5 Repairing of Cable

Joints

INTRODUCTION
Electrical joints and terminations provide the required
electrical connection as well as the mechanical support
and physical protection to the cable. It is important
for the Cable jointing system to suit the service and
operational requirements for all industrial cable
jointing environments and applications. These devices
are important for jointing the cables and wires. A
good cable jointing and installation provides a better
supply of power (Fig. 5.1). Cable
jointing has become the preferred pick
over conventional systems for cable
termination, cable abandonment, low
voltage cable jointing and cable repair.
The cable termination and jointing
kits are often specialised in wire
installations worldwide.
Cables play a very important role in
the distribution system of power. There
are different types of cables like LT
cable, 11 KV cable and 33 KV cable.
Fig. 5.1 Electrical joint and terminations
Cables are used in places where bare
conductor cannot be used due to narrow roads. Cables
are costlier than the conductor and the same cannot be
replaced often.

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 SESSION 1: ELECTRICAL CABLE JOINTING
METHODS
Jointing of power cables should be as simple as twisting
and taping the wire. For jointing of a cable variety of
in-line adapters and connectors are used. The method
used for a cable joint depends on the voltage, type of
cable, type of joint, type of connector, application and
other factors. Proper tools and equipment are to be used
for jointing the cable.
Given below are some important factors to ensure
reliable connections, such as
� proper size of connectors should be used for a
particular cable,
� proper tools and equipment are to be used,
� cuts and stripping should be very clean,
� proper technique is to be used for cable jointing
and
� restoring the insulation, outer-sheath
and armour.

Western Union Splice Joint

The cables are manufactured for a particular length. To
increase the length of a cable a straight joint is used for
small solid cables (Figs. 5.2 and 5.3).
1. Remove the insulation of cable
2. Bring the two conductors to a crossed position
and then make a long bend or twist in each wire.
3. Wrap the end of one of the wires around the Fig 5.2 Western union splice and
straight joints
straight portion of the other wire, and then do
the same for the other wire. Repeat this for about
four or five times. bare wires twisted
wires
4. Press ends of the wires down close to the straight
portions of the wire to prevent the ends from
piercing through the insulation tape.
5. Insulate the joint using the insulation tape

Fixture Joint Fig. 5.3 Rattail joints

This is a type of branch joint connecting a thin wire (for
branch line) to the thick wire (main line), such as those
used in lighting fixtures.

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 1. Remove the insulation of wire
2. Wrap the fixture wire around the branch wire
3. Bend the branch wire over the
completed turns
4. Wrap the remaining fixture wire over the bent
branch wire
5. This can be followed by soldering and taping, or
Fig. 5.4 Fixture joint simply taping of the joint (Fig. 5.4).

Knotted Tap Joint

The knotted tap joint is also used for branch joints
to connect a branch wire (thin wire) to a continuous
or main wire (thick wire) (Fig. 5.5).
1. Remove about 1 inch of insulation from the
main wire and about 3 inches from the branch
Fig. 5.5 Knotted tap joint wire.
2. Place the branch wire behind the main wire so
that three-fourths of its bare wire extends above
the main wire.
3. Bring the branch wire over the main wire, around
itself, and finally over the main wire so that it
forms a knot. Wrap the wire around the main
conductor in short, tight turns and trim the end

Joints Using Wire Nut and Split Bolt

The rattail joint is replaced by wire nut. The nut is
usually housed in a plastic insulating casing. To make
a joint.
1. Strip the conductors
2. Place the two joints to be joined into the wire nut
3. Twist the nut

Split Bolt Connector

The split bolt is used to join big sized conductors. This
replaces the knotted tap joint and can be used to join
three ends or join a branch conductor to a continuous
(main) conductor (see Fig. 5.6).
The bare wires are placed through the space between
the two bolts, after which the nut is tightened to ensure

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 a sound joint. The material required for making straight
or branch joints for steel wired armour cables are as
follows:
y Connectors
y Copper mesh tape
y Constant force springs for holding the wire
armour and copper mesh tape
y Standard PVC/Vinyl tape, which provides a Fig. 5.6 Split bolt
mechanical barrier between the over sheath layer
and the armour layer.

Preparing the Cable

Preparing the cable before jointing includes the
following steps (Fig. 5.7):
1. Remove the over sheath and the wire armour
2. Separate the wire armour and bend the wires
away from the cable, place the support ring under
the armour at each side of the joint
3. Cut back the cable insulation
4. Remove the insulation from each of the conductors
A+A
B A
Oversteam
Side A
Wire armour
A less B
Cut Back Side B

C Insulation

D
D
D
Support ring

E+E

Fig. 5.7 Preparation of a three-core armoured cable

Crimping and Insulating Each Cable

Once the cable is ready, connect each end of the
three conductors to a suitable connector (copper or

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 aluminium). Suitable-sized connectors are to be
used. Tightly fix the suitable connectors and test the
connection.
Tape the crimped connectors, wrap around and
extend to cover at least 25mm of the cable insulation of
the conductor entering the connectors (Fig. 5.8).

Fig. 5.8 Taped, crimped connectors on individual cables

Binding the Cables

Bind the wires tightly and then tape them together (Fig. 5.9).

Fig. 5.9 Wires taped together Restoring Armour and Applying Mesh Tape
1. Tightly wrap the cable from armour to armour
while applying adequate tension around the
insulation.
2. Join the wire armour from one end to the other
end and cut excess wire to the correct length.
Ensure the armour spreads evenly over the entire
joint.
3. Wrap the cable with the mesh tape and then use
the standard vinyl/PVC tape to wrap over the
mesh to provide a insulation against
stray wire ends. For the branch joint,
bring both the main and branch cables
together before wrapping.
Next, use standard vinyl or PVC tape
Fig. 5.10 Wrapping the cable with mesh tape to wrap over the constant force springs
placed over the under-armour rings. The
tape provides a barrier against sharp edges (Fig. 5.10).

Re-establish the Over Sheath

1. Use a self fusing tape to wrap over the cable and
establish the outer sheath. Start in the center
and apply one layer of tape to one end, wrapping

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 over the jacket for at least 25 mm. Apply the tape
from the end towards the center so that you have
two layers on each side.
2. For branch joints, wrap over the insulation for
both the main and the branch cable, by at least
50mm. Bring the two together and fill it in with
the insulating putty from both sides. Do this up
to 25 mm away from the place where the branch
and the main cables are joined.
3. Put the two cables together and bind the main
and branch tightly over the filling. Finally, wrap
the crotch while pulling the branch away from the
main cable (Fig. 5.11).

Fig. 5.11 Restoring the over sheath on a branch joint

Electrical Power Cable Terminations Crimped

The electrical cable termination is a cable end that connector
plug
connects to the terminal of the equipment or another
cable to extend the length (Fig. 5.12). core insulation
The method used for termination of the cables varies
according to the type of cable, type of connector and cable gland
application. Some common types of terminations are
y crimp connection cable plate

y soldered connection
y compression termination Fig. 5.12 Low voltage cable
y wire-wrapping connection termination
y direct connection
y loop or eye connection

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 Some of the factors which are considered for
termination of cables are:
y Outdoor or indoor cable
y Voltage of the line
y Overhead or underground cable
y Type of connector on the equipment where the
cable will be connected

Cable Joints
A power cable consists of two or more electrical
conductors, held together wrapped with insulation and
outer surface with an overall sheath (Fig. 5.13).
The cables are used for transmission of electrical
power. Power cables is being used for permanent
wiring within buildings. The cable can be run under
ground, run overhead, or exposed. Cables consist
of three major components: conductors, insulation
Fig. 5.13 Cable joint and protective jacket. The structure of individual
cables varies according to application. Power cables use
stranded copper or aluminium conductors, although in
some cases solid conductors is used.
After the introduction of electric cables in electrical
circuit the problem of how to join them together arises
in order to achieve the degree of insulation, tensile and
crushing strengths, conductivity and accessibility. To
cope up the requirements a junction box is introduced.
The junction box typically incorporates:
y a method of securing the cable conductors
(usually by soldering, screw-clamps or
compressed ferrules).
y a method of insulation, which may be air,
oil, bitumen or insulation applied in the form
of tapes.
y a method of enclosure and protection applicable
to the environment.
As per The Electricity Regulations every joint and
connection should be mechanically and electrically
suitable for its use. In this respect the joint or connection
should be of proper construction as regards conductivity,
insulation, mechanical strength and protection.
Joints in Non-flexible Cables
Underground cables are joined by ferrules or lugs
(crimped) and the outer protection enclosure or box is

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 usually filled with a plastic or bituminous compound.
Such joints are often used above-ground for non-flexible
cables and are adequately protected and supported.
Other cables which are fixed wiring installations enclosed
junction boxes are used to making a joint between two
cables. These junction boxes are not securing the cable
against strain.

Joints in Flexible Cables

Joints in flexible cables are not usually satisfactory
because:
1. stranded conductors are not suitable for certain
methods of jointing.
2. mechanical tensile strength and resistance are
difficult to maintain.
3. fatigue damage may occur when rigid joint is
being done.
Some joints and cable connectors are much more
acceptable these incorporate terminals or compression
fittings suitable for stranded conductors. Cable
clamps are used for plugs to reduce the flexing.
Heat-shrinkable or pre-stretched sleeving may be
adequate in some cases but other circumstances may
demand additional protection.

Types of Cable Joints and Equipment

A great majority of failure in cable network is associated
with faulty cable jointing. It is, therefore, essential to
use proper jointing technique, good quality insulating
material and standard accessories for cable jointing.
Cable joints are of three types:

Straight through Joint

Straight through Joints are an important part of today’s
power cable networks (Fig. 5.14). These joints offer
reliability and flexibility to meet the demands of cable
network.
Straight through Joints provide
y quick cable preparation
Fig. 5.14 Single Core Straight
y high electrical insulation through Joint Kits
y no moisture ingress
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 y good mechanical strength
Semi-conductive tape y compact dimensions and is suitable
Waterproof seal gum
Semi-conductive tubing
for all conductor, shape and material
Outer insulation tubing
Cable insulation layer
Inner insulation tubing Straight through Joints are made by
Connector tubing
Semi-conductive metal joining processes, such as welding
Stress control tubing and soldering (Fig. 5.15).
Semi-conductive tubing
Copper screen T-Joint
Fig. 5.15 Straight through Joint These types of joints are used for branching
of a service cable from a main cable.
T-joints are helpful as turning and twisting of cable
damages its outer core (Fig. 5.16).
Terminal Joint
These type of joints connect cable to switch gear,
transformer terminal or to an overhead line (Fig. 5.17).
Fig. 5.16 T-Joint
Conductor Joint
The length of distribution lines are in kilometers and one
coil of conductor is unable to solve the length problem.
Hence, jointing the conductor is necessary.
Britannia Joint
This type of joint is made only on solid conductors
and cannot be made on stranded conductor. Two
Fig. 5.17 Terminal Joint conductors to be joined are brought in front of each
other of about 6 inch (150 mm) of length. Both the
conductors should be clean. If the conductor is of
copper; it should make good electrical connection.
Then ends of both conductors are bent through
half centimetre and placed on each other.
The length of contact portion should be min.
100 mm. This joint should be bound by 14 mm copper
wire as shown in Fig. 5.18.
Fig. 5.18 Britannia Joint Telephone Joint (Western Union)
This joint is used only for solid conductors. It is used
for conductors of size 8 SWG or higher size. First,
bend is given at 100 to 125 mm from the edge and are
placed over each other. Then each one is twisted with
another conductor.

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 Married Joints
This joint is made between copper conductors having
central strand of GI wire (Fig. 5.19). It should not be made
between aluminium (Al) conductors. Approximately 175
to 200 mm length conductor strands are unwound. The
GI strand of both conductors should be broken up to
175 mm in length. Both conductors should be brought
in front of each other and their strands should be woven
in each other. The strand of one conductor is twisted
on other conductor, and strand of other conductor is
twisted on the first. Likewise all the strands twisted and
then soldered. This is used only for small span length.

Before Jointing
Preparation of ‘T’ Joint

After Jointing ‘T’ Joint After Completion

Fig.5.19 Married Joint Fig. 5.20 ‘T’ Joint

Sleeve Joint
It can be made with any type of aluminium
conductor. Graphite Greece is applied over the
Fig. 5.21 Sleeve Joint
conductor and as shown in Figs. 5.20 and 5.21
sleeves should be taken. These sleeves should be
placed on the conductor as shown. Sleeves should be
twisted by twisting wrench. This joint is made for LT,
HT, ACSR, AAC conductor up to 0.06 cm2.

Compression Joint
This joint is used for conductors of more than
0.06 cm2 sizes. For jointing, two different sleeves are
used. Steel sleeve is used for steel conductor strands
and aluminium. sleeve is used for Al. conductor strands.
There are two holes in Al. sleeve. Rebating is done

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 through these holes. Then Al. sleeve to be mounted on
one side. The length of steel sleeve is then measured.
Its half distance is taken. Suppose it is ‘X’ cm. Then
the ends which are to be joined and more to ‘X’ cm
distance is taken on the conductor is banded there.
The Al. strands are opened up to that point and cut.
Steel strand should not be touched during this. They
are placed in the steel sleeve. They should be kept in
front of each other. Then the center of steel sleeve is
compressed through compression machine. Then on
the half portion of the right side sleeve be compressed
and then on the left half portion. Due to compression
the length of sleeve will be increased by 6mm on both
sides and it will reach Al. strands. Then Al. sleeve
should be measured. It should be halved. Suppose it is
‘Y’ cm then ‘Y’ cm should be measured and marked on
both sides of conductor measured from center of steel
sleeve. Both parts of conductor are brought in sleeve
in front of each other. The filler parts should be filled
in the sleeve by Grease until it comes out of the holes.
Both the holes are then closed by rivets and hammered
by hammer. There is one stencil mark on Al. sleeve.
The first compression will be there; afterwards it will be
compressed up to one end. Similarly the other part is
compressed up to the other end.
Jumpering
Connecting two conductors or wires is called jumpering
(Fig. 5.22).
Jumper should not be connected to the main
conductor. The jumper should always be connected by
PG clamps.
When the jumpers are near metallic portion, all such
Fig. 5.22 Jumpering
jumpers are covered with alkathane pipe.
Conductor joints are marked on ACSR conductor
when dispatched. Mid-span joint should be made before
stringing as the steel strand is not kept continuous.
Hence, it is necessary to replace the company joint.
Care should be taken that mid-span joint is
not less than 40 ft. from pole. Every joint should be
done carefully.
Where conductor strands are cut, repair sleeve
is used. Conductor joint strength should be 95%
that of conductor, and resistance should be that of a
main conductor.

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 HV Cable Jointers Tools
Using the correct cable tools to prepare industrial and
utility cables before cable jointing and terminating
reduces catastrophic cable failures. Some of the
important cable jointer tools include:
y Cable cutting tool
y Cable crimping tool (hydraulic, battery, ratchet)
copper/aluminium cables
y Cable spiking tools for LV-HV cables (cartridge/
hydraulic)
y Heat shrink gas torches for LV-HV jointing
y Screen scoring tools for bonded/easy peel
HV cables
y Outer sheath stripping tools, LV-HV cables
y Insulation (XLPE) stripping tools, HV cables
y Insulated tools for live-working
y Cable laying rollers, socks, jacks and pulling
equipment
y Conduit duct rods

Procedure for Heat Shrink Straight

through Joint

Mark reference line Park outer scaling sleeves Remove sheath

and armour

Adjust support
Adjust support ring Adjust support ring
ring

Secure SWA onto

support ring

Remove bedding
Mark reference
line

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 File screen cut
Remove copper tape shield
Cut cores at
reference line

Shrink stress control tubing

Remove insulation
Remove conductive layer

Apply filler putty

Park insulation tubing Apply stress control patch

Apply copper mesh shielding

Position insulation tubing
Position and secure armour case

Protect protruding edges

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 Check Your Progress

A. Write short notes on

1. LT cables Joints
2. Straight through joint
3. Britannia Joint
4. T-joint

B. State whether the following statements are True or False

1. Western Union joint are used for all conductors.
2. Meried joint should not be made between
aluminium conductors.
3. Crimping is necessary for jointing the cable.

C. Short answer questions

1. List the steps used in preparing of the cable.
2. Explain the different types of joints.
3. Differentiate between fixture joint and western union
splice joint.
4. Explain the procedure for heat shrinking straight
through joint.

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