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Please note. This is not a treatise on cable installation. It is supplementary information intended
to enhance engineers, technicians, electricians and cable installation personnels knowledge of
cable installation.
Cognisance must also be taken of Installation practices specified in BS 7671, IEC 60364 and
other International Standards for Electrical Installations.
We hope users find this information useful and invite and constructive (or corrective) criticism.
Cable Drums
a) Cable drums should be clearly marked or labeled with the following information:
1. Manufacturers name or trade mark.
2. Rated voltage, rated area, number of cores and specification.
3. Length of the cable in meters.
4. Year of manufacture.
5. Gross mass in kilograms.
6. The instruction NOT TO BE LAID FLAT.
7. Serial number or other identification.
8. On each flange an arrow with the words ROLL THIS WAY.
9. Mark of the Standards authority (if applicable).
b) Both ends of the cable on the drum should be sealed and the inner end fixed to the
flange of the cable drum to prevent loose coiling. The outer end is fixed to the flange as
well, for the same reason.
c) Drum protective closure should be maintained until cable is utilised.
d) Cable drums should stand on firm, well drained surfaces.
e) It is recommended that periodically the drum is rotated.
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Cable transportation
a) Preparation
i. The truck must be suitable for the drum size and weight.
ii. Do not overload trucks
iii. Cable ends must be sealed, secured and protected.
iv. Use special cable trailers for depot to site transportation where possible. (See
below). Cables should not be removed from the cable drum and transported
independently to the installation site.
b) Loading
i. Check drums for correct cable and size, serial number, mass and any
form of possible damage.
ii. Select correct forklift or crane.
iii. Select correct slings and spindle and check their condition.
iv. If a crane is to be used, ensure that a spreader is incorporated to prevent damage to
drum flanges.
v. If the drum is to be rolled, observe correct rolling direction by referring to arrows on
the drum flanges.
vi. Ensure the drum bolts are tight.
vii. Ensure that the truck surface is clear of obstructions, nails, etc.
viii. Do Not drop drums onto truck loading bed.
c) Securing
i. Secure drums to the truck bed to prevent sliding and rolling, using adequate steel
chains and chocks.
ii. Always try and pack drums flange to flange.
iii. Do not lay cable flat.
iv. Stop the vehicle at periods during transportation and check that the load is secure.
d) Off Loading
i. Check the drums for any trace of damage. Damaged drums to be reported before off
loading.
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ii.
iii.
iv.
v.
vi.
vii.
viii.
Select correct spindle slings for the drum size and mass and ensure that they are in
good order. Ensure that a spreader is used.
Do not drop the drums. Lower gently onto a firm and relatively level surface.
Off load drums in such a way that they are easily accessible.
If using a forklift, ensure that it is of adequate size relative to the task at hand.
Ensure the forklift forks lateral spacing is correct.
Take care that the protruding forks do not damage other equipment or drums.
There are two methods of rolling drums off loading beds if cranes are not available.
(see below).
Method 1: Hole excavated (Maximum slope 1 in 10) to receive truck.
Drum stop
Cable Storage
a. Indoors
i.
Stack flange to flange and preferably not one on top of the other. Do not lay the
cable drum flat.
ii. Stack so that drums are easily accessible.
iii. Observe fire precaution rules.
iv. Cable ends must be sealed at all times.
v. If drums are expected to be stored for a long time they should be specially treated,
or, if applicable, use pesticides at regular intervals in the storage area to avoid
termite and rodent attack on wooden drums.
vi. Despatch on a first in first out basis.
b. Outdoors
i. Drums should be stored on a hard surface at a slight angle and the area should have a
drainage system.
ii. Drums should be released on a first in first out basis.
iii. Cable ends must be sealed at all times.
iv. Stack flange to flange, but if this is not possible, limit vertical stacking practice to
smaller drums only. Do not store the cable drum flat.
v. Stack in such a way that drums are easily accessible.
vi. In areas having a hot climate, drums should be stored under a shade and should be
protected from direct sunlight.
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vii.
viii.
ix.
x.
F = 0.94 * D4 * 10-6 kN
F = 0.39 * D4 * 10-6 kN
F = 0.26 * D4 * 10-6 kN
Attempts should be made to limit the pulling force required to a minimum to avoid
stretching in the outer layers of the cable. This is particularly relevant when installing cables
at high ambient temperatures when thermoplastic bedding and sheathing materials may be
softer than usual, and thus having reduced tensile properties.
An increase in the pulling force is permissible when the cable is laid by means of a pulling
eye attachment to the conductors. As a rule of thumb, the following forces may be applied
to a conductor :Copper conductor
Aluminum conductor
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Then, for example, the maximum force that should be applied via a pulling eye to a 70mm2
3 core copper cable is :70 * 3 * 4.9 * 10-2 = 10.29kN
Generally when cables are installed using well-oiled rollers and jacks, the following forces
can be expected :Straight route
2 - 90 bends
Cables laid in open trenches should be left slightly snaked so that any longitudinal
expansion or contraction can be accommodated. Similarly when cables are installed in
cleats or on hangers a slight sag between fixing points is recommended.
Pulling cables Through Pipes or Ducts
When a cable is pulled through a pipe, friction between the cable serving and the pipe
material increases the longitudinal force requirements. Representative values for the coefficient of friction () between the more common cable servings and pipe materials are
given in the table below.
Serving Material
PVC
PVC
PVC
PVC
Bitumenised
Hessian
or Jute
Pipe Material
Asbestos
Metal (Steel)
Pitch Fibre
PVC
Asbestos
Metal (Steel)
Pitch Fibre
PVC
Co-efficient of friction ()
0.65
0.48
0.55
0.35
0.97
0.76
0.86
0.55
For Cables with servings of PE or LSF material, use the same Co-efficient of friction as PVC
This information can readily be used to determine the maximum length of cable that can be
pulled through a given pipe without exceeding the maximum permissible pulling force. Take
for example the 70mm2 3 core cable previously quoted, is this is a low voltage cable with a
PVC sheath and it is desired to know the maximum length of PVC pipe it can be pulled
through then :Maximum pulling force
For PVC to PVC
But force
=
=
=
=
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=
=
* Cable mass/102
10.29/0.35 * 102
= 2998 kg
(1kN = 102kg)
The mass of a 70mm2 3 core copper PVC insulated and wire Armoured cable is 3.6kg/m.
Thus the maximum length of this cable that can be pulled through a PVC pipe is :2998/3.6
=
832 metres
If there are any bends in the route then these will create additional loading and reduce the
length of cable that can be installed.
In certain instances when long runs in pipes or ducts are encountered it may be beneficial
to grease the cable with petroleum jelly or some other non aggressive compound to
facilitate pulling-in.
Considerable damage can be done to cable servings at the mouth of a pipe and precautions
should be exercised at such points. (The potential for damage is increased when a cable is
installed in hot conditions, as materials may soften due to the heat and the tensile strength
of the serving material is thus reduced). Fitting of a rubber grommet, or a Bellmouth*, at
the mouth to the pipe will reduce the potential for serving damage.
*
A Bellmouth (in separable hinged halves) will guide the cable into the duct, avoiding
potential damage at the ducts entrance edges.
iii.
Provision to indicate on the as laid drawings, the serial or drum number of the
cable installed.
iv.
Suitability of the cable type to the installation. e.g. LSF cables are not
recommended for use in installations in direct sunlight* (Cables with LSF properties
are usually used in buildings or confined spaces where smoke and fumes in a fire
situation could endanger human life), or, buried direct in soil ( LSF properties serve
no purpose in the ground, the additional cost is therefore wastage). * LSF materials
have lower mechanical strength than conventional materials, and therefore extreme caution must
be exercised when installing this type of cable. Twisting or over bending the cable during
installation could result in increased forces being exerted within the cable that could cause cracking
or splitting of the outer sheath. This is particularly important when installing this type of cable in
areas with hot climates.
v.
Correct derating factors for cable current ratings for multiple circuits, differing soil
or ambient temperatures, depth of burial, etc. ( Variation of installation conditions along a
route - When the heat dissipation differs in one part of a route to another, the current carrying
capacity shall be determined so as to be appropriate for the part of the route having the most
adverse conditions).
b. Drum Handling
i. Always use the best hoisting equipment available.
ii. Do not drop drums of cable onto the ground as this can damage the drum as well
as the cable.
iii. It is most important that a minimum of rolling the drums on the ground be allowed
and then only in the direction of the arrows indicated on the drum.
iv. When rolling a drum of cable, to change direction use 2 steel plates with grease
between them, and by standing one flange on these plates the cable drum may
then be swiveled in the desired direction.
v. Position the drum prior to cable-pulling so that the cable is pulled from the top of
the drum.
vi. Note that a drum of power cable can weigh in excess of 10 tons, so make sure that
adequate cable drum jacks are used, that the spindle is strong enough to hold the
drum and that the jacks stand on firm ground and that they hold the spindle
horizontal.
vii. Site the drum at the most convenient place for cable-pulling, usually at the start of
a reasonably straight section near the commencement of the trench work.
viii. Allow for drum braking.
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Page 8 of 14
Page 9 of 14
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
Before pulling, cut the inner end of the cable free. Failure to do this will cause
buckling of the cable.
The cable must be payed off from the top of the drum, but take care not to bend
it too sharply.
Cable pulling stockings should be examined and placed over the nose of the
cable with care. The pulling rope or wire must be attached to the stocking in
such a way that the cable cap will not be damaged during the pull. The use of
swivels is recommended to prevent twisting of the stocking. The use of rope or
slings attached directly to the cable for the pull-in is not recommended.
Permissible mechanical forces are indicate in the section titled Mechanical
Forces on Cables during Installation. A dynamometer should be attached in line
with the pulling rope to indicate the pulling force exerted on the cable.
Bending radius of cables should not be less than what the cable manufacturer
recommends. Usually a minimum of 15 * the cable overall diameter is used.
One man should remain at the drum and brake the drum in order to maintain
the correct tension on the cable during the pull. If the drum is allowed to
continue turning when cable pulling has ceased, there is a danger of the cable
kinking or twisting.
Avoid twisting the cable, as it can result in bird caging of the armour wires and
subsequent damage to the outer serving of the cable. This is particularly
important if the cable is to be installed by the flaking (Figure of 8) method where
twisting within the cable is more prevalent, especially in areas with hot climates,
as the heat can soften the sheathing material resulting in lower tear resistance of
the material. If the flaking method is used, the radius of bend should be as large
as the available space allows, but never less than the supplier specified radius,
and the number of layers at cross-over points must not be excessive.
Page 10 of 14
xvii.
Cables should be snaked on either side of each joint position to relieve the
joints of any thermo mechanical stresses.
xviii.
If a winch is being used to pull the cables and unavoidable sharp bends are
encountered, a snatch block could be used to assist the pulling tension at the
bend.
The cable end is manhandled onto the first rollers and tied to the steel rope (see below)
at intervals of about 2 meters. Start the winch and as the nose arrives at the snatch
block untie it from the steel cable, take it around the corner roller and retie on the
straight.
Once the nose has reached the winch end, and allowing the necessary slack, the cable
can be untied, the steel rope rewound onto the bond carrier. Further preparation for
backfilling may then be commenced.
i.
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Above this backfill layer, the trench soil, if suitable, can be replaced and
consolidated, in layers of 150mm. A Mechanical compactor can be used at
this stage.
If a marker tape is required, install it at a depth of about 200mm below
the ground surface.
j.
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We trust this basic procedure will assist you with your cable
installations.
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