Chapter 8 - Sagging, Terminations, Suspending

ACCC Conductor Installation Guidelines
Chapter 8 Sagging, Terminations,

Suspensions, Ancillary Hardware
WI-750-077
Rev A
Page 1 of 12
Chapter 8 Sagging, Terminations, and Suspensions Table of Contents

1.
PURPOSE .......................................................................................................................................... 1
2.
SCOPE ............................................................................................................................................... 2
3.
DEFINITIONS ..................................................................................................................................... 2
4.
ASSOCIATED DOCUMENTS ................................................................................................................ 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. TEN INSTALLATION DONTS .............................................................................................................. 8
11.1. DONT OVER-BEND! ....................................................................................................................................... 8
11.2. TWO Tensioner DON'TS ................................................................................................................................. 8
11.3. TWO Payout Reel DON'TS ............................................................................................................................. 8
11.4. THREE Handling and Equipment DON'TS ...................................................................................................... 8
11.5. TWO Pulling / Stringing DONTS .................................................................................................................... 8
Appendix A ACCC Deadend Installation Instructions .............................................................................. 9
Appendix B ACCC Splice Installation Instructions .................................................................................. 10
Appendix C Compression Die Chart ......................................................................................................... 11
1. PURPOSE
1.1. This is Chapter 8 of the ACCC Conductor Installation Guidelines, covering ACCC
sagging, suspensions, terminations, and ancillary hardware. The chapter also covers
bundling. The Guidelines consist of nine chapters, each written to stand alone to address
specific installation subjects. Taken together, the chapters comprise the entire Installation
Guidelines:
1.1.1. Chapter 1 General Installation Guidelines
1.1.2. Chapter 2 Safety
1.1.3. Chapter 3 Training
1.1.4. Chapter 4 Reel Handling and Storage
1.1.5. Chapter 5 Site Considerations and Set-ups
1.1.6. Chapter 6 Required Equipment
1.1.7. Chapter 7 Stringing / Pulling
1.1.8. Chapter 8 Terminations, Sagging, and Suspending
1.1.9. Chapter 9 Maintenance and Repair
1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project
managers and planners, field inspectors, utility personnel and linemen with guidelines,

WI-750-077
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Page 2 of 12
recommendations and requirements necessary to safely and successfully install the ACCC
composite-core bare overhead conductor and accessories. This document is an overview
and guideline covering what to do but not necessarily how to do it. It is not intended to
serve as a more intensive training manual or act as a substitute for proper training, required
personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully install all
sizes of ACCC conductor.
2.2. These guidelines include additional equipment and techniques that are required for UltraLow Sag (ULS) ACCC conductor sizes.
3. DEFINITIONS
3.1. ACCC is a registered trademark of CTC Global, and is defined as Aluminum Conductor
Composite Core, stranded with Aluminum 1350-0 (where 0 stands for fully annealed) or
Aluminum 1350-0 Z-wire trapezoidal wire.
3.2. Initial Sag occurs when new conductor is pulled and clipped in.
3.3. Final Sag occurs when conductor has been energized.
3.4. Ruling Span is the assumed uniform, or average span that best represents the actual spans
in any specified section of a line.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors.
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalents.
4.3. IEEE Standard 516 Guide for Maintenance Methods on Energized Power Lines
4.4. The remaining Chapters of the Installation Guidelines
5. SAGGING
5.1. There is nothing unique about sagging ACCC versus any other bare conductor. This
guideline assumes that the user is familiar with industry standard sagging techniques.
5.2. Any of the four common methods of sagging may be used: line of sight, transit, stopwatch,
and dynometer (least preferred).
5.3. It is recommended that conductors not be allowed to hang in the stringing blocks more than
24 hours before being pulled to the specified sag. If this time is exceeded, the cable
manufacturer should be consulted to determine if short-term creep correction factors are
required. The total time that the conductors are allowed to remain in the stringing blocks
before being clipped should never be more than 72 hours. If this time is exceeded, damage

WI-750-077
Rev A
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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.

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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

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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.

WI-750-077
8.4.2.
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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.

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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.

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11.TEN INSTALLATION DONTS

11.1. DONT OVER-BEND!
11.1.1. Dont allow the conductor to contact surfaces that present sharp angles or small
diameters.
11.2. TWO Tensioner DON'TS
11.2.1. Dont use a conventional tensioner fairlead for ACCC conductor. A multipleroller 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.
11.3. TWO Payout Reel DON'TS
11.3.1. 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.
11.3.2. 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.
11.4. THREE Handling and Equipment DON'TS
11.4.1. 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!
11.4.2. 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.
11.4.3. Dont hoist the conductor in any manner which causes a sharp bend in the
conductor.
11.5. TWO Pulling / Stringing DONTS
11.5.1. Dont install any ACCC with under-diameter sheaves on the first and last
structure or any angles that are over 30 degrees.
11.5.2. Don't pull in conductor using old conductor if it is rusty. Dont use old conductor
with splices or broken strands for pulling. 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.

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Rev A
Page 9 of 12
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.
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).
Note: Appropriate sized dies for each conductor

size must be utilized to complete
crimps/compressions see Appendix C

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Page 10 of 12
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).
18. Side B Liberally apply oxidation inhibitor to the outer diameter of the inner
sleeve; slide the inner sleeve into the outer sleeve. Make sure the outer tube
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).
Note: Appropriately sized dies for each

conductor size must be utilized to complete
crimps/compressions see Appendix C

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Page 11 of 12
Appendix C Compression Die Chart

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

WI-750-077
Rev A
REVISION HISTORY
REV.
CHANGE REQUEST #
121515-1
DATE
Page 12 of 12

Chapter 8 - Sagging, Terminations, Suspending

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ACCC Conductor Installation Guidelines