ACCC Conductor Installation Guidelines 20181

ACCC® Conductor Installation Guidelines
Chapter 1 – General Guidelines

WI-750-070 Rev B Page 1 of 8
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 .................................................................................................................................................. 6
7. TEN INSTALLATION DON’TS .............................................................................................................. 7
7.1. DON’T OVER-BEND! ....................................................................................................................................... 7
7.2. ONE Tensioner DON'T .................................................................................................................................... 7
7.3. TWO Payout Reel DON'TS .............................................................................................................................. 7
7.4. THREE Handling and Equipment DON'TS ....................................................................................................... 7
7.5. TWO Pulling / Stringing DON’TS .................................................................................................................... 7
7.6. ONE Termination DON’T ................................................................................................................................ 7
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.
©2017 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-O (where O stands for fully annealed) or
Aluminum 1350-O Z-wire trapezoidal wire.
4. ASSOCIATED DOCUMENTS
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors
4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and
1926.950 or ISO 29.240.20 or local country equivalent
4.3. The remaining Chapters of the Installation Guidelines
5. 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 conductor’s rated tensile strength is designed into the ACCC® composite core
after the knee point is achieved , not relying on 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
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.
6.2.4. Hanging equipment or personnel from a conductor using a rope, hook, or narrow
strap.
X X
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.
6.2.7. Failure to control conductor “tail” or angles at exit points of grips.
X X
✓ ✓

X
6.3. Sharp Angles
6.3.1. Any conductor stringing angle which is greater than 30 degrees, or any situation
that includes severe uplift or down pull must use a larger block, tandem sheave
blocks or multiple roller sheaves. Even with large sheaves, the extended contact
area between the sheave and the outer layer of aluminum strands will tend to
loosen the strands, especially at higher tension levels. To avoid loosening, always
use a larger block or tandem sheaves for sharp angles.

7. TEN INSTALLATION DON’TS

7.1. DON’T OVER-BEND!
7.1.1. Don’t allow the conductor to contact surfaces that present sharp angles or small
diameters.
7.2. ONE Tensioner DON'T
7.2.1. Don’t 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. Don’t 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. Don’t 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. Don’t use grips that aren’t 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. Don’t hoist the conductor in any manner which causes a sharp bend in the
conductor.
7.5. TWO Pulling / Stringing DON’TS
7.5.1. Don’t 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. Don’t 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 DON’T
7.6.1. Don’t 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
3.1 Corrected “1350-0” to “1350-O”

5.2 Deleted “…loosening and…”
Added 6.2.7
B
Added Red “X” to 6.24, 6.25, and 6.26
Added Green “✓” to 6.3.1
Update copyright footer to 2017

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. DON’T 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
4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors
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


REVISION HISTORY
A 121515-1 15 Dec 2015
B Changed copyright footer to 2017 7 July 2017

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 DON’Ts (Classroom and Field)............................................................................................................ 4
1. PURPOSE
1.1. This is Chapter 3 of the ACCC® Conductor Installation Guidelines, covering installation
training. The Guidelines consist of nine chapters, each written to stand alone to address
specific installation subjects. Taken together, the nine chapters comprise the entire
recommendations and requirements necessary to safely and successfully install ACCC®

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 and accompanying Script (F-750-066)
5. TRAINING
5.1. CTC provides an ACCC® specific Installation Training course which consists of
approximately 2 to 4 hours classroom instruction, hands-on deadend / splice assembly
instruction, and up to 6 days of on-the-job training, for all new projects with previously
untrained crews.
5.2. Attendance by installation supervisor(s) should be mandatory. CTC strongly recommends
that all line personnel, safety inspectors, and construction crew(s) attend the ACCC®
Installation Training Course prior to the start of installation. Should a change in crew
supervision occur during the course of construction, ACCC® installation training should be
repeated before that crew starts work.
5.3. Improper installation equipment or methods could result in line damage or failure and are
not covered by the CTC Warranty.
5.4. An appropriate classroom equipped with digital projector is needed for the classroom
instruction portions of the ACCC® Training Course.
5.5. A language interpreter may be needed for presentation of training, both classroom and
hands-on.
5.6. The training course concludes with a written test. Graduates are issued an ACCC®
Installation Training Course Diploma.

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 Dampers (Classroom and Field)
6.6.3. Installing Terminal Pads and “T” Taps (Classroom and Field)
6.6.4. Installing Ancillary Hardware

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
6.7.6. Equipment Readiness Review
6.8. The 10 DON’Ts (Classroom and Field)
REVISION HISTORY
A 121515-1 15 Dec 2015
3.1 Corrected “1350-0” to “1350-O”

5.1 Added “…, and up to 6 days of on-the-
job training for all new projects with
B 7 July 2017
previously untrained crews.”
5.5 Deleted “CTC training is available in
English and Spanish only at this time.”
Deleted 5.7 and 5.8
Changed copyright footer to 2017

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. DON’T OVER-BEND! ....................................................................................................................................... 6
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:
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 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 manufacturer’s 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.
6.4. Reels are constructed so that they must be supported either by the reel flanges from below
or on an axle (mandrel) through the arbor hole. When an axle through the arbor hole is used
to lift reels, a spreader bar must be employed to prevent damage to the reel flanges, or
conductor, or both, by inward force on the reel flange.
A spreader bar with slings or chains rigged vertically to each end of an adequately sized
axle through the arbor hole is the preferred method of hoisting. If a spreader bar is not
available at least 3 – 4 meter (15’) steel or nylon slings or lifting chains must be used to
prevent damage to the top of the reel flange
6.5. Returnable metal reels may be supported by a singletree arrangement that clamps to the
flange and is lifted from above.
6.6. Reels may be placed on flat ground or floor. Always chock the reel flanges (never chock
under the conductor itself or it’s protective lagging) to prevent rolling.

6.7. At no time shall a loaded reel be laid on its side either during handling, loading, unloading
or storage.
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.
X X
7.2. Identification tags and other markings should be retained on all packages until the
conductor is to be used. Identification tags should be protected from weather to retain
information.
7.3. The reels are delivered from the factory with a protective wrapping which could include

wood lagging and/or fiber board held down with steel bands over the outermost layer of
conductor. The outermost protective covering should be left on the reels if stored for an
extended period of time.
7.4. Storage Temperatures:

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


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

REVISION HISTORY
A 121515-1 15 Dec 2015
3.1 Corrected “1350-0” to “1350-O”

B Deleted Appendix A 7 July 2017

Chapter 5 – Site Considerations & Set-ups
WI-750-074 Rev C Page 1 of 9
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................................................................................................................................................. 3
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. DON’T 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
1.1.8. Chapter 8 — Sagging, Terminations, and Suspending

1.2. The purpose of the Guidelines is to provide experienced transmission engineers, project managers
and planners, field inspectors, utility personnel and linemen with guidelines, recommendations and
requirements necessary to safely and successfully install the ACCC® composite-core bare overhead
conductor and accessories. This document is an overview and guideline covering what to do but
not necessarily how to do it. It is not intended to serve as a more intensive training manual or act as
a substitute for proper training, required personnel skill sets, or industry experience.
2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully install all sizes of
ACCC® conductor.
2.2. These guidelines include additional equipment and techniques that are required for Ultra-Low Sag
(ULS) ACCC® conductor sizes.
3. DEFINITIONS
5. SITE CONSIDERATIONS
5.1. Setup areas
5.1.1. Setup areas, where conductor reel handling equipment will be placed, must allow for
access for the delivery, unloading and handling of new reels of conductor, and for the
loading and handling of take-up reels. Additional detail regarding storage and handling of
conductor reels is found in Chapter 4.
5.1.2. Setup areas must allow for access by and proper placement of payout reel stands and
tensioners. The tensioner should be positioned at least three (3) times the height of the first
structure back from the first structure. The payout reel must be at least 50’ (15 meters)
away from the tensioner. See 6.1.
5.1.3. With proper use of sheaves, the tensioner and / or payout reel equipment may be offset to
avoid obstacles or take advantage of better setup areas.

5.1.4. Tensioners and payout reel stands must be prevented from shifting or movement during
use. In some soil conditions, this can be done with screw anchors or dug-in “dead man”
anchor. In some cases, concrete weighting may be used. Often, large trucks or heavy
equipment is used for anchoring.
5.1.5. For bundled conductor projects, conductor bundles should be pulled simultaneously.
Allow for extra sets of payout reels, tensioners, and pullers at setup areas. Additional
detail regarding bundled conductor considerations is found in Chapters 7 and 8.
5.1.6. Clearance distances from existing electric power lines shall be respected and maintained:
Voltage Minimum Clearance Minimum Clearance
(nominal, kV, alternating current) Distance (feet) Distance (meters)
up to 50 10 3
over 50 to 200 15 5
over 200 to 350 20 6.5
over 350 to 500 25 8
over 500 to 750 35 11
over 750 to 1,000 45 14
over 1,000 * *
* (as established by the utility owner/operator or registered professional engineer who is a
qualified person with respect to electrical power transmission and distribution).
Note: The value that follows "to" is up to and includes that value. For example, over 50 to 200
means up to and including 200kV.
Note: This table from OSHA 1906.1408
5.1.7. Live lines nearby can induce voltage and current into the conductor, especially parallel
live lines, and this is common when re-conductoring. ALWAYS follow recommended
grounding procedures.
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.
6.1.2. 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.

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.

6.2.4. For bundled applications, use individual sheaves between each payout reel and the
tensioner to allow for slight differences in payout speeds or tensions and differences in
payout stand placements and conductor path adjustments.
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.
X ✓
6.3.3. Assure that contact between the sheave and the structure itself does not restrict the
alignment between the sheave groove and conductor path.
X
6.4. Restricted Area Alternatives
6.4.1. The purpose of the 3:1 rule (paragraph 6.1.1) is to keep the angle of the conductor over the
first sheave under about 20° and to provide sufficient length for the conductor to absorb
the opening of strands that tends to occur when any helical wound conductor passes over a
sheave under tension. When set-up areas are restricted and the 3:1 rule cannot be achieved,
the alternatives are, in order of preference:
6.4.2. Use a larger sheave at the first structure.
6.4.3. Use a tandem sheave block at the first structure.
6.4.4. Reduce the height of the first structure sheave.
6.4.5. Move the set-up area for tensioner / payout reel to the other direction side and pull that
reel in from the other direction.
6.4.6. Skip that set-up area: pull back-to-back reels instead (usually last choice).
6.4.7. The choice of alternatives is best made by experienced personnel based on site conditions.
In all cases, watch for strand opening at the tensioner and each sheave. If opening is
observed, reduce stringing tension if possible.
6.5. Back-to-Back Reel Pulls
6.5.1. Reels of ACCC conductor may be pulled back-to-back for a variety of reasons including
to avoid difficult setup areas. Two reels to four reels may be pulled back-to-back,
sometimes more, please check with CTC Field Service. As a guideline, pulls should not
be more than 20 spans. See Chapter 7 for specific guidelines for pulling multiple reels.


7.1.1. Don’t allow the conductor to contact surfaces that present sharp angles or small diameters.
7.2.1. Don’t 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.
7.3.1. Don’t 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. Don’t 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.
7.4.1. Don’t use grips that aren’t 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. Don’t hoist the conductor in any manner which causes a sharp bend in the conductor.
7.5.1. Don’t 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. Don’t 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.
7.6.1. Don’t 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
A 121515-1 15 Dec 2015
B April, 2016
Added Section 5.1.5 Bundled Conductors

Deleted Section 6.1.2
C Added Section 6.2.4 Tension Feed Sheaves for July 2017
Bundled Applications
Copyright 2017

Chapter 6 – Tools and Equipment
WI-750-075 Rev D Page 1 of 19
Chapter 6 – Tools & Equipment – Table of Contents

1. PURPOSE .......................................................................................................................................... 1
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
4. ASSOCIATED DOCUMENTS ................................................................................................................ 2
5. TOOLS & EQUIPMENT ....................................................................................................................... 2
5.1. Tools & Equipment Checklists ....................................................................................................................... 2
5.2. Safety Equipment.......................................................................................................................................... 3
5.3. Reel Handling Equipment ............................................................................................................................. 3
5.4. Payout Reel Stand ......................................................................................................................................... 3
5.5. Tensioner ...................................................................................................................................................... 5
5.6. Tensioner Fairlead ........................................................................................................................................ 5
5.7. Core Retainer (Bug)....................................................................................................................................... 6
5.8. Pulling Grips (Socks) ...................................................................................................................................... 6
5.9. Tension Grips ................................................................................................................................................ 7
5.10. Blocks (Sheaves or Travelers)........................................................................................................................ 8
5.11. Hoisting Equipment ...................................................................................................................................... 8
5.12. Puller ............................................................................................................................................................. 9
5.13. Swivels .......................................................................................................................................................... 9
5.14. Terminating and Splicing............................................................................................................................. 10
6. SPECIAL EQUIPMENT FOR BUNDLED APPLICATIONS ........................................................................ 12
6.1. Tensioner .................................................................................................................................................... 12
6.2. Payout Reels ............................................................................................................................................... 12
6.3. Tensioner Feed-In Sheaves ......................................................................................................................... 12
6.4. Sheave Blocks.............................................................................................................................................. 12
6.5. Running Board or Balance Board ................................................................................................................ 13
6.6. Puller ........................................................................................................................................................... 13
7. TEN INSTALLATION DON’TS ............................................................................................................ 14
7.1. DON’T OVER-BEND! .................................................................................................................................... 14
7.2. ONE Tensioner DON'T ................................................................................................................................. 14
7.3. TWO Payout Reel DON'TS ........................................................................................................................... 14
7.4. THREE Handling and Equipment DON'TS .................................................................................................... 14
7.5. TWO Pulling / Stringing DON’TS.................................................................................................................. 14
7.6. ONE Termination DON’T ............................................................................................................................. 14
Appendix A — Equipment Readiness Review Form .................................................................................... 15
Appendix B — Minimum Sheave and Tensioner Sizes ................................................................................ 16
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

1.1.6. Chapter 6 — Tools and Equipment
2. SCOPE
2.1. These guidelines apply to specific equipment and techniques required to successfully install
all sizes of ACCC® Conductor.
Low Sag (ULS) and Ultra-High Strength (AZR™) (Ice Load) ACCC® Conductor types
and bundled conductor installations.
3. DEFINITIONS
Composite Core, stranded with Aluminum 1350-0 (where 0 stands for fully annealed) or
AT3 Aluminum Zirconium alloy in trapezoidal or Z-trapezoidal wire configurations.
4.1. IEEE Standard 524Ô Guide to the Installation of Overhead Transmission Line Conductors.
1926.950 or ISO 29.240.20 or local country equivalent.
5. TOOLS & EQUIPMENT

5.1. Tools & Equipment Checklists
5.1.1. The Tools & Equipment described herein 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).
5.1.3. CTC can produce a size-specific Tooling and Equipment 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
ACCC® Conductor and installation equipment.
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 Equipment
5.3.1. ACCC® Conductor is supplied on reels to customer specification and conforming
to DIN 46395 or NEMA WC 26 for steel reels (recommended) or DIN 46395 or
NEMA WC 26 Class 3 for wooden reels. However, minimum winding surface
(drum or hub) diameters are specified per CTC document number F-750-032.
5.3.2. Conductor reels may be moved by forklift, hoist or crane. See Chapter 4 for
procedure and precautions.
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® Conductor 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® Conductor 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
F-750-032.
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 it’s 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® Conductor installation. If disc brakes are
used, the brakes must be in excellent condition and fully capable of quickly and
smoothly stopping a full reel rotating at payout speed.

5.5. Tensioner
5.5.1. Tensioner bull wheels must be a minimum diameter as specified in Appendix B,
measured at the bottom of the grooves of the bull wheel.
5.5.2. Only multi-groove tensioners and a minimum of four grooves should be used. The
number of grooves in the bullwheel shall be sufficient to prevent conductor
slipping and to maintain good tension control.
5.5.3. Tensioner bull wheel groove radius should be minimum .55 times conductor
diameter to help control strand opening.
5.5.4. Tensioner bull wheel grove material shall be hard enough to avoid friction on outer
layer of strands sufficient to cause strand loosening or birdcage.
5.5.5. See Section 6.1 for bundled applications.
5.6. Tensioner Fairlead
5.6.1. Poor tension control of the conductor feeding the tensioner will cause the
conductor to bounce or pull tight on the rollers of the tensioner fairlead. This will
damage the conductor core. Poor tension control at the fairlead is always caused
by poor control of the brake on the payout reel stand, due either to poor condition
or under capacity brake, or brake operation error. This has been the most common
installation error in the history of ACCC®. It is critical to a) maintain good control
of payout reel braking and b) correctly set-up the tensioner fairlead.
5.6.2. A curved, multi-roller (banana) fairlead on the input side of the tensioner is highly
recommended for use with ACCC®Conductor. Pictured below is Tesmec/Condux,
fairlead part number AYU077.

5.7. 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® Conductor 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
5.7.3.2. Core punch (included with bug)
5.7.3.3. Fine-Tooth (32 TPI or more) Hack Saw
5.7.3.4. Steel Wire Brush
5.7.3.5. 15” Crescent Wrench (2)
5.8. Pulling Grips (Socks)
5.8.1. 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.
5.8.2. Banding Tool

5.9. Tension Grips
5.9.1. Grips and Clamps – Parallel Jaw type must be long jaw, 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. Use 1628-16P
(7.25-inch jaws) for conductors 21.793mm (0.858 inches) outside diameter and
smaller. Use 1628-30 (10.75-inch jaws) for larger conductors.
5.9.2. Wedge Type Clamps are suitable alternative. Must be rated for the loads and use
inserts correctly sized for the conductor diameter. Do not use wedge grips for
pulling conductor. Use only for applying sagging tensions.
5.9.3. Tension grips and clamps should be inspected for rough surfaces and rough edges
which may scratch or gouge the soft aluminum surface strands of ACCC®. Rough
edges or surfaces must be corrected with fine tooth file or sandpaper.

5.10. Blocks (Sheaves or Travelers)
5.10.1. 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.
5.10.2. See Minimum Sheave Size Chart, Appendix B
5.11. Hoisting Equipment

5.11.1. A Capstan Hoist will provide a smooth hoisting alternative to manual methods
which can damage the ACCC® core. Ensure that the hoist rating exceeds the
loads.
5.11.2. Chain Hoist. Ensure that the hoist rating exceeds the loads.

5.11.3. 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 ✓ ✓
5.12. Puller
5.12.1. Ensure that pulling machine rating exceeds the calculated loads.
5.13. Swivels
5.13.1. Pulling swivels must be in good condition, rotate freely, and be rated for the
pulling tensions.

5.14. Terminating and Splicing
5.14.1. Termination Hand Tools
5.14.1.1. Ratchet Cutter or Cable Cutter – for rough cuts only! Never use a
ratchet cutter or cable cutter for final cut.
5.14.1.2. 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.
5.14.1.3. Fine Tooth (32 TPI or more) Hacksaw. In all cases, the final cut of
ACCC® core MUST be made with a fine tooth hacksaw!
5.14.1.4. Metal File – Smooth tooth, to remove flashing from deadend or splice
crimping process.
5.14.1.5. Crescent Wrenches (2) – approximately 15” or 380mm length.

5.14.2. Presses and Dies

5.14.2.1. Presses must be of sufficient capacity to properly crimp the termination
hardware. Double-acting pumps and presses will dramatically improve
the termination process time.
5.14.2.2. 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.
5.14.3. Consumables
• Hacksaw Blades – Fine Tooth (32 TPI)
• 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.

6. SPECIAL EQUIPMENT FOR BUNDLED APPLICATIONS
6.1. Tensioner
Tensioners – Each conductor in the bundle should be tensioned by a separately controlled
set of bull wheels. This is required for pulls with significant line angle or elevation
changes. Multiple tensioner machines may be used but must be “synchronized” such that a
single operator is controlling all the wheels. Major tensioner manufacturers offer models
that handle up to 6 conductors simultaneously.
6.2. Payout Reels
With multiple payout reels turning simultaneously, the payout reel brake controls are
critical and must be automatically controlled from the tensioner(s). Automatic (hydraulic)
reel control is an optional feature from all the major tensioner manufacturers.
6.3. Tensioner Feed-In Sheaves
With multiple payout reels at every set-up site, perfect alignment is often not possible. A
separate tensioner feed sheave between payout reel and tensioner fairlead is required for
every conductor. This sheave, properly placed, will correct for vertical and elevation
differences and can facilitate the placement of payout reels behind one another with respect
to the tensioner. When supported in the plane of the conductor travel, the tensioner feed-in
sheave can correct for horizontal or fleet angles where the payout reel(s) cannot be
sufficiently aligned with the tensioner.
6.4. Sheave Blocks
Multi-sheave blocks must be used (same diameter as would be used for single conductor
pulling). Multi-sheave blocks should include one more sheave than the number in the
bundle, the extra one in the center for the pilot line and running board tail.
When even numbers of conductors are strung, a symmetrical arrangement is used with an
equal number of conductors on each side of the pulling line. The independent center sheave
is provided only for the pulling line and should be of suitable material to withstand the
abrasion of the pulling line.

When odd numbers of sub conductors are strung, the center one could follow the pulling
line in the center sheave. However, this is usually not desirable because of the material of
the groove or because of contaminants deposited in this groove by the pulling line, or
because of both.
Offset-type bundle conductor travelers are used that balance the load by properly spacing
the even and odd number(s) of conductors on each side of the pulling force. These travelers
are directional and should be color-coded. Care should be taken to ensure their proper
orientation.
6.5. Running Board or Balance Board
A special device called a “running board” or “balance board” (or “gator”) distributes the
pulling force from a single pilot line to the conductors evenly, establishes the spacing, and
prevents the conductor bundle from twisting during pulling with a heavy “tail” which keeps
the board level as it travels between structures. These should be used when pulling multiple
conductors.
Multi-sheave bundle conductor type travelers and running boards must be designed to
complement each other and work in unison. Running boards should have their safe working
load displayed.
6.6. Puller
Pullers and winches must be capable of the required pulling forces. In bundled applications
this is the sum of all the conductors plus the pulling line. Note: pulling force will increase
approximately 2% at each block, for each subconductor.

diameters.
7.2.1. Don’t let ACCC® Conductor run hard on the end roller of the fairlead. Always
use a tensioner feed sheave between the payout reel and tensioner to guide the
conductor into the middle of the tensioner fairlead opening. A multiple-roller
“banana” fairlead is highly recommended.
damaged.
pocketbook grips!
back of the grip.
conductor.
7.5.1. Don’t install any ACCC® Conductor with under-diameter sheaves.
7.5.2. Don't pull in ACCC® Conductor using old conductor if the old conductor is rusty.
Don’t 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® Conductor using the pilot line. Always use a pilot line for
long spans and river crossings.

Chapter 6 – Required Tools and Equipment
Appendix A — Equipment Readiness Review Form

Appendix B — Minimum Sheave and Tensioner Sizes

F-750-071-E
Minimum ACCC® Installation Working Diameters
ACCC® Conductors
Minimum Sheave Minimum Tensioner
ACCC® Core Diameter International ASTM Working Diameter Bull Wheel Diameter
millimeters inches Name Name millimeters inches millimeters inches
Silvassa
Helsinki
5.97 0.235 Copenhagen Linnet 511 20.1 1000 39.4
Rovinj Oceanside
Gdansk
Zadar
Reykjavik Oriole
7.11 0.280 Casablanca Laredo 610 24
Lisbon Hawk
Jaipur
Glasgow Waco
7.75 0.305 Amsterdam Dove 650 25.6
Cordoba
8.13 0.320 Brussels Grosbeak 710 28 1200 48
Oslo Irving
Stockholm Lubbock
Warsaw Galveston
Hamburg Plano
8.76 0.345 Milan Corpus Christi
Vienna Cardinal
Prague El Paso
Paris Bittern
Leipzig
Dublin Drake 800 31.5
Kolkata
9.53 0.375 Rome Arlington
Budapest Fort Worth
Mumbai
Munich Beaumont (Dhaka)
London San Antonio
9.78 0.385 Antwerp Dallas
Madrid Lapwing
10.03 0.395 Chukar 1500 60
Chukar II
Monte Carlo
25mm
Warwick
Curlew 1000 39
10.54 0.415 Bordeaux
Berlin
Houston
Falcon
Athens Bluebird
ACCC® ULS Conductors

ULS Oslo ULS Irving
ULS Warsaw
ULS Stockholm
ULS Lubbock
ULS Galveston
ULS Hamburg ULS Plano
8.76 0.345 ULS Milan ULS Corpus Christi 1000 39 1500 59
ULS Prague
ULS El Paso
ULS Bittern
ULS Vienna ULS Cardinal
ULS Paris
ULS Leipzig
ULS Kolkata
ULS Dublin ULS Drake
9.53 0.375 ULS Rome ULS Arlington
ULS Budapest ULS Fort Worth
ULS Mumbai
ULS Beaumont (ULS Dhaka) 1600 63
ULS London 1200 47
ULS Dallas
9.78 0.385 ULS San Antonio
ULS Antwerp
ULS Madrid ULS Lapwing
ULS Chukar
10.03 0.395 ULS Chukar II
ULS Algiers
ULS Mahakam
ULS Monte Carlo
ULS Warwick
ULS 25mm 4-roller Pivoting Array Blocks 1800 70.9
10.54 0.415 ULS Bordeaux
ULS Curlew
Tesmec, Zeck, or equivalent
ULS Berlin ULS Houston
ULS Falcon
ULS Athens ULS Bluebird
Notes:
1) Diameters above are WORKING diameters, measured at bottom of groove
2) One working size diameter smaller is allowed for sheaves in intermediate or tangent structures unless large belly or total angle > 20°
3) For total conductor angle > 35° contact CTC Global Field Service (fieldservice@ctcglobal.com)

Appendix C — Compression Dies

F-750-069-D
Compression Die Chart
Diameter (mm) AFL Burndy Dalekovod
Jumper Terminals
International Deadends & Jumper T-Tap & Repair Deadends & W/O Inner W/ Inner T-Tap & Repair Deadends & Jumper T-Tap & Repair
Core Conductor Name ASTM Name Splices Terminals Sleeve Splices Sleeve Sleeve Sleeve Splices Terminals Sleeve
14.35 Silvassa TBD TBD TBD L727W (41) TBD TBD TBD TBD TBD TBD
15.65 Helsinki Pasadena TBD TBD TBD L727W (41) L725W (37) N/A L717W1 (23) 48.100.50.40 48.100.50.40 TBD
5.97 17.10 Rovinj TBD TBD TBD L727W (41) L725W (37) N/A TBD TBD TBD TBD
17.27 Oceanside TBD TBD TBD L727W (41) L725W (37) N/A TBD TBD TBD TBD
18.29 Copenhagen Linnet TBD TBD TBD L727W (41) L725W (37) L717W (24) L717W (24) TBD TBD TBD
17.09 Zadar TBD TBD TBD L727W (41) L725W (37) N/A TBD TBD TBD TBD
18.82 Reykjavik Oriole TBD TBD TBD L727W (41) L725W (37) L717W (24) L717W (24) TBD TBD TBD
7.11
20.50 Casablanca Laredo TBD TBD TBD L727W (41) L725W (37) L720W (29) L720W (29) TBD TBD TBD
21.79 Lisbon Hawk TBD TBD TBD L727W (41) L725W (37) L720W (29) L720W (29) TBD TBD TBD
16.50 Jaipur TBD TBD TBD L727W (41) L725W (37) N/A L717W1 (23) TBD TBD TBD
7.75 19.53 Glasgow Waco TBD TBD TBD L727W (41) L725W (37) N/A L719W (27) TBD TBD TBD
23.55 Amsterdam Dove TBD TBD TBD L727W (41) L725W (37) L722W (32) L722W (32) TBD TBD TBD
8.13 25.15 Brussels Grosbeak TBD TBD TBD L727W (41) N/A L724W (35) L724W (35) TBD TBD TBD
22.40 Oslo Irving TBD TBD TBD L735W (54) L725W (37) L722W (32) L722W (32) TBD TBD TBD
26.39 Stockholm Lubbock TBD TBD TBD L735W (54) N/A L725W (37) L725W (37) TBD TBD TBD
27.69 Warsaw Galveston TBD TBD TBD L735W (54) N/A L725W (37) L725W (37) TBD TBD TBD
28.63 Hamburg Plano TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
8.76
29.11 Milan Corpus Christi TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
30.43 Vienna Cardinal TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
31.78 Prague El Paso TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
34.16 Paris Bittern TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
25.14 Leipzig TBD TBD TBD L735W (54) N/A L724W (35) L724W (35) TBD TBD TBD
28.14 Dublin Drake TBD TBD TBD L735W (54) N/A L725W (37) L725W (37) TBD TBD TBD
28.62 Kolkata TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
29.90 Rome Arlington TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
9.53
31.50 Budapest Fort Worth TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
31.78 Mumbai TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
32.84 Munich TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
32.84 Dhaka Beaumont TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
33.40 London San Antonio TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
9.78 36.86 Antwerp Dallas TBD TBD TBD L7351W N/A L7351W (53) TBD TBD TBD TBD
38.20 Madrid Lapwing TBD TBD TBD L735W (54) N/A L735W (54) L735W (54) TBD TBD TBD
40.74 Chukar TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
10.03
43.69 Chukar II TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
20.79 Monte Carlo TBD TBD TBD L735W (54) L725W (37) L720W (29) L720W (29) TBD TBD TBD
25.00 25 mm TBD TBD TBD L735W (54) N/A L724W (35) L724W (35) TBD TBD TBD
28.96 Curlew TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
29.00 ULS Mahakam TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
10.54 33.40 Warwick TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
35.76 Bordeaux TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
38.20 Berlin Houston TBD TBD TBD L735W (54) N/A L735W (54) L735W (54) TBD TBD TBD
39.24 Falcon TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
44.76 Athens Bluebird TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
TBD = to be determined
Burndy requires use of 60 ton press and only Burdy brand dies. Order from Burndy: http://apps.burndy.com/dsl/distributors Page 1
mm
Dalekovod dies for 100 ton Zeck press. Recommended Dalekovod or Zeck brand dies, alternates allowed. Compression tolerance +0.1 / -0 mm.
Burndy and AFL (parenthesis) are mm between hex flats, reference only

mm
Appendix C — Compression Dies - continued
F-750-069-D
Diameter (mm) Dervaux (Sicame) Forjasul PLP

International Deadends & Jumper T-Tap & Repair Deadends & Jumper T-Tap & Repair Deadends & Jumper T-Tap & Repair
Core Conductor Name ASTM Name Splices Terminals Sleeve Splices Terminals Sleeve Splices Terminals Sleeve
14.35 Silvassa 47 47 23.5 TBD TBD TBD 430AH100 430AH100 430AH100
15.65 Helsinki Pasadena 46 46 32 5727/04 TBD TBD 430AH100 430AH100 430AH100
5.97 17.10 Rovinj TBD TBD TBD TBD TBD TBD TBD TBD TBD
17.27 Oceanside 46.5 46.5 31.5 TBD TBD TBD TBD TBD TBD
18.29 Copenhagen Linnet 45 45 35 5727/04 TBD TBD 430AH100 430AH100 430AH100
17.09 Zadar 46.5 46.5 32 TBD TBD TBD TBD TBD TBD
18.82 Reykjavik Oriole 45.5 45.5 35 TBD TBD TBD 430AH100 430AH100 430AH100
7.11
20.50 Casablanca Laredo 46 46 40 TBD TBD TBD 430AH100 430AH100 430AH100
21.79 Lisbon Hawk 46 46 40.5 TBD TBD TBD 430AH100 430AH100 430AH100
16.50 Jaipur 46.5 46.5 31.5 TBD TBD TBD TBD TBD TBD
7.75 19.53 Glasgow Waco 46.5 46.5 36 5727/04 TBD TBD 430AH100 430AH100 430AH100
23.55 Amsterdam Dove 46 46 43 5727/04 TBD TBD 430AH100 430AH100 430AH100
8.13 25.15 Brussels Grosbeak 47 47 45.5 5727/04 TBD TBD 430AH100 430AH100 430AH100
22.40 Oslo Irving 58 58 41.5 TBD TBD TBD 565AH100 565AH100 565AH100
26.39 Stockholm Lubbock 57 57 46.5 5729/04 TBD TBD 565AH100 565AH100 565AH100
27.69 Warsaw Galveston 56 56 46 TBD TBD TBD 565AH100 565AH100 565AH100
28.63 Hamburg Plano 57 57 47 TBD TBD TBD 565AH100 565AH100 565AH100
8.76
29.11 Milan Corpus Christi 57.5 57.5 47.5 TBD TBD TBD 565AH100 565AH100 565AH100
30.43 Vienna Cardinal 56.5 56.5 44 TBD TBD TBD 565AH100 565AH100 565AH100
31.78 Prague El Paso 56.5 56.5 50 TBD TBD TBD 565AH100 565AH100 565AH100
34.16 Paris Bittern TBD TBD TBD TBD TBD TBD 565AH100 565AH100 565AH100
25.14 Leipzig TBD TBD TBD TBD TBD TBD TBD TBD TBD
28.14 Dublin Drake 56.5 56.5 46.5 5729/04 TBD TBD 565AH100 565AH100 565AH100
28.62 Kolkata 57 57 47 TBD TBD TBD TBD TBD TBD
29.90 Rome Arlington 56 56 47 TBD TBD TBD 565AH100 565AH100 565AH100
9.53
31.50 Budapest Fort Worth 56.5 56.5 50 TBD TBD TBD 565AH100 565AH100 565AH100
31.78 Mumbai 57 57 50.5 TBD TBD TBD TBD TBD TBD
32.84 Munich 64 64 51 TBD TBD TBD 565AH100 565AH100 565AH100
32.84 Dhaka Beaumont TBD TBD TBD TBD TBD TBD TBD TBD TBD
33.40 London San Antonio 56.5 56.5 41 TBD TBD TBD 565AH100 565AH100 565AH100
9.78 36.86 Antwerp Dallas 64 64 58 TBD TBD TBD 600AH100 600AH100 600AH100
38.20 Madrid Lapwing 56.5 56.5 58 TBD TBD TBD 600AH100 600AH100 600AH100
40.74 Chukar TBD TBD TBD TBD TBD TBD 600AH100 600AH100 600AH100
10.03
43.69 Chukar II TBD TBD TBD TBD TBD TBD TBD TBD TBD
20.79 Monte Carlo 57 57 40 5727/04 TBD TBD TBD TBD TBD
25.00 25 mm TBD TBD TBD TBD TBD TBD TBD TBD TBD
28.96 Curlew 57.5 57.5 47.5 TBD TBD TBD TBD TBD TBD
29.00 ULS Mahakam 56.5 56.5 47 TBD TBD TBD TBD TBD TBD
10.54 33.40 Warwick TBD TBD TBD TBD TBD TBD TBD TBD TBD
35.76 Bordeaux TBD TBD TBD TBD TBD TBD TBD TBD TBD
38.20 Berlin Houston 61 61 56.5 TBD TBD TBD 600AH100 600AH100 600AH100
39.24 Falcon TBD TBD TBD TBD TBD TBD 600AH100 600AH100 600AH100
44.76 Athens Bluebird TBD TBD TBD TBD TBD TBD 600AH100 600AH100 600AH100
Dervaux requires 60T press. Dimensions are average of 3 flats. Tolerance is +0.4/-0 mm. Order from CEGERS (Sicame group). Alternate brand dies allowed. mm Page 2
Forjasul dies for 100 ton press. Dervaux, and PLP Die Sizes are mm between hex flats
PLP requires use of 100 ton press and only PLP brand dies. Compression tolerance is +0.2 / -0.2 mm. Order from any PLP sales office, worldwide.

REVISION HISTORY
REV
CHANGE REQUEST # DATE
.
A 121515-1
Title Tools and Equipment was Required Equipment

Section 5.15.3 added 32 TPI
Section 5.51 Bullwheel diameters as specified was 40D
Deleted Section 5.6.3
Added Section 6, Special Equipment for Bundled
C Applications July, 2017
Appendix A: Equip. Readiness Review was Tooling
Checklist
Appendix B: F-750-071_C was _B
Appendix C was D; F-750-069_C was _B
Copyright (footer) 2017 was 2016
Added AZR to Section 2.2 and 3.1

Changed Section 5.14.1.3 and 5.7.3.3 32 was 24
Modified Section 5.3.2 to include crane; Deleted 5.3.3
Section 5.5.1 deleted 1800mm requirement for all ULS
bullwheels
Added Section 5.5.4 bullwheel groove material
Added Section 5.5.5 reference section 6.1
Deleted Section 5.12 and 5.13, Bucket and Stinger Trucks
Modified Section 5.13.1.3 and 5.7.4.1 to 24 TPI or more
D Deleted Section 5.13.3 Caulking Gun
August, 2018
Changed Section 5.5.3 “depth” to “radius”

Separated Section 5.9 into pulling and tension grips
Added Section 5.9.2 allowing wedge type tension grips
Modified Section 6.1 wording
Modified Section 6.6 Added Note
Appendix B: F-750-071-E was -C
Appendix C: F-750-069-D was -C
Changed footer copyright to 2018

Chapter 7 – Stringing and Pulling
Chapter 7 – Stringing / Pulling – Table of Contents

1. PURPOSE .......................................................................................................................................... 2
2. SCOPE ............................................................................................................................................... 2
3. DEFINITIONS ..................................................................................................................................... 2
5. PAYOUT REEL SET-UP ........................................................................................................................ 3
6. INSTALL CORE RETAINER (Bug) .......................................................................................................... 3
7. INSTALL PULLING SOCK (Wire Mesh Grip) ......................................................................................... 3
8. TENSIONER FEED SHEAVE ................................................................................................................. 4
9. PAYOUT REEL OPERATION ................................................................................................................ 4
10. TENSIONER OPERATION .................................................................................................................... 5
11. CONNECT TO PULLING LINE............................................................................................................... 6
12. HOISTING TO FIRST STRUCTURE ........................................................................................................ 7
13. STRUCTURE SHEAVES ........................................................................................................................ 7
13.2. Pulling Angles ................................................................................................................................................ 8
14. PULLER ............................................................................................................................................. 8
15. STRINGING TENSION ......................................................................................................................... 9
16. FOLLOW THE FLAG ............................................................................................................................ 9
17. BIRDCAGE ......................................................................................................................................... 9
18. BACK-TO-BACK PULLING ................................................................................................................. 10
19. LONG SPANS, RIVER CROSSINGS ..................................................................................................... 10
20. BUNDLED CONFIGURATIONS .......................................................................................................... 10
21. MANUAL STRINGING ...................................................................................................................... 12
22. REWINDING .................................................................................................................................... 12
23. SPECIAL CONDITIONS ...................................................................................................................... 13
23.1. Weather ...................................................................................................................................................... 13
23.2. Live Lines ..................................................................................................................................................... 13
23.3. Long Spans, Crossings ................................................................................................................................. 13
23.4. Mountains, Swamps, Inaccessible Terrain .................................................................................................. 13
23.5. Mountains, Large elevation changes .......................................................................................................... 13
24.1. DON’T OVER-BEND! .................................................................................................................................... 15
24.2. ONE Tensioner DON'T: ................................................................................................................................ 15
24.3. TWO Payout Reel DON'TS: .......................................................................................................................... 15
24.4. THREE Handling and Equipment DON'TS: ................................................................................................... 15
24.5. TWO Pulling / Stringing DON’TS: ................................................................................................................ 15
24.6. ONE Termination DON’T: ............................................................................................................................ 15
Appendix A — Minimum Sheave and Tensioner Sizes ................................................................................ 16
©2018 CTC Global – For use with ACCC® Conductor only.

1. PURPOSE
1.1. This is Chapter 7 of the ACCC® Conductor Installation Guidelines, covering ACCC
Conductor stringing or pulling. The Guidelines consist of nine chapters, each written to
stand alone to address specific installation subjects. Taken together, the chapters comprise
the entire Installation Guidelines:
considerations, and requirements necessary to safely and successfully install the ACCC
2. SCOPE
sizes of ACCC® Conductor.
3. DEFINITIONS

5. PAYOUT REEL SET-UP

5.1. Verify that the Payout Reel Brake is of sufficient capacity and is in good working order.
5.2. 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.
5.3. Control the free end of the conductor when it is released from its shipping constraint. The
residual energy of the coiled conductor can cause that end to whip as it tends to straighten
which can cause personal injury or death, and can damage the conductor.
6. INSTALL CORE RETAINER (Bug)

6.1. 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.
6.2. Core Retainers are ACCC Conductor 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.
6.3. 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.
6.4. Core retainers are re-usable and should be re-used unless damaged, bent, rusted, or bad
threads or the inner tapered collet is not in one piece.
7. INSTALL PULLING SOCK (Wire Mesh Grip)

7.1. 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.
7.2. Wipe the conductor free of oil, dirt or other contamination for at least the length of the
sock.
7.3. The full length of the wire mesh must be fully installed on conductor or the sock will be
damaged and could fail.

7.4. ALWAYS anchor the far end of the wire mesh sock. Preferred anchor method is two bands
using the banding tool and appropriate banding (see Chapter 6). Alternatively, two screw-
type radiator hose clamps may be used. NEVER anchor the sock anywhere except on the
END furthest from the eye.
7.5. Tape the anchor. It is CRITICAL that the anchoring installed above is completely covered
by plastic electrical tape to protect the lining on the blocks and assure smooth travel
through blocks.
7.6. Tape between the eye and end of the sock, to prevent the core retainer (bug) from coming
out of the sock and to protect the lining on the blocks and assure smooth travel through
blocks.
7.7. When removing the sock after use, all of the protective tape MUST also be removed from
the sock. The tape will retain moisture and cause rusting which will weaken the sock and
may cause it to fail.
7.8. There may be occasions when it is necessary or desirable to pull a long (single) span with a
deadend attached. Never pull a deadend through a sheave. Always be very careful of
creating sharp angles in the conductor where it exits the deadend.
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. PAYOUT REEL OPERATION

9.1. Payout Reel Brake. The tensioner pulls conductor from the reel and the payout reel brakes
provide light tension to keep the wraps on the payout reel tight. Never use the payout reel

to assist the tensioner in supplying stringing tension. The payout reel braking system must
be in good operating condition. It is NEVER acceptable to use or operate a payout reel that
does not have a working brake system.
9.2. Correct operation of the payout reel brake is critical to maintain even, light tension between
the reel and the tensioner. Brake tension should be set just high enough to prevent over-run
when the pulling stops. Never use the payout reel brake to supply stringing tension, that is
the job of the tensioner machine.
9.3. If the brake tension is too high the conductor may begin to wedge into the underlying
layers on the reel which will damage the conductor and may damage the core.
9.4. As the reel empties, the moment arm available to overcome the brake drag is reduced, and
therefore the tension rises. This may cause the conductor to wedge
into the underlying layers on the reel which may damage the
conductor core. Hydraulic braking systems automatically avoid this
condition. For other braking systems, it is important to periodically
adjust the brake as the conductor is payed out.
10. TENSIONER OPERATION

10.1. Threading the Tensioner
10.1.1. The minimum bend diameter of the conductor must be respected
at all times during the threading of the tensioner.
10.1.2. ACCC Conductors nearly 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. If conductor is left hand lay, this is
reversed.
10.1.3. Incorrect tensioner feed (in = right, out = left) will cause loosening of the strands on
the tensioner and could result in bird-caging.
10.1.4. The material and finish of the grooves must be maintained properly so it will not
damage the surface of the conductor. Lined grooves are recommended for all
conductors, but are particularly important for non-specular finished conductors.
Groove material must be relatively hard. Soft groove material will promote loosening
of strands and birdcaging as it proceeds through the bull wheels. When a semi-
conducting elastomer is used for lining the grooves, it must not be relied upon for
grounding.
10.1.5. The tensioner should be threaded with conductor using a rope around the bull wheels.
Install a core retainer (bug) on the conductor per Section 6, install the pulling sock per
Section 7 and attach the sock to an approved swivel. The swivel is then attached to the
rope. The rope then pulls the conductor through the tensioner bull wheels. See Section
11 below.
10.2. As the puller advances conductor through the pull, it is the tensioner which controls the
tension on the pull and the sag or “bellies” in the spans of the pull.
10.3. Constant, open, priority communication between puller operation and tensioner operation is
required to coordinate stops, starts, and speed of the pull.
10.4. Tensioner and puller operation is critical and must be accomplished by experienced
operators, familiar with all of the controls of the tensioner and the puller.
10.5. Never use the tensioner “emergency” stop function for normal stoppages in the pulling
process. The sudden emergency stop can over-tension the conductor.
10.6. Synchronized Tensioner-Payout Reel Stand Operation.
10.6.1. Tensioner / Payout Reel Stand equipment may be equipped with hydraulic
synchronization. Synchronized operation is strongly preferred for ACCC installation.
In this case, the tensioner operator also operates the braking functions of the payout
reel and is responsible for smooth operation of the payout reel as above. It is critical
that the tensioner operator takes out the belly of the conductor between the reel and the
tensioner before the pull begins.
11. CONNECT TO PULLING LINE

11.1. Old conductor may be used to pull in new ACCC Conductor 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 cause pulling equipment to fail and drop the conductor.
11.2. Connect the pulling line to the new ACCC Conductor pulling sock with a swivel of
sufficient capacity and in good working order.

11.3. If the old conductor has ANY splices, they must first be cut out and replaced with two
socks (wire mesh grips) connected with a swivel or a double sock.
11.4. If the old conductor has is rusted or has broken strands, then a pulling (pilot wire) line must
be used. The condition of static wire may be used to help evaluate the condition of the
existing conductor.
12. HOISTING TO FIRST STRUCTURE

12.1. If old conductor is to be used for pulling, the new ACCC Conductor 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, and jerking, or 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 such method can damage the conductor
where acceptable bending would normally exist. Use a capstan hoist to pull the conductor
up smoothly.
X ✓
13. STRUCTURE SHEAVES
13.1. Sheaves sizes are always required to respect minimum working diameters, see Appendix B.

13.2. Pulling Angles

13.2.1. Where there is a severe uplift, down pull, or angles over 30º, it is critical to use
oversize or tandem sheaves. For angles over 60º, please contact CTC Global service
department (Fieldservice@ctcglobal.com) for review and recommendations.
13.3. The sheaves in a tandem set must have their axles rigidly mounted together such that the
sheave flanges are close and the sheaves relatively fixed.
13.4. Tandem sheaves must be mounted to allow free movement of the tandem set in the plane of
the pull. If the sheaves are not allowed to pivot as a pair, they cannot share the load and
halve the angle as intended.
Where structures introduce changes in line or right-of-way angles, sheaves will not be
vertical. Rig sheaves to stay in the plane of the conductor path.
14. PULLER
14.1. If there is room, use the same 3:1 ratio for distance from the tower to the height of the
tower, as was used for the tensioner set-up. In this case ACCC Conductor may be pulled
through the last sheave if it is minimum working diameter or greater.
14.2. An alternate set-up is to use “square rigging” wherein a sheave is used at the arm where the
conductor is being pulled, another where the arm is attached, another at the square of the

structure and one at the bottom of the structure. Do not pull ACCC Conductor through any
of these sheaves.
15. STRINGING TENSION

15.1. Stringing tensions must be kept high enough to a) clear any obstructions in the right of way
during pulling, and b) avoid excessive belly in the conductor between structures.
15.2. Stringing tensions should not exceed 50% of initial (sag chart) tensions. Contact
fieldservice@ctcglobal.com for recommendations if this guideline is to be exceeded.
16. FOLLOW THE FLAG

16.1. Attach an easily visible flag near the swivel between the pulling line and the leading end of
the ACCC Conductor.
16.2. 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.
17. BIRDCAGE
17.1. Loosening and opening of the conductor strands, commonly called “birdcage” is not a
failure, is difficult to avoid in some special situations, and can usually be corrected.
17.2. There are three causes (or “sources”) of birdcage or strand loosening. In all cases, the
loosening normally appears not at the source, but where the strands are constrained near the
source. If the nearest constraint is far enough away (about 15m in the case of ACCC
Conductor), the strands have room to distribute the displacement and the loosening is not
noticeable.
17.3. The first cause is displacement of the aluminum in each strand as a result of compression of
the conductor, either in a grip or installation of a compression sleeve – deadends and
splices for example. These can usually be avoided by making successive compressions
away from the constraint.
17.4. A second cause is also displacement of the aluminum in each strand which can occur if the
conductor passes over a sheave with an incorrect groove size, under tension. Sheave
groove radius should be 0.53 to 0.55 times the conductor diameter.
17.5. A third cause occurs if there is key-stoning of the top layer of conductor. This may allow
relative movement between the layers, effectively allowing displacement of the top layer.
Keystone is normally a defect in the stranding of the conductor.
17.6. If loosening occurs, it often takes care of itself when the constraint is removed, allowing
the displacement to re-distribute over a longer length of conductor and become
unnoticeable.
17.7. The re-distribution can be assisted if necessary, by applying pulling force after the
constraint has been removed. Tapping the conductor with a rubber hose can supply
vibration which facilitates the re-distribution.

17.8. Never strike the conductor with wood or hammer in an effort to address a bird cage
condition. Never attempt to realign strands with screwdriver or other tools.
17.9. Extreme birdcage, when the loosening causes severe plastic deformation of the strands,
cannot be corrected and must be replaced.
18. BACK-TO-BACK PULLING

18.1. 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 maximum three
reels if the site conditions don’t allow proper access. As a guideline, pulls should not be
more than 20 spans.
18.2. Back-to-Back pulls require higher pulling tensions. Double check equipment load ratings
and condition of wire mesh (sock) grips used for back-to-back reel pulls. NEW tension
bearing equipment is recommended for back-to-back pulls.
18.3. Back-to-Back pulls must always be joined by two socks (wire mesh grips), with core
retainers (bugs) on each ACCC end, joined by a swivel. Splices must be installed after the
conductor is in place or pulled through the last relevant sheave. Splices must never be
pulled through sheaves.
18.4. Core retainers (bugs) must be installed for each sock grip.
18.5. Swivels must be used between reels. Special attention should be paid to the capacity and
condition of swivels.
18.6. When multiple reels are pulled to extend sections, splices are normally installed only after
the conductor has been pulled into position. ACCC Conductor splices must never be
allowed to run through sheaves, unless specialized splices and procedures are certified to
facilitate safe, reliable installation.
19. LONG SPANS, RIVER CROSSINGS

19.1. Long pulls 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.
19.2. When re-conductoring long spans, a pilot wire must be used to pull the ACCC Conductor.
Do not pull ACCC in with the old wire.
19.3. 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 (fieldservice@ctcglobal.com).
19.4. 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.
20. BUNDLED CONFIGURATIONS

20.1. When line design calls for multiple conductors per phase, additional considerations for
stringing and pulling are required.
20.2. All of the guidelines for single conductor pulling apply to bundled pulling. This section
identifies additional concerns, requirement, and special equipment.
20.3. All conductors in the phase bundle may be pulled in simultaneously using a single pilot
line. Because the cost of pulling line failure is multiplied by the number of conductors,
new pilot line is required. Size the pilot line for the cumulative loads of the individual
conductors and remember to add 2% to the total pulling tension for each structure.
20.4. If sub-conductors in a bundle must be pulled in separately, or in groups less than the entire
bundle, the “alternate” sagging procedures (Chapter 8, Section 9.5) must be used.
20.5. Site considerations and set-ups have additional consideration for bundled applications. See
Chapter 5.
20.6. Pulling multiple conductors simultaneously requires some specialized equipment. See
Chapter 6.
20.7. Pulling multiple conductors simultaneously requires some specialized methods:
20.7.1. Tensions of the individual sub-conductors in the bundle must be adjusted to provide
for the same belly or sag between sub-conductors during the pull.
Tensions of the individual sub-conductors in the bundle must be adjusted to keep the
running board horizontal and level, except when the running board approaches a
structure that introduces an angle in the right-of-way. The sheave block at such a
structure should be rigged to match the plane of the conductor path – it will not be
perfectly vertical. As the running board approaches any sheave block, the stringing
speed should be slowed. For angles, the tension of sub-conductors should be adjusted
such that the angle of the running board matches the angle of the sheave block before
the running board enters the block.
20.7.2. Pulling at constant speed is critical for a smooth stringing operation. 5 km/h (3.1 mph)
is the maximum recommend pulling speed.
20.8. Sagging ACCC bundled conductors must be done correctly to achieve desired sag
performance. See and follow the Guidelines in Chapter 8 for Bundled Conductors.

21. MANUAL STRINGING

21.1. In special situations, especially when re-conductoring, the use of powered pulling
equipment (pullers and/or tensioners) may not be possible. In these cases, manual stringing
of ACCC Conductor may be required. Layout Method (fixed reel) or Slack Method
(moving reel) are allowed.
21.2. Keep the conductor out of the dirt. Lay the conductor on matting on the ground.
21.3. Don’t allow any bellies during manual stringing. Do not allow sharp bends anywhere.
21.4. Always control the end of the conductor when lifting up to structure to avoid sharp angles.
21.5. 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.
21.6. 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.
21.7. 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.
21.8. 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.
22. REWINDING
22.1. If conditions arise that excess ACCC Conductor must be rewound on its reel, the conductor
can be rewound either manually or hydraulically and shall have medium-light back tension
applied at all times. The conductor MUST NOT be allowed to cross over itself during the
rewinding process. When tension is applied to such cross-overs, the core may be damaged.

22.1.The conductor MUST NOT be allowed to rub or scrape on the reel flanges during
rewinding. This will damage the soft aluminum surface of the conductor and may deform
the strands.
23.SPECIAL CONDITIONS
23.1. Weather
23.1.1. No special considerations exist for ACCC Conductor installation with respect to any
other conductor installation, due to weather conditions.
23.2. Live Lines
23.2.1. No special considerations exist for ACCC Conductor installation with respect to any
other conductor installation, when working live. CTC recommends strict adherence to
the procedures for working energized lines found in IEEE-516.
23.3. Long Spans, Crossings
23.3.1. It is especially important to respect minimum sheave diameter requirements for long
spans. For long spans, use a pilot line (hard line). See Section 19.
23.4. Mountains, Swamps, Inaccessible Terrain
23.4.1. Where structures are inaccessible for a variety of reasons, transport of materials may
require special measures including helicopter, off-road vehicles, work animals, or even
by foot in some extreme cases.
23.4.2. Where tensioned stringing equipment cannot be optimally located, long pulls and
pulling through dead-end structures (paragraph 18) may be considered, or manual
stringing techniques (paragraph 21) may be employed.
23.4.3. CTC offers ACCC® Stringing Plan Review Service℠ for help with planning for
successful installation of ACCC Conductor in exceptional, challenging, and difficult
applications. Please contact Fieldservice@ctcglobal.com
23.5. Mountains, Large elevation changes

23.5.1. Where a single pull includes large elevation changes, the stringing tenstion is
increased by the net weight of the conductor in the vertical change. This must be
accounted for when selecting and sizing equipment and tooling. Respect equipment
and tooling load ratings and use new and/or test all equipment which will be exposed
to tension loads.
23.5.2. This increased stringing tension must not exceed the final sag tension or sag behaviour
will be affected.
23.5.3. It is generally preferable to pull from high to low when possible because better tension
control can be achieved from the tensioner machine and because tension loads on the
pulling wire or line are minimized versus pulling uphill.
23.6. Please contact CTC for advice regarding special conditions not covered in the installation
guidelines: Fieldservice@ctcglobal.com


Don’t allow the conductor to contact surfaces that present sharp angles or small diameters.
24.2. ONE Tensioner DON'T:
Don’t let ACCC® Conductor run hard on the end roller of the fairlead. Always use a
tensioner feed sheave between the payout reel and tensioner to guide the conductor into the
middle of the tensioner fairlead opening. A multiple-roller “banana” fairlead is highly
recommended.
24.3. TWO Payout Reel DON'TS:
Don’t 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.
Don’t use a payout reel with insufficient brakes. Poorly maintained or undersized brakes
24.4. THREE Handling and Equipment DON'TS:
Don’t use grips that aren’t designed for installing ACCC Conductor. Use Klein “Chicago”
long jaw grips or equal, designed for the size conductor being installed. Properly sized
wedge type tension grips are permitted. Never use pocketbook grips!
Don't allow the conductor tail or the deadend to fall or droop unsupported while handling
Don’t hoist the conductor in any manner which causes a sharp bend in the conductor.
24.5. TWO Pulling / Stringing DON’TS:
Don’t install any ACCC Conductor with under-diameter sheaves on the first and last
Don't pull in conductor using old conductor if it is rusty. Don’t use old conductor with
splices or broken strands for pulling. Instead, pull in a pilot line using the old conductor and
pull in ACCC Conductor using the pilot line. Always use a pilot line for long spans and
river crossings.
24.6. ONE Termination DON’T:
Don’t 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.

Appendix A — Minimum Sheave and Tensioner Sizes

F-750-071-E
Minimum ACCC® Installation Working Diameters
ACCC® Conductors
Silvassa
Helsinki
5.97 0.235 Copenhagen Linnet 511 20.1 1000 39.4
Rovinj Oceanside
Gdansk
Zadar
Reykjavik Oriole
7.11 0.280 Casablanca Laredo 610 24
Lisbon Hawk
Jaipur
Glasgow Waco
7.75 0.305 Amsterdam Dove 650 25.6
Cordoba
8.13 0.320 Brussels Grosbeak 710 28 1200 48
Oslo Irving
Stockholm Lubbock
Warsaw Galveston
Hamburg Plano
8.76 0.345 Milan Corpus Christi
Vienna Cardinal
Prague El Paso
Paris Bittern
Leipzig
Dublin Drake 800 31.5
Kolkata
9.53 0.375 Rome Arlington
Budapest Fort Worth
Mumbai
Munich Beaumont (Dhaka)
London San Antonio
9.78 0.385 Antwerp Dallas
Madrid Lapwing
10.03 0.395
Chukar 1500 60
Chukar II
Monte Carlo
25mm
Warwick
Curlew 1000 39
10.54 0.415 Bordeaux
Berlin
Houston
Falcon
Athens Bluebird
ACCC® ULS Conductors

ULS Oslo ULS Irving
ULS Warsaw
ULS Stockholm
ULS Lubbock
ULS Galveston
ULS Hamburg ULS Plano
8.76 0.345 ULS Milan ULS Corpus Christi 1000 39 1500 59
ULS Prague
ULS El Paso
ULS Bittern
ULS Vienna ULS Cardinal
ULS Paris
ULS Leipzig
ULS Kolkata
ULS Dublin ULS Drake
9.53 0.375 ULS Rome ULS Arlington
ULS Budapest ULS Fort Worth
ULS Mumbai
ULS Beaumont (ULS Dhaka) 1600 63
ULS London 1200 47
ULS Dallas
9.78 0.385 ULS San Antonio
ULS Antwerp
ULS Madrid ULS Lapwing
ULS Chukar
10.03 0.395 ULS Chukar II
ULS Algiers
ULS Mahakam
ULS Monte Carlo
ULS Warwick
ULS 25mm 4-roller Pivoting Array Blocks 1800 70.9
10.54 0.415 ULS Bordeaux
ULS Curlew
Tesmec, Zeck, or equivalent
ULS Berlin ULS Houston
ULS Falcon
ULS Athens ULS Bluebird
Notes:
1) Diameters above are WORKING diameters, measured at bottom of groove
2) One working size diameter smaller is allowed for sheaves in intermediate or tangent structures unless large belly or total angle > 20°
3) For total conductor angle > 35° contact CTC Global Field Service (fieldservice@ctcglobal.com)

REVISION HISTORY
A 121515-1 Feb, 2016
B Updated Section 17, Back-to-Back pulling April, 2016
Revised graphic at 13.3

Added paragraph 13.6
Added Section 15, “Stringing Tension”
Revised paragraph 18.1
Added new paragraph 18.2
Added new Section 20, “Bundled Configurations”
C July, 2017
Added paragraphs 21.2, 21.3, and 21.4
Added new Section 23 “Special Conditions” subsections:
23.3 – Long Spans and Crossing
23.4 - Mountains, Swamps, Inacessible Terrain
23.5 – Large Elevation Changes
Appendix A changed from F-750-071 revision B to C
Added AZR to Section 2.2 and 3.1
Modified Title “Stringing and Pulling” was “Stringing / Pulling”
Added paragraph 5.3
Moved INSTALL CORE RETAINER (BUG) to Section 6
Moved INSTALL PULLING SOCK to Section 7
September,
D Replaced “double socks” with “two socks”, Sections 11.3 and
2018
18.3
Changed Section 18.3 “ACCC Splices” to “Splices”
Section 20.3 “may” was “must”
Appendix A: F-750-071-E was -C

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
6.6. Double Grips ................................................................................................................................................. 4
7. CUTTING THE CONDUCTOR ............................................................................................................... 4
8. TERMINATIONS................................................................................................................................. 5
8.1. Dead-Ends ..................................................................................................................................................... 5
8.2. Mid-Span Splices ........................................................................................................................................... 6
8.3. Bowing of Fittings ......................................................................................................................................... 6
8.4. Terminal Pads ............................................................................................................................................... 7
8.5. T-Taps............................................................................................................................................................ 7
8.6. Compression Dies ......................................................................................................................................... 7
9. SAGGING BUNDLED CONDUCTORS ................................................................................................... 7
9.4. Bundled Sagging Procedure – Preferred ....................................................................................................... 7
9.5. Bundled Sagging Procedure – Alternate ....................................................................................................... 8
10. CLIPPING IN – SUSPENSIONS and ANCILLARY HARDWARE................................................................. 9
10.4. Mountainous Terrain .................................................................................................................................... 9
11.1. DON’T OVER-BEND! ........................................................................................ Error! Bookmark not defined.
11.2. TWO Tensioner DON'TS .................................................................................. Error! Bookmark not defined.
11.3. TWO Payout Reel DON'TS ............................................................................... Error! Bookmark not defined.
11.4. THREE Handling and Equipment DON'TS ........................................................ Error! Bookmark not defined.
11.5. TWO Pulling / Stringing DON’TS...................................................................... Error! Bookmark not defined.
Appendix A - Compression Die Chart ........................................................................................................ 11
1. PURPOSE
Conductor sagging, suspensions, terminations, and ancillary hardware. The chapter also
covers sagging of bundled conductors. The Guidelines consist of nine chapters, each
written to stand alone to address specific installation subjects. Taken together, the chapters
comprise the entire Installation Guidelines:

2. SCOPE
2.1. These guidelines apply to specific equipment and techniques required to successfully install
all sizes of ACCC® Conductor.
3. DEFINITIONS
3.2. Initial Sag occurs when new conductor is pulled, deadended and connected.
3.3. Initial Sag Tension is the target “Initial” tension from the design sag charts.
3.4. Final Sag occurs when the conductor is at or above its thermal kneepoint. Thermal
kneepoint is the temperature at which all of the tension load is on the ACCC® core, and the
aluminum strands share of the tension load is zero.
3.5. Ruling Span is the calculated span length that will have the same changes in conductor
tension due to changes of temperature and conductor loading as will be found in a series of
spans of varying lengths between deadends.
4.3. IEEE Standard 516Ô Guide for Maintenance Methods on Energized Power Lines
5. SAGGING
5.1. This guideline assumes that the user is familiar with industry standard sagging techniques.

5.2. There is nothing unique about sagging procedures for ACCC® Conductor versus any other
bare conductor, however the annealed aluminum causes ACCC® Conductor to be more
sensitive to over-tension and creep time with respect to sag. Follow the recommendations
below to achieve expected sag performance.
5.3. Any of the four common methods of sagging may be used: line of sight, transit, stopwatch,
or dynamometer.
5.4. Sagging Procedure:
5.4.1. Assemble and connect the soft-side deadend.
5.4.2. Apply tension, at least 90% of initial sag tension, but DO NOT EXCEED initial sag
tension.
5.4.3. Allow the conductor to remain at this tension for at least 10 hours or overnight. If
sagging must be done same day, subtract 5° C (9° F) from the conductor temperature
in the sagging chart.
5.4.4. Apply sag chart tension and mark the conductor for deadending
5.4.5. Assemble hard-side deadend and connect to insulator linkage. It is recommended that
hard siding be done in the air and not lowered to the ground.
6. INSTALL GRIPS
6.1. NEVER use wire mesh or “sock” grips for sagging, only parallel jaw or wedge type
grips.
6.2. The free end of the conductor MUST be supported during installation of grip and deadend
hardware. This may be done with small ropes.
6.3. Grips are heavy and awkward, especially for larger size conductors. The free end of the
conductor MUST be controlled to prevent over-bending and possible damage of the core.
Good working platforms (hook ladders, bucket trucks, baker boards) should be provided
for personnel for these operations.
6.4. The grip should be attached 4-5 meters (12 – 15’) from the end of the insulator to provide
working room to install the deadend hardware. Install a split rubber hose over the
conductor to protect the aluminum from the rigging. Use small ropes to fasten the free end
of the conductor to the rigging.
6.5. Set the grip. It is permissible to “set” a grip after placement on the conductor and after

taking a small amount of tension on the grip, then sharply strike it’s lever arm with a
hammer once or twice.
6.6. Double Grips

6.6.1. For higher tension loads; long pulls or crossings (if the load is expected to exceed the
lesser of 42 kN (4300 kg; 9,500 lbs.) or 30% of RTS) or special conditions such as
residual stranding oil or other contamination, or for additional safety redundancy it
may be necessary to double-grip the conductor.
6.6.2. In these cases, use a short sling (approximately 6 feet or 2 meters) to equalize the pull
tension between the two grips.
6.6.3. Always use a pulley or snatch block to connect the hoist to the sling to assure that the
grips share the load equally. Protect the exposed portions of the conductor between
the grips and next to the snatch block with split rubber hose.
6.6.4. 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.
6.6.5. Take some tension, “set” (tap) the grip lever arms, mark the conductor at the grips,
take more tension, and verify that there is no slippage in relation to your marks before
taking full tension.
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
cut is at least ½ meter (18”) from final cut and the tail tension is relaxed so that a bird cage
doesn’t occur as the aluminum will contract toward the grip which is still under tension.
7.2. The final cut of ACCC®core must be done with a fine-tooth (32 tooth-per-inch TPI)
hacksaw only. Any other cutting method is unacceptable.
Cutting of the aluminum strands of ACCC® Conductor may be accomplished by either a
hacksaw or approved conductor stripper with the correct bushing. However, the method
used must NEVER nick or scratch the ACCC® 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.

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 450 mm (18 inches) 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.
300mm (12 in.)
Final Cut Rough Cut
8. TERMINATIONS
8.1. Dead-Ends
Installing ACCC® Conductor deadends is very similar to installing deadends for any common
bare overhead conductor with two exceptions:
8.1.1. Conductor, Grip, and Deadend Handling. The weight of the deadend and/or conductor
is sufficient to damage the ACCC®core at the point where it exits the grip. The
deadend must be supported in line with the conductor during installation and
subsequent handling.
Similarly, it is possible to damage the ACCC®core at the point where it enters or

exits the deadend if too much bending force or weight is allowed there.
8.1.2. Back Pressing. 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® Conductor and cause a bird-cage.
8.1.3. Step-by-step instructions for correct installation of ACCC® Conductor deadends are
covered in ACCC® Installation Training℠, are available for free download on the
CTC Global website, and are packaged with each dead-end hardware kit.
8.1.4. Deadends may be assembled on the ground, but CTC prefers dead end assembly in
the air to reduce potential conductor damage due to improper handling. Deadends are

never permited to be pulled through sheaves.

8.2. Mid-Span Splices
8.2.1. Installing an ACCC® Conductor mid-span splice is very similar to installing a mid-
span splice for any common bare overhead conductor with two exceptions: a)
Conductor, Grip, and Splice Handling – same issues as with deadends above, and b)
Pressing Direction. Splices must be pressed from the short side of the conductor span
toward the long side of the conductor span.
8.2.2. Step by step instructions for correct installation of ACCC® Conductor splices are
covered in ACCC® Installation Training℠, are available for free download on the
CTC Global website, and are packaged with each splice hardware kit.
8.2.3. Splices may be assembled on the ground, but assembly in the air is preferred to
reduce potential conductor damage due to improper handling. Splices are never
allowed to be pulled through sheaves.
8.3. Bowing of Fittings
8.3.1. During compressions, care must be taken to keep both ends of the termination
(deadend or splice) in line with the center line of the press dies. The aluminum
becomes quite pliable as it nears maximum compression and as little as one (1)
kilogram (2.2 pounds) of force on the free end can cause a slight bend at the
compression. Several bends in a row result in a bowing or “banana” shape of the
ideally straight assembly. Rotate the assembly 180º in the dies every two
compressions to help keep the assembly straight as compressions proceed.
8.3.2. Slight bowing may be corrected during subsequent original compressions. During the
compression cycle, and ONLY during this period, it is possible to exert light pressure
to correct bowing from prior compressions. Again, one to two (1 - 2) kilograms is
sufficient, for 2 to 5 compressions. Check often with a straight edge if needed. Do
not stand or sit on the end - too much pressure can cause hairline fractures.
8.3.3. An alternative method to prevent bowing may be used: assemble the collet, housing,
and eyebolt per the instructions, and then connect the eyebolt to the insulator bells.
Measure the distance between the housing and the aluminum strands (should be
50mm or two (2) inches). Then slowly release tension on the grip. The measurement
may grow; up to total of 100mm or four (4) inches is permissible. If the grip is fully
released at this point, it may be removed. If the 100mm limit is reached, then leave
the remaining tension on the grip until the deadend is completed. Finally, slide the
outer and inner housings into place and compress per the instructions.
8.3.4. Maximum allowable bowing is one-half (1/2) conductor diameter for deadends and
one (1) conductor diameter for splices. Measure by placing a straight edge from end
to end of the fitting and measure at the point of maximum bow.
8.3.5. Never attempt to straighten a bowed fitting after it has been compressed. This can
cause micro cracks in the work-hardened aluminum which can lead to eventual
mechanical failure of the fitting.

8.4. Terminal Pads

8.4.1. Installing ACCC® Conductor terminal pads is identical to installing terminal pads
for any common bare overhead conductor with one exception: ACCC® Conductor
terminal pads are back-pressed for the same reason as deadends.
8.5. T-Taps
8.5.1. Installing ACCC® Conductor T-Taps is identical to installing T-Taps for any
common bare overhead conductor with one exception: ACCC® Conductor T-Taps
must be pressed AWAY from the nearest deadend, for the same reason that deadends
are back-pressed.
8.5.2. Avoid placing T-Taps closer than one (1) meter from a deadend.
8.6. Compression Dies
8.6.1. A chart showing correct part numbers for compression dies for all ACCC® Conductor
hardware is CTC Global document number F-750-069. The latest revision is
available for free download on the CTC Global website and included as Appendix A
to this Chapter.
9. SAGGING BUNDLED CONDUCTORS

9.1. See Chapter 7, Section 20 for guidelines for stringing bundled conductor configurations.
9.2. ACCC® Conductor is more sensitive to variance in sagging than conventional conductor
types. Sagging bundled conductors is therefore critical to achieve expected bundle sag
performance.
9.3. Never apply tension above the initial (sag chart) tension. Over-tension will cause the
conductors’ sag behavior to differ which will result in uneven bundle sagging.
9.4. Bundled Sagging Procedure – Preferred
9.4.1. This is essentially the same procedure used for single conductors as in Section 5
above. The critical differences are in italics.
9.4.2. Turnbuckles or sagging links are recommended for final sag tension adjustment.
9.4.3. Assemble and connect the soft-side deadends.
9.4.4. Place the conductor in sheaves at each tower which are positioned at the bundle’s
final horizontal spacing and location to provide proper wire length in the clipped-in
position.
When multiple conductors are strung in bundled conductor type travelers, reduced
horizontal spacing between grooves can result in conductor oscillation, even in a
very light crosswind, too severe to permit satisfactory sagging. (For example, groove
spacing of 5.4 conductor diameters permitted sagging of conductors in a crosswind
condition that repeatedly prevented sagging with a groove spacing of 2.7 conductor
diameters because of very active conductor oscillation.)
9.4.5. Apply equal tension to all sub-conductors; at least 90% of initial sag chart tension,

but DO NOT EXCEED initial sag chart tension. All conductors in a phase bundle
must be brought up to this tension within a few minutes of one another.
9.4.6. Allow the conductors to remain at this tension for at least 10 hours or overnight. If
sagging must be done same day, subtract 5° C (9° F) from the ambient temperature
from the sagging chart.
9.4.7. Apply sag chart tension and mark the conductor for deadending. All conductors in a
phase bundle must be brought to the target tension and marked as closely as possible
at the same time…all within maximum 15 minutes of each other.
9.4.8. Suspension (clipping) of bundled conductors must be done together for all the
conductors in the bundle.
9.5. Bundled Sagging Procedure – Alternate
9.5.1. This alternate procedure should be used when sub conductors have not been strung
simultaneously or brought up to the target sag within 15 minutes of each other.
9.5.2. This alternate procedure includes leaving conductors in sheaves for extended
periods. Risk of high wind lifting the conductors out of their sheave grooves exists
which may damage conductor or core. Do not use this alternate procedure when
high wind conditions exist or are forecast.
9.5.3. Turnbuckles or sagging links are required for final sag tension adjustment.
9.5.4. Assemble and connect the soft-side deadends.
9.5.5. Place the conductor in sheaves at each tower which are positioned at the bundle’s
final horizontal spacing and location to provide proper wire length in the clipped-in
position.
When multiple conductors are strung in bundled conductor type travelers, reduced
horizontal spacing between grooves can result in conductor oscillation, even in a
very light crosswind, too severe to permit satisfactory sagging.
9.5.6. Apply tension to all sub-conductors, AT LEAST 90% of initial sag chart tension, but
DO NOT EXCEED initial sag chart tension.
9.5.7. Allow the conductor to remain at this tension for AT LEAST 72 hours after initial sag
chart (90% or greater) is applied to the LAST sub-conductor pulled.
9.5.8. Apply sag chart tension or sag and mark one conductor for deadending.
9.5.9. Match the sag (not tension) of the remaining sub-conductors to the first one.
9.5.10. Assemble the hard-side deadends and connect
9.5.11. Make final adjustments to match sag of all subconductors with the turnbuckles or
sagging links.
9.5.12. Suspension (clipping) of bundled conductors must be done together for all the
conductors in the bundle.

10. CLIPPING IN – SUSPENSIONS and ANCILLARY HARDWARE

10.1. ACCC® Conductor 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.
10.2. 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.
10.3. Tandem suspensions and yoke plates must be used where change of direction angles exceed
30 degrees.
10.4. Mountainous Terrain
This section taken from IEEE-524 2004:
10.4.1. In a series of suspension spans located in hilly terrain, wire in the sheaves will tend to
run downhill. Gravity acting on the wire in the sheaves will cause excessive sag in the
lower spans of the section and too little sag in the upper spans. The unbalanced
horizontal tensions will result in the insulators being pulled off from plumb in an
uphill direction. To equalize the horizontal tensions, it is necessary to redistribute the
wire between the spans. This process of pulling the wire uphill is known as “clipping
offsets.” The theory of clipping offsets is based upon the fact that, between snub
structures, the total length of conductor at sag in the travelers is equal to the total
length of conductor at sag in the suspension clamps. The distance that the clamp
should be offset from the plumb position is calculated in order to pull slack from the
lower spans and move it to the overly tight uphill spans.
10.4.2. There are several conditions that should be understood regarding the application of
clipping offsets.
a) Offsets must be calculated for the exact section being sagged. Insertion of a
temporary snubbing position will change the offsets; therefore, offsets cannot
be calculated until the sagging operation is determined.
b) All offsets must be marked prior to any clipping-in of the wire.
c) Offsets can be minimized by the judicious use of snubbing positions to
separate line sections at different elevations.
10.4.3. Sags and clipping offsets are interrelated because sag corrections required for
computing sags are dependent upon clipping offset computations. The application of
sags and clipping offsets computed in this manner will produce balanced horizontal
forces that will be the same for each structure within the sag section.
See IEEE-524 2004, Annex E for calculations and further detailed information.
Consider CTC’s ACCC® Stringing Plan Review Service℠ for technical installation
assistance. Contact us at fieldservices@ctcglobal.com.


Don’t allow the conductor to contact surfaces that present sharp angles or small diameters.
11.2. ONE Tensioner DON'T:
Don’t let ACCC® Conductor run hard on the end roller of the fairlead. Always use a
tensioner feed sheave between the payout reel and tensioner to guide the conductor into the
middle of the tensioner fairlead opening. A multiple-roller “banana” fairlead is highly
recommended.
11.3. TWO Payout Reel DON'TS:
Don’t 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.
Don’t use a payout reel with insufficient brakes. Poorly maintained or undersized brakes
11.4. THREE Handling and Equipment DON'TS:
Don’t use grips that aren’t designed for installing ACCC Conductor. Use Klein “Chicago”
long jaw grips or equal, designed for the size conductor being installed. Properly sized
wedge type tension grips are permitted. Never use pocketbook grips!
Don't allow the conductor tail or the deadend to fall or droop unsupported while handling
Don’t hoist the conductor in any manner which causes a sharp bend in the conductor.
11.5. TWO Pulling / Stringing DON’TS:
Don’t install any ACCC Conductor with under-diameter sheaves on the first and last
Don't pull in conductor using old conductor if it is rusty. Don’t use old conductor with
splices or broken strands for pulling. Instead, pull in a pilot line using the old conductor and
pull in ACCC Conductor using the pilot line. Always use a pilot line for long spans and
river crossings.
11.6. ONE Termination DON’T:
Don’t 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.

Appendix A - Compression Dies

F-750-069-D
Diameter (mm) AFL Burndy Dalekovod
Jumper Terminals
International Deadends & Jumper T-Tap & Repair Deadends & W/O Inner W/ Inner T-Tap & Repair Deadends & Jumper T-Tap & Repair
Core Conductor Name ASTM Name Splices Terminals Sleeve Splices Sleeve Sleeve Sleeve Splices Terminals Sleeve
14.35 Silvassa TBD TBD TBD L727W (41) TBD TBD TBD TBD TBD TBD
15.65 Helsinki Pasadena TBD TBD TBD L727W (41) L725W (37) N/A L717W1 (23) 48.100.50.40 48.100.50.40 TBD
5.97 17.10 Rovinj TBD TBD TBD L727W (41) L725W (37) N/A TBD TBD TBD TBD
17.27 Oceanside TBD TBD TBD L727W (41) L725W (37) N/A TBD TBD TBD TBD
18.29 Copenhagen Linnet TBD TBD TBD L727W (41) L725W (37) L717W (24) L717W (24) TBD TBD TBD
17.09 Zadar TBD TBD TBD L727W (41) L725W (37) N/A TBD TBD TBD TBD
18.82 Reykjavik Oriole TBD TBD TBD L727W (41) L725W (37) L717W (24) L717W (24) TBD TBD TBD
7.11
20.50 Casablanca Laredo TBD TBD TBD L727W (41) L725W (37) L720W (29) L720W (29) TBD TBD TBD
21.79 Lisbon Hawk TBD TBD TBD L727W (41) L725W (37) L720W (29) L720W (29) TBD TBD TBD
16.50 Jaipur TBD TBD TBD L727W (41) L725W (37) N/A L717W1 (23) TBD TBD TBD
7.75 19.53 Glasgow Waco TBD TBD TBD L727W (41) L725W (37) N/A L719W (27) TBD TBD TBD
23.55 Amsterdam Dove TBD TBD TBD L727W (41) L725W (37) L722W (32) L722W (32) TBD TBD TBD
8.13 25.15 Brussels Grosbeak TBD TBD TBD L727W (41) N/A L724W (35) L724W (35) TBD TBD TBD
22.40 Oslo Irving TBD TBD TBD L735W (54) L725W (37) L722W (32) L722W (32) TBD TBD TBD
26.39 Stockholm Lubbock TBD TBD TBD L735W (54) N/A L725W (37) L725W (37) TBD TBD TBD
27.69 Warsaw Galveston TBD TBD TBD L735W (54) N/A L725W (37) L725W (37) TBD TBD TBD
28.63 Hamburg Plano TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
8.76
29.11 Milan Corpus Christi TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
30.43 Vienna Cardinal TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
31.78 Prague El Paso TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
34.16 Paris Bittern TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
25.14 Leipzig TBD TBD TBD L735W (54) N/A L724W (35) L724W (35) TBD TBD TBD
28.14 Dublin Drake TBD TBD TBD L735W (54) N/A L725W (37) L725W (37) TBD TBD TBD
28.62 Kolkata TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
29.90 Rome Arlington TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
9.53
31.50 Budapest Fort Worth TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
31.78 Mumbai TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
32.84 Munich TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
32.84 Dhaka Beaumont TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
33.40 London San Antonio TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
9.78 36.86 Antwerp Dallas TBD TBD TBD L7351W N/A L7351W (53) TBD TBD TBD TBD
38.20 Madrid Lapwing TBD TBD TBD L735W (54) N/A L735W (54) L735W (54) TBD TBD TBD
40.74 Chukar TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
10.03
43.69 Chukar II TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
20.79 Monte Carlo TBD TBD TBD L735W (54) L725W (37) L720W (29) L720W (29) TBD TBD TBD
25.00 25 mm TBD TBD TBD L735W (54) N/A L724W (35) L724W (35) TBD TBD TBD
28.96 Curlew TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
29.00 ULS Mahakam TBD TBD TBD L735W (54) N/A L727W (41) L727W (41) TBD TBD TBD
10.54 33.40 Warwick TBD TBD TBD L735W (54) N/A L728W (48) L728W (48) TBD TBD TBD
35.76 Bordeaux TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
38.20 Berlin Houston TBD TBD TBD L735W (54) N/A L735W (54) L735W (54) TBD TBD TBD
39.24 Falcon TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
44.76 Athens Bluebird TBD TBD TBD TBD N/A TBD TBD TBD TBD TBD
Burndy requires use of 60 ton press and only Burdy brand dies. Order from Burndy: http://apps.burndy.com/dsl/distributors Page 1
mm
Dalekovod dies for 100 ton Zeck press. Recommended Dalekovod or Zeck brand dies, alternates allowed. Compression tolerance +0.1 / -0 mm.
Burndy and AFL (parenthesis) are mm between hex flats, reference only

mm
Appendix A - Compression Dies - continued

F-750-069-D
Diameter (mm) Dervaux (Sicame) Forjasul PLP

International Deadends & Jumper T-Tap & Repair Deadends & Jumper T-Tap & Repair Deadends & Jumper T-Tap & Repair
Core Conductor Name ASTM Name Splices Terminals Sleeve Splices Terminals Sleeve Splices Terminals Sleeve
14.35 Silvassa 47 47 23.5 TBD TBD TBD 430AH100 430AH100 430AH100
15.65 Helsinki Pasadena 46 46 32 5727/04 TBD TBD 430AH100 430AH100 430AH100
5.97 17.10 Rovinj TBD TBD TBD TBD TBD TBD TBD TBD TBD
17.27 Oceanside 46.5 46.5 31.5 TBD TBD TBD TBD TBD TBD
18.29 Copenhagen Linnet 45 45 35 5727/04 TBD TBD 430AH100 430AH100 430AH100
17.09 Zadar 46.5 46.5 32 TBD TBD TBD TBD TBD TBD
18.82 Reykjavik Oriole 45.5 45.5 35 TBD TBD TBD 430AH100 430AH100 430AH100
7.11
20.50 Casablanca Laredo 46 46 40 TBD TBD TBD 430AH100 430AH100 430AH100
21.79 Lisbon Hawk 46 46 40.5 TBD TBD TBD 430AH100 430AH100 430AH100
16.50 Jaipur 46.5 46.5 31.5 TBD TBD TBD TBD TBD TBD
7.75 19.53 Glasgow Waco 46.5 46.5 36 5727/04 TBD TBD 430AH100 430AH100 430AH100
23.55 Amsterdam Dove 46 46 43 5727/04 TBD TBD 430AH100 430AH100 430AH100
8.13 25.15 Brussels Grosbeak 47 47 45.5 5727/04 TBD TBD 430AH100 430AH100 430AH100
22.40 Oslo Irving 58 58 41.5 TBD TBD TBD 565AH100 565AH100 565AH100
26.39 Stockholm Lubbock 57 57 46.5 5729/04 TBD TBD 565AH100 565AH100 565AH100
27.69 Warsaw Galveston 56 56 46 TBD TBD TBD 565AH100 565AH100 565AH100
28.63 Hamburg Plano 57 57 47 TBD TBD TBD 565AH100 565AH100 565AH100
8.76
29.11 Milan Corpus Christi 57.5 57.5 47.5 TBD TBD TBD 565AH100 565AH100 565AH100
30.43 Vienna Cardinal 56.5 56.5 44 TBD TBD TBD 565AH100 565AH100 565AH100
31.78 Prague El Paso 56.5 56.5 50 TBD TBD TBD 565AH100 565AH100 565AH100
34.16 Paris Bittern TBD TBD TBD TBD TBD TBD 565AH100 565AH100 565AH100
25.14 Leipzig TBD TBD TBD TBD TBD TBD TBD TBD TBD
28.14 Dublin Drake 56.5 56.5 46.5 5729/04 TBD TBD 565AH100 565AH100 565AH100
28.62 Kolkata 57 57 47 TBD TBD TBD TBD TBD TBD
29.90 Rome Arlington 56 56 47 TBD TBD TBD 565AH100 565AH100 565AH100
9.53
31.50 Budapest Fort Worth 56.5 56.5 50 TBD TBD TBD 565AH100 565AH100 565AH100
31.78 Mumbai 57 57 50.5 TBD TBD TBD TBD TBD TBD
32.84 Munich 64 64 51 TBD TBD TBD 565AH100 565AH100 565AH100
32.84 Dhaka Beaumont TBD TBD TBD TBD TBD TBD TBD TBD TBD
33.40 London San Antonio 56.5 56.5 41 TBD TBD TBD 565AH100 565AH100 565AH100
9.78 36.86 Antwerp Dallas 64 64 58 TBD TBD TBD 600AH100 600AH100 600AH100
38.20 Madrid Lapwing 56.5 56.5 58 TBD TBD TBD 600AH100 600AH100 600AH100
40.74 Chukar TBD TBD TBD TBD TBD TBD 600AH100 600AH100 600AH100
10.03
43.69 Chukar II TBD TBD TBD TBD TBD TBD TBD TBD TBD
20.79 Monte Carlo 57 57 40 5727/04 TBD TBD TBD TBD TBD
25.00 25 mm TBD TBD TBD TBD TBD TBD TBD TBD TBD
28.96 Curlew 57.5 57.5 47.5 TBD TBD TBD TBD TBD TBD
29.00 ULS Mahakam 56.5 56.5 47 TBD TBD TBD TBD TBD TBD
10.54 33.40 Warwick TBD TBD TBD TBD TBD TBD TBD TBD TBD
35.76 Bordeaux TBD TBD TBD TBD TBD TBD TBD TBD TBD
38.20 Berlin Houston 61 61 56.5 TBD TBD TBD 600AH100 600AH100 600AH100
39.24 Falcon TBD TBD TBD TBD TBD TBD 600AH100 600AH100 600AH100
44.76 Athens Bluebird TBD TBD TBD TBD TBD TBD 600AH100 600AH100 600AH100
Dervaux requires 60T press. Dimensions are average of 3 flats. Tolerance is +0.4/-0 mm. Order from CEGERS (Sicame group). Alternate brand dies allowed. mm Page 2
Forjasul dies for 100 ton press. Dervaux, and PLP Die Sizes are mm between hex flats
PLP requires use of 100 ton press and only PLP brand dies. Compression tolerance is +0.2 / -0.2 mm. Order from any PLP sales office, worldwide.

REVISION HISTORY
A 121515-1
Added paragraph 10.2
B Added Section 10.5, “Sagging Bundles” 3/1/2016

Expanded Section 5.5, “Sagging Procedure”
Revised section 6.6, added pulley block and graphic
C April, 2017
Added Section 8.4 “Bowing of Fittings”
Added Section 9.5 “Mountainous Terrain”
Expanded Section 10 “Sagging Bundled Conductors”
Deleted Section 5.4 (72 hours in sheaves limit)
Moved Section 9, Clipping to Section 10
Changed Section 9.4 (10.4) to “Preferred”
D August, 2018
Added Section 9.5 “Alternate”
Added Appendix A – Compression Die Chart

Chapter 9 – Maintenance and Repair
WI-750-019 Rev E 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:
1.1.8. Chapter 8 — Sagging, Terminations, and Suspensions
1.1.9. Chapter 9 — Maintenance & Repair
recommendations and requirements necessary to safely and successfully install and repair
ACCC® composite-core bare overhead conductor and accessories. This document is an
overview and guideline covering what to do but not necessarily how to do it. It is not
intended to serve as a more intensive training manual or act as a substitute for proper
training, required personnel skill sets, or industry experience.

2. SCOPE
2.1. These guidelines apply to equipment and techniques required to successfully maintain and
repair all sizes of ACCC® conductor.
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 to correctly identify the most appropriate repair.
6.2. If aluminum strand damage is observed and the condition of the core is suspected to have
been compromised, then a conductor trolley must not be used for access. Alternative
method of access should be used to allow further detailed investigation.

6.3. There are three methods of repair techniques for repairing damage to ACCC® conductor
that are available:
6.3.1. Pre-formed Helical Repair Sleeve (96” armor rod)
6.3.2. Compression Repair Sleeve
6.3.3. Mid-span Splice (ACCC® Splice)
6.4. Conventional methods are used to repair ACCC® conductor strands. Aluminum Repair
Methods:
Number of Damaged Helical Preform Compression
Aluminum Strands Repair (96”) Repair Mid Span Joint
1 Outer Layer Strands X X --
2 Outer Layer Strands -- X --
3+ Outer Layer Strands -- -- X
Any Inner Layer Strands -- -- X
6.5. Example One: Aluminum strand damage only. Use appropriate repair method from table
above.
6.6. Example Two: Conductor is damaged and core is damaged in a single area. Remove
damaged core area and install a mid-span splice.
6.7. Example Three: Conductor is damaged and core is damaged over a larger area than can be
replaced by a single splice. Using splices, replace 50’ to 100’ (15 to 30 m) of conductor
per each phase that is damaged. Keep splices at least 50’ (15 m) away from any structure.
6.8. Example Four: Conductor is damaged mid-span and also at one structure at the armor rod
suspension. Using splices, replace all damaged conductor, keeping splices at least 50’ (15
m) from any structure.
6.9. Example Five: Conductor is damaged and core is damaged in a dead-end span. Add a
section of conductor with a splice and add a new dead-end.

7. REPAIR GUIDELINES
7.1. Never install a splice any closer than 50’ (15 m) from a structure.
7.2. Repairs must always be made with materials and components which are rated for ACCC®
operating temperatures (180° C).
7.3. The minimum distance from a repair sleeve to another fitting on the conductor shall be
1.2m, this includes other repair sleeves. (If the repair sleeve is moved closer to the
deadend, the conductor strands may loosen and open and remain open).
7.4. A spacer damper of the appropriate size should be fitted 2 - 8 m from the repair sleeve to
prevent sub-conductor clashing near the repair.
7.5. ACCC® splices or dead-ends cannot be installed via live line maintenance because of the
mechanical way that the splice or dead-end fasten the core.
REVISION HISTORY
A 8 May 2012
B 10 May 2012
C 31 July 2013
D 121515-1 15 Dec 2015
3.1 Corrected “1350-0” to “1350-O”

E July 2017

ACCC Conductor Installation Guidelines 20181

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ACCC® Conductor Installation Guidelines

Chapter 1 – General Guidelines

Chapter 1 – General Guidelines – Table of Contents

©2017 CTC Global- For use with ACCC® Conductor only

5. ACCC® INSTALLATION DIFFERENCES

©2017 CTC Global- For use with ACCC® Conductor only

6. GENERAL CONDUCTOR HANDLING GUIDELINES

©2017 CTC Global- For use with ACCC® Conductor only

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

©2017 CTC Global- For use with ACCC® Conductor only

6.2.7. Failure to control conductor “tail” or angles at exit points of grips.

©2017 CTC Global- For use with ACCC® Conductor only

©2017 CTC Global- For use with ACCC® Conductor only

7. TEN INSTALLATION DON’TS

©2017 CTC Global- For use with ACCC® Conductor only

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015

3.1 Corrected “1350-0” to “1350-O”

©2017 CTC Global- For use with ACCC® Conductor only

Chapter 2 – Installation Safety – Table of Contents

©2017 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

©2017 CTC Global- For use with ACCC® Conductor only

©2017 CTC Global- For use with ACCC® Conductor only

©2017 CTC Global- For use with ACCC® Conductor only

7. TEN INSTALLATION DON’TS

©2017 CTC Global- For use with ACCC® Conductor only

©2017 CTC Global- For use with ACCC® Conductor only

©2017 CTC Global- For use with ACCC® Conductor only

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015

B Changed copyright footer to 2017 7 July 2017

©2017 CTC Global- For use with ACCC® Conductor only

Chapter 3 – Training – Table of Contents

©2017 CTC Global- For use with ACCC® Conductor only

©2017 CTC Global- For use with ACCC® Conductor only

6. INSTALLATION TRAINING SYLLABUS

©2017 CTC Global- For use with ACCC® Conductor only

6.7. Equipment Requirements (Classroom and Field)

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015

3.1 Corrected “1350-0” to “1350-O”

©2017 CTC Global- For use with ACCC® Conductor only

Chapter 4 – Reel Handling and Storage – Table of Contents

©2017 CTC Global- For use with ACCC® Conductor only

5. NEW CONDUCTOR REELS

©2017 CTC Global- For use with ACCC® Conductor only

6. CONDUCTOR REEL HANDLING

©2017 CTC Global- For use with ACCC® Conductor only

7. CONDUCTOR and CONDUCTOR REEL STORAGE

©2017 CTC Global- For use with ACCC® Conductor only

7.4. Storage Temperatures:

©2017 CTC Global- For use with ACCC® Conductor only

8. TEN INSTALLATION DON’TS

©2017 CTC Global- For use with ACCC® Conductor only

REV. CHANGE REQUEST # DATE

A 121515-1 15 Dec 2015

3.1 Corrected “1350-0” to “1350-O”

©2017 CTC Global- For use with ACCC® Conductor only

Chapter 5 – Site Considerations and Set-ups – Table of Contents

©2017 CTC Global- For use with ACCC® Conductor only

©2017 CTC Global- For use with ACCC® Conductor only

5.2. Wire Pull Plan