. 5
6.3. First Structure Sheave Set-up ........................................................................................................................ 6
6.4. Restricted Area Alternatives .......................................................................................................................... 7
6.5. Back-to-Back Reel Pulls ................................................................................................................................. 7
7.1. DONT OVER-BEND! ....................................................................................................................................... 8
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:
1.1.8. Chapter 8 Sagging, Terminations, and Suspending




2. SCOPE
3. DEFINITIONS
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 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




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.
5.2. Wire Pull Plan
5.2.1. A project will benefit from a detailed plan for the series of pulls to install the
conductor. A detailed wire pull plan can even order the correct amount of
conductor on each reel.
5.2.2. The pulling plan should consider available setup areas, length of pulls, and should
include planning of where conductor terminations and splices will be done,
whether on the ground (consider ground conditions) or in the air (consider
equipment and personnel access).
5.2.3. The pulling plan must consider clearance distances from existing electric power
lines, see table above.
5.2.4. The pulling plan should be available before the project start and should be
reviewed with the ACCC Field Representative.
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




enters the bullwheel groove, the pressure of contact tends to push the loose outer
strands back toward the reel where the looseness accumulates, leading to the
condition commonly known as birdcage. If this condition is not controlled, the
strands can become damaged to the extent that the damaged length of conductor
must be removed. This problem can be remedied by allowing enough distance
between the reel and tensioner to permit the strand looseness to distribute along the
intervening length of conductor and simultaneously maintaining enough back
tension on the reel to stretch the core and inner strands to sufficiently tighten the
outer strands.
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.




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.
6.3. 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.




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 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.




diameters.
damaged.
pocketbook grips!
back of the grip.
conductor.


REVISION HISTORY
A 121515-1 15 Dec 2015


Chapter 6 Required Tools and Equipment
Chapter 6 Required Tools & Equipment Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
5. REQUIRED TOOLS & EQUIPMENT ...................................................................................................... 2
5.1. Tools & Equipment Checklists ....................................................................................................................... 2
5.2. Safety Equipment .......................................................................................................................................... 2
5.3. Reel Handling ................................................................................................................................................ 3
5.4. Payout Reel Stand ......................................................................................................................................... 3
5.5. Tensioner ....................................................................................................................................................... 4
5.6. Tensioner Fairlead ......................................................................................................................................... 5
5.7. Core Retainer (Bug) ....................................................................................................................................... 6
5.8. Conductor Grips, Clamps, and Socks ............................................................................................................. 6
5.9. Blocks (Sheaves or Travelers) ........................................................................................................................ 7
5.10. Hoisting Equipment ....................................................................................................................................... 8
5.11. Puller ............................................................................................................................................................. 9
5.12. Bucket Truck (if available) ............................................................................................................................. 9
5.13. Stinger Truck (if available) ............................................................................................................................. 9
5.14. Swivels ......................................................................................................................................................... 10
5.15. Terminating and Splicing ............................................................................................................................. 10
6. TEN INSTALLATION DONTS ............................................................................................................ 13
6.1. DONT OVER-BEND! ..................................................................................................................................... 13
6.2. ONE Tensioner DON'T ................................................................................................................................. 13
6.3. TWO Payout Reel DON'TS ........................................................................................................................... 13
6.4. THREE Handling and Equipment DON'TS .................................................................................................... 13
6.5. TWO Pulling / Stringing DONTS .................................................................................................................. 13
6.6. ONE Termination DONT ............................................................................................................................. 13
Appendix A Equipment Checklist ........................................................................................................... 14
Appendix B Recommended Sheave Diameters ...................................................................................... 15
Appendix C Compression Dies ............................................................................................................... 17
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

2. SCOPE
2.1. These guidelines apply to specific equipment and techniques required to successfully install
all sizes of ACCC conductor.
3. DEFINITIONS
1926.950 or ISO 29.240.20 or local country equivalent.
5. REQUIRED TOOLS & EQUIPMENT

5.1. Tools & Equipment Checklists
5.1.1. The Tools & Equipment described herein and listed in Appendix A are generic for
all sizes of ACCC Conductors.
5.1.2. Major equipment (tensioners, payout reel stands, pullers) and a variety of minor
equipment (sheaves, grips, swivels, presses, dies, etc.) are specific to conductor
size (diameter). CTC can produce a size-specific checklist upon request. Send
your request, with the desired ACCC Conductor size, to:
Fieldservice@ctcglobal.com
5.2. Safety Equipment
5.2.1. Personal Safety Equipment: Hard hats, safety shoes, eye and ear protection, work
gloves, rubber gloves, high visibility clothing, long sleeves, long pants, and safety
harness with lanyard should be used as appropriate by personnel working around

5.2.2. Grounding Safety Equipment: Hot sticks, voltage tester, ground cables with
appropriate clamps, driven or screw type ground rods, grounding mats if needed,
rubberized blankets if needed, equal potential area warning tape, conductor
working zone boundary flags, all may be needed and should be used, but are
outside the scope of this document.
5.3. Reel Handling
5.3.1. Spreader Bar
5.3.2. Nylon Slings
5.4. Payout Reel Stand
5.4.1. Brakes. The function of the payout reel stand is to feed new conductor to the
tensioner UNDER CONTROLLED TENSION so the conductor feeds smoothly
and evenly into the tensioner. The brakes effect this tension and must be
maintained in excellent operating condition. Many reel stands are equipped with
disc brakes. These are often undersized and poorly maintained. Hydraulic brakes
are preferred to be used for ACCC installation, preferably synchronized with the
tensioner. NEVER use timbers, boards, poles or other make-shift devices for
brakes!
5.4.2. Mandrel / Arbor Sizes
5.4.2.1. ACCC is shipped on heavy duty reels appropriate to support and
protect the conductor for its storage and transport mode(s). The reels,
depending on conductor size, will typically have one of the following
arbor (bore) sizes. Complete reel specifications are found in the
Appendix of Chapter 4.
ASTM (inches) International (mm)
Small 3.25 100 or 125
Large 5.25 140 or 200 or 250
5.4.2.2. Bushings must be used, if needed, to adjust the payout reel mandrel size
up to the arbor size so that the reel rotates evenly about its axis.
5.4.3. Wooden Reel Stands are equipped with a mandrel that supports the weight of the
reel and arms that clamp onto the wooden reel flanges and effect the rotational
control of the reel. Wooden reel stands should NOT be used with metal reels
unless the wooden reel stand is adapted to hold the metal reels so that good brake
control is achieved. Ideally, metal reel stands should be used for metal reels and
wooden reel stands should be used for wooden reels.

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. Tensioner Fairlead
5.6.1. Poor tension control of the conductor feeding the tensioner will cause the
conductor to bounce 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 ACCC. Pictured below is Tesmec/Condux, fairlead part
number AYU077.
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.

5.7. Core Retainer (Bug)

5.7.1. ACCC conductor is constructed with a smooth composite core surrounded by one
or more layers of aluminum strands. The core retainer (bug) prevents the core
from slipping back inside during conductor installation so that the core is
accessible for termination procedures. The bug is temporary, used only during
handling and pulling/stringing.
5.7.2. Bugs are ACCC specific and supplied by CTC. Bugs may be re-used but should
not be used indefinitely. Do not reuse a bug when the nut does not screw into the
body easily or if the inside collet appears worn or damaged.
5.7.3. Bug Installation / Removal Tools

5.7.3.1. Hammer
5.7.4. Core punch (included with bug)
5.7.4.1. Fine-Tooth Hack Saw
5.7.4.2. Steel Wire Brush
5.7.4.3. 15 Crescent Wrench (2)
5.8. Conductor Grips, Clamps, and Socks
5.8.1. Grips and Clamps Must be long jaw, lever type, rated for the loads as determined
by the conductor size and the project pulling and sagging tensions. Klein brand
Chicago style (1628 series) grips are recommended.

5.8.2. 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.
5.8.3. Wire Mesh Grips or Socks must be correctly sized, and kept in good condition,
free of rust or other contamination. Hubbell brand Kellems K-Type Pulling Grips
or Arrow Heart K-type Heavy Duty Pulling Grips are recommended.
5.8.4. Banding Tool
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. Hoisting Equipment

5.10.1. A Capstan Hoist will provide a smooth hoisting alternative to manual methods
which can damage the ACCC conductor core. Ensure that the hoist rating
exceeds the loads.
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
5.11. Puller
5.11.1. Ensure that the rating exceeds the loads.
5.12. Bucket Truck (if available)

5.12.1. Personnel lifts, platforms, or buckets greatly enhance safety and efficiency
5.12.2. Should be insulated and designed for electrical work.
5.13. Stinger Truck (if available)

5.13.1. A stinger truck is a boom crane mounted on a flatbed truck equipped with outboard
stabilizers. It is used for equipment handling and can be equipped with a personnel
bucket, if equal potential ground is assured.

5.14. Swivels
5.14.1. Pulling swivels must be in good condition, rotate freely, and be rated for the
pulling tensions.
5.15. Terminating and Splicing

5.15.1. Termination Hand Tools
5.15.1.1. Ratchet Cutter or Cable Cutter for rough cuts only! Never use a
ratchet cutter or cable cutter for final cut.
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.
5.15.1.5. Crescent Wrenches (2) approximately 15 or 380mm length.
5.15.2. Presses and Dies

5.15.2.1. Presses must be of sufficient capacity to properly crimp the termination
hardware. Double-acting pumps and presses will dramatically improve
the termination process time.

5.15.2.2. Dies - the use of proper press dies, sized and configured correctly for
both the press and the hardware, is critical for successful termination
hardware installation. See the Compression Die Chart, Appendix B.
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.

diameters.
damaged.
pocketbook grips!
back of the grip.
conductor.

Appendix A Equipment Checklist
Personnel Safety Equipment Stinger Truck

Reel Hoisting Spreader Bar Swivels
Reel Hoisting Slings Termination Hand Tools
Payout Reel Stand Cable Trimmer
Correct Size Mandrel Cable Cutter
and/or Bushings Ratchet Cutter
Brakes Good Condition Fine Tooth Hacksaw
Tensioner Fine Tooth File
Tensioner Fairlead Large Adjustable
Banana Wrenches
Bugs Die Press
Hammer and Punch Dies
Fine Tooth Hack Saw Caulking Gun
Large Adjustable Wrenches Consumables
Steel Wire Brush Hacksaw Blades Fine Tooth
Chicago Grips Deadend Body and Splice
Kellum Socks Body Lubricant or Soap
Banding Tool, Banding, Sandpaper - 220 Grit
Hammer Electrical Tape
Tape Electrical Joint Compound
Blocks, Sheaves Black Permanent Felt Tip
Tandem Sheaves Markers
Good Nylon Rope Filler Compound
Capstan Hoist
Chain Hoist
Wide Conductor Hoist Hooks
Nylon Straps, Short Slings
Puller
Radios
Bucket Truck

Appendix B Recommended Sheave Diameters

F-750-071 Rev A
Recommended Common Sheave and Tensioner Wheel Sizes for ACCC
Diameter - Inches (millimeters)
First and Last Intermediate Direction Change
International Name ASTM Name Conductor
Structure Structures* 20 - 30
Helsinki Pasadena 0.616 (15.646) 24 (610) 22 (560) 24 (610)
Copenhagen Linnet 0.72 (18.288) 24 (610) 22 (560) 24 (610)
Reykjavik Oriole 0.741 (18.821) 24 (610) 22 (560) 24 (610)
Glasgow 0.818 (19.533) 24 (610) 22 (560) 24 (610)
Waco 0.77 (19.558) 24 (610) 22 (560) 24 (610)
Casablanca Laredo 0.807 (20.498) 24 (610) 22 (560) 24 (610)
Monte Carlo 0.818 (20.777) 35 (890) 35 (890) 35 (890)
Lisbon Hawk 0.0858 (21.793) 24 (610) 22 (560) 24 (610)
Oslo Irving 0.882 (22.403) 35 (890) 28 (710) 35 (890)
Amsterdam Dove 0.927 (23.546) 28 (710) 24 (610) 28 (710)
Brussels Grosbeak 0.99 (25.146) 28 (710) 24 (610) 28 (710)
Stockholm 1.039 (26.391) 35 (890) 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

Appendix B Minimum Sheave Diameters

F-750-071 Rev A
ACCC Sheave Wheels
page 2 - Sheave Wheel Selection Guidelines
Minimum Sheave Wheel Sizes
Diameter (mm) Sheave Minimum Working Diameter
International Name ASTM Name
Core Conductor Millimeters Inches
5.97 15.65 Helsinki Pasadena 500 19.69
5.97 18.29 Copenhagen Linnet 495 19.49
7.11 18.82 Reykjavik Oriole 595 23.43
7.11 19.53 Glasgow 595 23.43
7.11 20.50 Casablanca Laredo 595 23.43
7.11 21.79 Lisbon Hawk 595 23.43
7.75 19.56 Waco 645 25.39
7.75 23.55 Amsterdam Dove 645 25.39
8.13 25.15 Brussels Grosbeak 640 25.20
8.76 22.40 Oslo Irving 745 29.33
8.76 26.39 Stockholm 745 29.33
8.76 26.42 Lubbock 745 29.33
8.76 27.69 Galveston 745 29.33 Reference
8.76 27.71 Warsaw 745 29.33
Size
8.76 28.63 Hamburg Plano 745 29.33
8.76 29.11 Milan Corpus Christi 745 29.33
8.76 30.43 Vienna Cardinal 745 29.33
8.76 31.78 Prague 745 29.33
8.76 31.80 El Paso 745 29.33 Working
8.76 34.16 Paris Bittern 745 29.33 Diameter
9.53 28.14 Dublin Drake 795 31.30
9.53 28.63 Kolkata 795 31.30
9.53 29.90 Rome Arlington 795 31.30
9.53 31.50 Budapest Fort Worth 795 31.30
9.53 31.78 Mumbai 795 31.30
9.53 32.84 Munich 795 31.30
9.53 32.87 Beaumont 795 31.30
9.78 33.40 London San Antonio 800 31.50
9.78 36.86 Antwerp 800 31.50
9.78 36.88 Dallas 800 31.50
9.78 38.20 Madrid Lapwing 800 31.50
10.03 40.74 Chukar 800 31.50
10.54 20.78 Monte Carlo 805 31.69
10.54 28.96 Curlew 875 34.45
10.54 35.76 Bordeaux 875 34.45
10.54 38.20 Berlin 875 34.45
10.54 38.25 Houston 870 34.25
10.54 39.24 Falcon 870 34.25
Groove Radius4
10.54 44.75 Athens 870 34.25
10.54 44.76 Bluebird 870 34.25
ULS Conductors 1) Sheaves are required to respect Minimum Working
8.76 22.40 ULS Oslo ULS Irving 1000 39.37 Diameter for first and last structure, and structures
8.76 26.40 ULS Stockholm 1000 39.37 where stringing path is other than structure to
8.76 26.42 ULS Lubbock 1000 39.37 structure. (For ex: where a splice is made on the
8.76 27.69 ULS Galveston 1000 39.37 ground and then let up.)
8.76 29.11 ULS Milan ULS Corpus Christi 1000 39.37 2) Sheaves are recommended to respect Minimum Working
8.76 28.63 ULS Hamburg ULS Plano 1000 39.37 Diameter for interim structures. Smaller interim
8.76 31.78 ULS Prague 1000 39.37 sheave sizes may be considered where stringing
8.76 31.80 ULS El Paso 1000 39.37 b) for spans greater than 1.2 times the ruling span
8.76 34.16 ULS Bittern 1000 39.37 tensions are high enough to always keep the angle
9.53 25.15 ULS Leipzig 1000 39.37 over the sheave less than 20 degrees.
9.53 28.14 ULS Dublin ULS Drake 1090 42.91 3) Tandem sheaves are required:
9.53 29.90 ULS Rome ULS Arlington 1090 42.91 a) where stringing angle exceeds 20 degrees
9.78 36.86 ULS Antwerp 1000 39.37 c) for changes of direction > 30
9.78 36.88 ULS Dallas 1000 39.37 d) for ULS Conductors, first and last structures
10.54 20.79 ULS Monte Carlo ULS Monte Carlo 1200 47.24 4) Groove Radius must be at least 0.55 times
10.54 25.00 ULS 25mm 1000 39.37 conductor diameter. Neoprene, Nylon, or Urethane
10.54 28.96 ULS Curlew 1000 39.37 lined grooves are recommended.
10.54 29.01 ULS Mahakam 1200 47.24
Page 2

Appendix C Compression Dies F750069B

CompressionDieChartforDeadends,Splices,andBurndyTerminalPads
Diameter(mm) Burndy DeadendsandSplices
International TerminalPads Deadends& Forjasul
Core Conductor Name ASTMName W/OInnerSleeve W/InnerSleeve Splices Dervaux PLP (Tramontina) AFLCore AFLSleeve
15.65 Helsinki Pasadena
5.97
18.29 Copenhagen Linnet 40mm(+3/0.2)
L717W 10014SH 10024AH
18.82 Reykjavik Oriole
46mm
7.11 20.50 Casablanca Laredo L725W
L720W L727W 43mm
21.79 Lisbon Hawk 10014SH 10030AH
19.53 Glasgow Waco 40mm(+3/0.2)
7.75
23.55 Amsterdam Dove L722W 40.8mm(+3/0.2)
50.5mm
8.13 25.15 Brussels Grosbeak L724W
22.40 Oslo Irving L722W L725W
26.39 Stockholm Lubbock
L725W 10018SH 10040AH
27.69 Warsaw Galveston
28.63 Hamburg Plano 52.2mm(+3/1)
8.76
29.11 Milan CorpusChristi
L727W
30.43 Vienna Cardinal
31.78 Prague ElPaso
34.16 Paris Bittern L728W
L735W 56.5mm 56.5mm
25.15 ULSLeipzig L724W
28.14 Dublin Drake L725W 10018SH 10040AH
28.63 Kolkata
9.53 29.90 Rome Arlington
L727W
31.50 Budapest FortWorth
31.78 Mumbai
32.84 Munich Beaumont
L728W
33.40 London SanAntonio
9.78 36.86 Antwerp Dallas L7351W L7351W
38.20 Madrid Lapwing L735W L735W
10.03 40.74 Chukar
20.78 MonteCarlo
25.00 ULS25mm L724W
56.5mm 56.5mm
28.96 Curlew L727W L735W
10.54 29.01 ULSMahakam L727W
38.20 Berlin Houston L735W
39.24 Falcon
44.76 Athens Bluebird
tobedetermined
Dervaux,PLP,andForjasulDieSizesaremmbetweenhexflats

REVISION HISTORY

A 121515-1

Chapter 7 Stringing / Pulling


Chapter 7 Stringing / Pulling Table of Contents
1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
5. PAYOUT REEL SET-UP ........................................................................................................................ 2
6. INSTALL PULLING SOCK (GRIP) .......................................................................................................... 3
7. PAYOUT REEL OPERATION ................................................................................................................ 3
8. TENSIONER FEED SHEAVE ................................................................................................................. 5
9. TENSIONER OPERATION .................................................................................................................... 5
9.5. Synchronized Tensioner-Payout Reel Stand Operation. ................................................................................ 6
10. INSTALL CORE RETAINER (BUG) ......................................................................................................... 6
11. CONNECT TO PULLING LINE .............................................................................................................. 7
12. HOISTING TO FIRST STRUCTURE ........................................................................................................ 7
13. STRUCTURE SHEAVES ........................................................................................................................ 8
13.3. Sharp Pulling Angles ...................................................................................................................................... 8
14. PULLER ............................................................................................................................................. 9
15. FOLLOW THE FLAG ............................................................................................................................ 9
16. BIRDCAGE ......................................................................................................................................... 9
17. BACK-TO-BACK PULLING ................................................................................................................. 10
18. LONG SPANS, RIVER CROSSINGS, ROAD CROSSINGS ....................................................................... 10
19. MANUAL STRINGING ...................................................................................................................... 11
20. REWINDING .................................................................................................................................... 12
21. SPECIAL CONDITIONS ...................................................................................................................... 12
21.1. Weather ....................................................................................................................................................... 12
21.2. Live Lines ..................................................................................................................................................... 12
22. TEN INSTALLATION DONTS ............................................................................................................ 13
22.1. DONT OVER-BEND! ..................................................................................................................................... 13
22.2. ONE Tensioner DON'T ................................................................................................................................. 13
22.3. TWO Payout Reel DON'TS ........................................................................................................................... 13
22.4. THREE Handling and Equipment DON'TS .................................................................................................... 13
22.5. TWO Pulling / Stringing DONTS .................................................................................................................. 13
22.6. ONE Termination DONT ............................................................................................................................. 13
Appendix A Recommended Sheave Diameters ...................................................................................... 14
1. PURPOSE
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:



considerations, and requirements necessary to safely and successfully install the ACCC
2. SCOPE
3. DEFINITIONS
5. PAYOUT REEL SET-UP

5.1. Load the reel of new ACCC conductor into the payout reel stand. Refer to reel handling
guidelines in Chapter 3. The reel mandrel, or axle, must be sized to match the arbor holes
in the reel. Use arbor spacers (bushings) if needed. The reel must turn smoothly on the
mandrel to avoid jumping or bouncing of the conductor during payout.
5.2. Verify that the Payout Reel Brake is of sufficient capacity and is in good working order.



6. INSTALL PULLING SOCK (GRIP)
6.1. Wire Mesh Grips or Socks are used to pull in conductor. They must be correctly sized
and kept in good condition, free of rust or other contamination. Hubbell brand Kellems
K-Type Pulling Grips or Arrow Heart brand K-type Heavy Duty Pulling Grips are
recommended. Pulling socks must be equipped with guarding on the wires at the eye end
to prevent the conductor end strands or bug from damaging the sock wires. Do not use
grips with broken or rusted wires.
6.2. Wipe the conductor free of oil, dirt or other contamination for at least the length of the
sock.
6.3. The full length of the wire mesh must be fully installed on conductor or the sock will be
damaged and could fail.
6.4. ALWAYS anchor the far end of the wire mesh sock. Preferred anchor method is 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.
6.5. 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.
6.6. Tape between the eye and end of the sock, to prevent the bug from coming out of the sock
and to protect the lining on the blocks and assure smooth travel through blocks.
6.7. 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.
6.8. There may be occasions when it is necessary or desirable to pull long spans 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.
7. PAYOUT REEL OPERATION

7.1. Payout Reel Brake. The tensioner pulls conductor from the reel and the payout reel brakes
resist the pulling. 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.
7.2. 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.



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.



8. TENSIONER FEED SHEAVE
8.1. 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.
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



for all conductors, but are particularly important for non-specular finished
conductors. When a semi-conducting elastomer is used for lining the grooves, it
must not be relied upon for grounding.
9.1.5. The tensioner should be threaded with conductor using a rope around the bull
wheels. Install a bug on the conductor, insert the conductor into the sock and
anchor the sock with two bands or a radiator hose clamp. Tape the eye of the sock
to eliminate any sharp edges and attach the sock to an approved swivel. The
swivel is then attached to the rope. The rope is then pull the conductor through the
tensioner bull wheels. See Section 9 and 10 below.
9.2. As the puller advances conductor through the pull, it is the tensioner which controls the
tension on the pull and the sag in the spans of the pull.
9.3. Constant, open, priority communication between puller operation and tensioner operation is
required to coordinate stops, starts, and speed of the pull.
9.4. 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.
9.5. Synchronized Tensioner-Payout Reel Stand Operation.
9.5.1. 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.
10. INSTALL CORE RETAINER (BUG)

10.1. ACCC conductor is constructed with a smooth composite core surrounded by one or more
layers of aluminum strands. The core retainer (bug) prevents the core from slipping back
inside during conductor installation so that the core is accessible for termination
procedures. The bug is temporary, used only during handling and pulling/stringing.
10.2. Core Retainers are ACCC specific and supplied by CTC. Bugs may be re-used but should
not be used indefinitely. Do not reuse a bug when the nut does not screw into the body
easily or if the inside collet appears worn or damaged.
10.3. Detailed, step by step instructions for installing and removing bugs are included in CTC
training and an instruction sheet that ships with each new bug.



11. CONNECT TO PULLING LINE
11.1. Old conductor may be used to pull in new ACCC ONLY if the old conductor is entirely
free of splices and damage. Splices or old conductor damage can damage sheave surfaces,
which can then transfer that damage to the surface of the new ACCC. Splices or damage
can hang up in sheaves, creating violent bouncing which can damage the new conductor or
drop the conductor onto the ground
11.2. If the old conductor has ANY splices, or if the core is rusted or has broken strands, then a
pulling (pilot wire) line must be used.
11.3. Connect the pulling line to the new ACCC pulling sock with a swivel of sufficient
capacity and in good working order.
12. HOISTING TO FIRST STRUCTURE

12.1. If old conductor is to be used for pulling, the new ACCC must be hoisted to connect to it
it. After threading the tensioner, hoisting to the first structure must be done smoothly using
a capstan hoist or similar motorized device, tractor or truck. Manual lifting, jerking, and
bouncing of the conductor must be avoided. If a pilot line is used to pull in the new
conductor, the pilot line can pulled to the tensioner and the pilot line attached to the
conductor at that point. Hoisting to the first structure must not put bending load on the
conductor at the grip. Use ropes to avoid sharp angles.



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 and uneven speed of such equipment
can expose the conductor to damage. Use a capstan hoist, tractor or truck 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.
13.2. 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.



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.
15. FOLLOW THE FLAG

15.1. Attach an easily visible flag near the swivel between the pulling line and the leading end of
the ACCC.
15.2. An individual in reliable radio contact with the puller/tensioner operator should keep this
flag in sight at all times during pulling, watching especially for hang-ups at blocks and
paying special attention at angles.
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



source. If the nearest constraint is far enough away (about 15m in the case of ACCC), the
strands have room to distribute the displacement and the loosening is not noticeable.
16.3. 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.
16.4. The second cause is also displacement of the aluminum in each strand which can occur if
the conductor passes over a sheave with an undersized groove, under tension. Sheave
groove radius should be 0.53 to 0.55 times the conductor diameter.
16.5. The third cause occurs if there is keystoning of the top layer of conductor. Compressing a
keystoned section also causes displacement of the aluminum strands. Keystone is normally
a defect in the stranding of the conductor.
16.6. 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.
16.7. 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.
16.8. 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. BACK-TO-BACK PULLING

17.1. Also see Back-To-Back Pulling set up considerations in Chapter 5, Section 6.5.
17.2. Core retainers (bugs) must be used at each end of ACCC conductor for back-to-back
pulls.
17.3. Special attention should be paid to the capacity and condition of wire mesh (sock) grips
used for back-to-back reel pulls.
17.4. Swivels must be used between reels. Special attention should be paid to the capacity and
condition of swivels.
17.5. Splices between reels must be installed only after the conductor has been pulled into
position. A splice must never be allowed to pass through a sheave.
18. LONG SPANS, RIVER CROSSINGS, ROAD CROSSINGS

18.1. Long pulls often require higher pulling tensions. Double check equipment load ratings.
Use only NEW wire mesh (Kellum) (sock) grips on the ACCC conductor for long, critical
pulls. Use only NEW or new condition swivels and hardware.
18.2. When re-conductoring, a pilot wire must be used to pull the ACCC. Do not pull ACCC
in with the old wire.



18.3. Consider the structures at each end of a long pull to be first and last structures when
selecting sheave sizes. When tall structures combined with large belly in the conductor
during the pull results in angles greater than 20, always use tandem sheave blocks. When
angles greater than 30 are expected, special multiple-sheave blocks may be required;
please consult with CTC Service (service@ctcglobal.com).
18.4. Temporary guys or support for towers or arms may be necessary to compensate for the
additional weight and tension applied to structures during long pulls.
19. MANUAL STRINGING

19.1. In special situations, especially when re-conductoring, accommodation of powered pulling
equipment (pullers and/or tensioners) may not be possible. In these cases, manual stringing
of ACCC may be required.
19.2. Manual stringing situations must be especially
careful of dropping or pulling the conductor over
obstacles or edges which are of smaller effective
diameter than minimum allowable. Fences,
rocks, walls, roofs, scaffolding are examples of
obstacles which can cause ACCC conductor
damage. When in doubt, and if unavoidable,
cover such obstacles with protection that assures
the conductor will contact only surfaces that are
minimum sheave working diameter or greater.
Split liquid storage drums can work well in this
situation.
19.3. Rotation of the payout reel must always be controlled, and light tension on the paid-out
conductor must always be maintained to prevent loosening of conductor wraps on the reel.
If conductor wrap loosening is allowed, and then placed under tension, the conductor could
be damaged if the top layer of conductor drops down into the next layer causing it to catch
on the next layer down. If loosening of conductor wraps on the reel occurs, it may be
corrected by rewinding under light tension just enough to keep the wraps smooth and
even.
19.4. Paid-out conductor must be kept clean until it is hoisted into place. Do not drag or drop the
new conductor in dirt or mud. Do not allow the new conductor to lay in dirt or mud.

19.5. Special care must be used when hoisting the conductor to always respect the minimum
allowable bending diameter. Pay special attention to placing strain on the conductor where
it exits deadends or grips. A capstan winch or equipment which starts, stops, and operates
smoothly should be used for hoisting. Manual hoisting can cause bouncing and jerking
during the hoist, which can damage the conductor.



20. REWINDING
20.1. If conditions arise that excess ACCC needs to be rewound on its reel, the conductor can
be rewound either manually or hydraulically and shall have 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.

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



diameters.
damaged.
pocketbook grips!
back of the grip.
conductor.
with splices or broken strands for pulling. Instead, pull in a pilot line using the old
conductor and pull in ACCC using the pilot line. Always use a pilot line for long
spans and river crossings.



Appendix A Recommended Sheave Diameters
F-750-071 Rev A

Recommended Common Sheave and Tensioner Wheel Sizes for ACCC
Diameter - Inches (millimeters)
Conductor
First and Last Intermediate Direction Change
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



Appendix A Minimum Sheave Diameters

F-750-071 Rev A
ACCC Sheave Wheels
page 2 - Sheave Wheel Selection Guidelines
Minimum Sheave Wheel Sizes
Diameter (mm) Sheave Minimum Working Diameter
Core Conductor Millimeters Inches
5.97 15.65 Helsinki Pasadena 500 19.69
5.97 18.29 Copenhagen Linnet 495 19.49
7.11 18.82 Reykjavik Oriole 595 23.43
7.11 19.53 Glasgow 595 23.43
7.11 20.50 Casablanca Laredo 595 23.43
7.11 21.79 Lisbon Hawk 595 23.43
7.75 19.56 Waco 645 25.39
7.75 23.55 Amsterdam Dove 645 25.39
8.13 25.15 Brussels Grosbeak 640 25.20
8.76 22.40 Oslo Irving 745 29.33
8.76 26.39 Stockholm 745 29.33
8.76 26.42 Lubbock 745 29.33
8.76 27.69 Galveston 745 29.33 Reference
8.76 27.71 Warsaw 745 29.33
Size
8.76 28.63 Hamburg Plano 745 29.33
8.76 29.11 Milan Corpus Christi 745 29.33
8.76 30.43 Vienna Cardinal 745 29.33
8.76 31.78 Prague 745 29.33
8.76 31.80 El Paso 745 29.33 Working
8.76 34.16 Paris Bittern 745 29.33 Diameter
9.53 28.14 Dublin Drake 795 31.30
9.53 28.63 Kolkata 795 31.30
9.53 29.90 Rome Arlington 795 31.30
9.53 31.50 Budapest Fort Worth 795 31.30
9.53 31.78 Mumbai 795 31.30
9.53 32.84 Munich 795 31.30
9.53 32.87 Beaumont 795 31.30
9.78 33.40 London San Antonio 800 31.50
9.78 36.86 Antwerp 800 31.50
9.78 36.88 Dallas 800 31.50
9.78 38.20 Madrid Lapwing 800 31.50
10.03 40.74 Chukar 800 31.50
10.54 20.78 Monte Carlo 805 31.69
10.54 28.96 Curlew 875 34.45
10.54 35.76 Bordeaux 875 34.45
10.54 38.20 Berlin 875 34.45
10.54 38.25 Houston 870 34.25
10.54 39.24 Falcon 870 34.25
Groove Radius4
10.54 44.75 Athens 870 34.25
10.54 44.76 Bluebird 870 34.25
ULS Conductors 1) Sheaves are required to respect Minimum Working
8.76 22.40 ULS Oslo ULS Irving 1000 39.37 Diameter for first and last structure, and structures
8.76 26.40 ULS Stockholm 1000 39.37 where stringing path is other than structure to
8.76 26.42 ULS Lubbock 1000 39.37 structure. (For ex: where a splice is made on the
8.76 27.69 ULS Galveston 1000 39.37 ground and then let up.)
8.76 29.11 ULS Milan ULS Corpus Christi 1000 39.37 2) Sheaves are recommended to respect Minimum Working
8.76 28.63 ULS Hamburg ULS Plano 1000 39.37 Diameter for interim structures. Smaller interim
8.76 31.78 ULS Prague 1000 39.37 sheave sizes may be considered where stringing
8.76 31.80 ULS El Paso 1000 39.37 b) for spans greater than 1.2 times the ruling span
8.76 34.16 ULS Bittern 1000 39.37 tensions are high enough to always keep the angle
9.53 25.15 ULS Leipzig 1000 39.37 over the sheave less than 20 degrees.
9.53 28.14 ULS Dublin ULS Drake 1090 42.91 3) Tandem sheaves are required:
9.53 29.90 ULS Rome ULS Arlington 1090 42.91 a) where stringing angle exceeds 20 degrees
9.78 36.86 ULS Antwerp 1000 39.37 c) for changes of direction > 30
9.78 36.88 ULS Dallas 1000 39.37 d) for ULS Conductors, first and last structures
10.54 20.79 ULS Monte Carlo ULS Monte Carlo 1200 47.24 4) Groove Radius must be at least 0.55 times
10.54 25.00 ULS 25mm 1000 39.37 conductor diameter. Neoprene, Nylon, or Urethane
10.54 28.96 ULS Curlew 1000 39.37 lined grooves are recommended.
10.54 29.01 ULS Mahakam 1200 47.24
Page 2



REVISION HISTORY
A 121515-1

Chapter 8 Sagging, Terminations,
Suspensions, Ancillary Hardware
Chapter 8 Sagging, Terminations, and Suspensions Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
5. SAGGING .......................................................................................................................................... 2
6. INSTALL GRIPS .................................................................................................................................. 3
6.5. Double Grips .................................................................................................................................................. 4
7. CUTTING THE CONDUCTOR ............................................................................................................... 4
8. TERMINATIONS ................................................................................................................................ 5
8.1. Deadending ................................................................................................................................................... 5
8.3. Splicing .......................................................................................................................................................... 5
8.6. Terminal Pads ................................................................................................................................................ 6
8.7. T-Taps ............................................................................................................................................................ 6
9. SUSPENSIONS and ANCILLARY HARDWARE ....................................................................................... 6
10. BUNDLED CONDUCTORS ................................................................................................................... 7
11.1. DONT OVER-BEND! ....................................................................................................................................... 8
11.2. TWO Tensioner DON'TS ................................................................................................................................. 8
Appendix A ACCC Deadend Installation Instructions .............................................................................. 9
Appendix B ACCC Splice Installation Instructions .................................................................................. 10
Appendix C Compression Die Chart ......................................................................................................... 11
1. PURPOSE
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:
2. SCOPE
3. DEFINITIONS
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.
4.3. IEEE Standard 516 Guide for Maintenance Methods on Energized Power Lines
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
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.
6.5. Double Grips

6.5.1. In cases where gripping the conductor due to residual stranding oil or other
contamination or high tension due to long spans, or high sagging tension, it may be
necessary to double grip the conductor.
6.5.2. In these cases, use a short sling (approximately 3 feet or 1 meter) to equalize the
pull tension between the two grips. Protect the exposed portions of the conductor
between the grips with split rubber hose.
6.5.3. The grips MUST NOT touch when under full load, and they MUST NOT be too
far apart or a bird-cage will be created between them.
7. CUTTING THE CONDUCTOR

7.1. Rough cuts of the conductor may be made by any conventional tools or methods such as
ratchet cutters or cable cutters. Note that any method other than hacksaw WILL damage the
ACCC core locally to the cut. When a rough cut of the conductor is made, ensure that the
tension is relaxed so that a bird cage doesnt occur as the aluminum will flow towards the
grip under tension.
7.2. The final cut of ACCC core must be done with a fine-tooth hacksaw only. Any other
cutting method is unacceptable.
7.3. Cutting of the aluminum strands of ACCC may be accomplished by either a fine tooth
hacksaw or approved conductor stripper with the correct bushing. However, the method
used must NEVER nick or scratch the core. To avoid core surface damage, the final
separation of the aluminum strands on the bottom layer must be by gentle, repetitive
bending fatigue only.
7.4. To ensure proper sagging dimensions, measure all of the linkage attached to the structure
including insulators and any linkage required to attach the dead end eye for the ACCC
conductor plus the dead end eye. Mark the conductor with this measurement. After
marking the conductor at the appropriate location, cut the conductor towards the structure
adding at least 12 inches (305 mm) of extra conductor in addition to the amount marked on
the conductor. The initial cut can be made with cable cutters or ratchet cutters. Make the
final cut according to the directions in the deadending kit.
Final Cut Rough Cut

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.
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. SUSPENSIONS and ANCILLARY HARDWARE

9.1. Armor rods or protector rods are always required for all suspension and ancillary hardware
and must be capable and rated for the higher operating temperatures for which ACCC is
rated.
9.2. ACCC is a high temperature, low sag (HTLS) conductor. It operates at much higher
temperatures than conventional conductors, up to 180 C (350 F). Appropriate high
temperature suspension hardware and ancillary hardware is REQUIRED.
9.3. Tandem suspensions and yoke plates must be used where change of direction angles exceed
30 degrees.
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.
10.2. All payout reel tensions should be consistent.

10.3. Multi-sheave blocks must be used (same diameter as would be used for single conductor
pulling). Running boards must be used for pulling, but not for alignment at anchors.
Always keep running boards (gators) at a constant speed going through travelers. (Do not
slow down when the gator gets to the blocks).
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.
11.TEN INSTALLATION DONTS

diameters.
11.2. TWO Tensioner DON'TS
11.2.1. Dont use a conventional tensioner fairlead for ACCC conductor. A multiple-
roller fairlead with large effective radius MUST be used.
11.2.2. Dont let ACCC run hard on the end roller of the fairlead. Use an interim sheave
to raise the conductor if needed.
damaged.
pocketbook grips!
back of the grip.
conductor.
with splices or broken strands for pulling. Instead, pull in a pilot line using the old
conductor and pull in ACCC using the pilot line. Always use a pilot line for long
spans and river crossings.
Appendix A ACCC Deadend Installation Instructions

1. With the tapered end of the inner sleeve facing the end of the

ACCC conductor slide it down the conductor about 3.5 ft (1.1
mm).

2. Slide the outer sleeve over the ACCC conductor with the pad
3.5 ft (1.1 mm) from the cut end of the conductor (See Fig 1).
3. Tape aluminum strands measured at the length of the collet

housing plus 2 inches (50mm) from conductor end.
4. Expose the solid core by cutting aluminum strands at the mark

one layer at a time.
5. CAUTION: Do not cut or nick the core. Ensure that the

core end is cut with a fine tooth hacksaw. Failure to follow
these instructions could result in a poor connection.
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.
7. Slide the collet housing, wrench flats toward the aluminum

strands onto the core (See Fig. 2).
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).
11. Liberally apply oxidation inhibitor to the outer diameter of the

aluminum inner sleeve and slide the inner sleeve into the
outer sleeve. Note: Appropriate sized dies for each conductor
size must be utilized to complete
crimps/compressions see Appendix C
12. Crimp/compress starting at opposite end from the eye using
correct die size (Appendix C) and slightly overlapping the
crimps in the direction of the eye until the
crimps/compressions meet the mark on the aluminum outer
tube (See Fig. 5).
13. Crimp/compress in the area marked on the aluminum outer

tube to secure the eye. Ensure washer is flush with pad. Do
not over crimp to damage washer. This should require 1 to 3
crimps to secure (See Fig. 5).
Appendix B ACCC Splice Installation Instructions

1. With the tapered end of the inner sleeve facing the end of the ACCC
conductor, slide the inner sleeves down the conductor about 3.5 feet (1.1 m).
(See Fig 1)
2. Slide the outer sleeve over the side furthest from the structure (Side B) with the
end of the tube 2.0 ft (0.61m) from the cut end of the conductor (See Fig 1).
3. Tape aluminum strands at the following distances from the conductor end:
a. Side A measure the length of the collet housing plus 2 inches
(50mm)
b. Side B measure the length of the collet housing only
4. Expose the solid core by cutting aluminum strands at the mark one layer at a
time (See Fig 1).
CAUTION: Do not cut or nick the core. Ensure that the core end is
uncrushed; if necessary square off with a hacksaw. Failure to follow these
instructions could result in a poor connection.
5. 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.
6. Slide the collet housing, wrench flats toward the aluminum strands onto the core
(See Fig. 2).
7. 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). Repeat for opposite side.
8. Install the coupling on Side A (closet to structure) and the collet retainer on the
opposite Side B (furthest from structure) and tighten by hand; complete the
tightening with wrenches (85 ft-lbs or 115 N-m torque required).
9. For Side A ensure that approximately 3.0 in (76 mm) core and the narrow end of
the collet are visible after tightening (See Fig. 4).
10. For Side B ensure that approximately 1.0 in (25 mm) core and the narrow end of
the collet are visible after tightening (See Fig. 4).
11. Bring the two sides together and hand-tighten the swivel end of coupling to the
collet retainer. Complete tightening with wrenches (85 ft-lbs or 115 N-m torque
required) (See Fig. 5).
12. Mark the conductor, on Side A, 17.0 in (432 mm) from the end of the aluminum
strands using tape or a felt tip marker. This mark will be the location of the inner
sleeve nose end. NOTE: If using tape you must remove before crimping (See
Fig. 5).
13. 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.
14. Slide the outer sleeve over the coupling assembly.
15. Side A Liberally apply oxidation inhibitor to the outer diameter of the inner
sleeve, slide the inner sleeve, nose end, into the outer sleeve up to the 17 in
(432 mm) marked spot on the conductor. Make sure the outer tube bump is up
against the inner sleeve. Move outer sleeve as necessary.
16. Once the outer sleeve is in place, crimp/compress (Appendix C) the outer
sleeve beginning form Side A, starting crimp point, in an inwards direction using
the correct die size and overlapping the crimps approximately 1/8 1/4 in (3 6
mm) ( to the end of the crimp zone on Side A (See Fig. 6).
17. Crimp the center of the outer tube to the coupling assembly with one crimp (See
Fig. 6).
Note: Appropriately sized dies for each
18. Side B Liberally apply oxidation inhibitor to the outer diameter of the inner conductor size must be utilized to complete
sleeve; slide the inner sleeve into the outer sleeve. Make sure the outer tube crimps/compressions see Appendix C
bump is up against the inner sleeve. (See Fig. 6)
19. Crimp Side B beginning form the inside mark (compressing outwards) up until
the ending crimp point. Ensure the inner sleeve is up against the bump of the
outer tube before making the first crimp. Overlap the crimps approximately 1/8
1/4 in (3 6 mm) to the end of the crimp zone on Side A (See Fig. 6).
Appendix C Compression Die Chart

F750069B
CompressionDieChartforDeadends,Splices,andBurndyTerminalPads
Diameter(mm) Burndy DeadendsandSplices
International TerminalPads Deadends& Forjasul
Core Conductor Name ASTMName W/OInnerSleeve W/InnerSleeve Splices Dervaux PLP (Tramontina) AFLCore AFLSleeve
15.65 Helsinki Pasadena
5.97
18.29 Copenhagen Linnet 40mm(+3/0.2)
L717W 10014SH 10024AH
18.82 Reykjavik Oriole
46mm
7.11 20.50 Casablanca Laredo L725W
L720W L727W 43mm
21.79 Lisbon Hawk 10014SH 10030AH
19.53 Glasgow Waco 40mm(+3/0.2)
7.75
23.55 Amsterdam Dove L722W 40.8mm(+3/0.2)
50.5mm
8.13 25.15 Brussels Grosbeak L724W
22.40 Oslo Irving L722W L725W
26.39 Stockholm Lubbock
L725W 10018SH 10040AH
27.69 Warsaw Galveston
28.63 Hamburg Plano 52.2mm(+3/1)
8.76
29.11 Milan CorpusChristi
L727W
30.43 Vienna Cardinal
31.78 Prague ElPaso
34.16 Paris Bittern L728W
L735W 56.5mm 56.5mm
25.15 ULSLeipzig L724W
28.14 Dublin Drake L725W 10018SH 10040AH
28.63 Kolkata
9.53 29.90 Rome Arlington
L727W
31.50 Budapest FortWorth
31.78 Mumbai
32.84 Munich Beaumont
L728W
33.40 London SanAntonio
9.78 36.86 Antwerp Dallas L7351W L7351W
38.20 Madrid Lapwing L735W L735W
10.03 40.74 Chukar
20.78 MonteCarlo
25.00 ULS25mm L724W
56.5mm 56.5mm
28.96 Curlew L727W L735W
10.54 29.01 ULSMahakam L727W
38.20 Berlin Houston L735W
39.24 Falcon
44.76 Athens Bluebird
tobedetermined
Dervaux,PLP,andForjasulDieSizesaremmbetweenhexflats
REVISION HISTORY
A 121515-1
Chapter 9 Maintenance and Repair
WI-750-019 Rev D Page 1 of 4
Chapter 9 Maintenance and Repair Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
5. MAINTENANCE ................................................................................................................................. 2
5.2. Conductor Trolleys ........................................................................................................................................ 2
6. REPAIR METHODS ............................................................................................................................. 2
7. REPAIR GUIDELINES .......................................................................................................................... 4
1. PURPOSE
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:
1.1.9. Chapter 9 Maintenance & Repair

2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully maintain and
repair all sizes of ACCC conductor.
3. DEFINITIONS
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)

6.3.2. Compression Repair Sleeve

6.3.3. Mid-span Splice (CTC Global 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 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
D 121515-1 15 Dec 2015

ACCC Installation Guidelines 2016

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ACCC Conductor Installation Guidelines

Chapter 1 General Guidelines

Chapter 1 General Guidelines Table of Contents

2016 CTC Global- For use with ACCC Conductor only

5. ACCC INSTALLATION DIFFERENCES

2016 CTC Global- For use with ACCC Conductor only

6. GENERAL CONDUCTOR HANDLING GUIDELINES

2016 CTC Global- For use with ACCC Conductor only

6.2.5. Applying tension or force (like conductor bouncing or dropping) over an

2016 CTC Global- For use with ACCC Conductor only

6.3. Sharp Angles

2016 CTC Global- For use with ACCC Conductor only

7. TEN INSTALLATION DONTS

2016 CTC Global- For use with ACCC Conductor only

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015

2016 CTC Global- For use with ACCC Conductor only

Chapter 2 Installation Safety Table of Contents

2016 CTC Global- For use with ACCC Conductor only

are found in the referenced documentation. CTC recommends strict adherence to a

5. ACCC UNIQUE SAFETY CONSIDERATIONS

2016 CTC Global- For use with ACCC Conductor only

2016 CTC Global- For use with ACCC Conductor only

2016 CTC Global- For use with ACCC Conductor only

7. TEN INSTALLATION DONTS

2016 CTC Global- For use with ACCC Conductor only

Section II Hazardous Ingredients/Identity Information

Section III Physical/Chemical Characteristics

Unusual Fire and Explosion Hazards

Section V Reactivity Data

Incompatibility (Materials to Avoid)

2016 CTC Global- For use with ACCC Conductor only

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015

2016 CTC Global- For use with ACCC Conductor only

Chapter 2 Installation Safety Table of Contents

2016 CTC Global- For use with ACCC Conductor only

are found in the referenced documentation. CTC recommends strict adherence to a

5. ACCC UNIQUE SAFETY CONSIDERATIONS

2016 CTC Global- For use with ACCC Conductor only

2016 CTC Global- For use with ACCC Conductor only

2016 CTC Global- For use with ACCC Conductor only

7. TEN INSTALLATION DONTS

2016 CTC Global- For use with ACCC Conductor only

Section II Hazardous Ingredients/Identity Information

Section III Physical/Chemical Characteristics

Unusual Fire and Explosion Hazards

Section V Reactivity Data

Incompatibility (Materials to Avoid)

2016 CTC Global- For use with ACCC Conductor only

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015

2016 CTC Global- For use with ACCC Conductor only

Chapter 3 Training Table of Contents

2016 CTC Global- For use with ACCC Conductor only

2016 CTC Global- For use with ACCC Conductor only

6. INSTALLATION TRAINING SYLLABUS

2016 CTC Global- For use with ACCC Conductor only

6.7. Equipment Requirements (Classroom and Field)

2016 CTC Global- For use with ACCC Conductor only

7. TEN INSTALLATION DONTS

2016 CTC Global- For use with ACCC Conductor only

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015