Cable Pulling & Jointing Tools and Equipment

Cable pulling, Jointing, and Termination equipment play very important roles to ensure quality work to operate a safe and long-life operation. Cable pulling tools make for easy and safe cable laying, less cable sheath or screen damage/scarce, applying pulling tension correctly, and spacing cable in trench or duct properly. Cable Joint and Termination tools are very much special for cable jointing and cable sealing end termination.

How Use Cable Pulling Tools & Prepare Cable Trench?

Before laying cable, cable trench or cable duct must prepare as per site requirement. Cable ducts or trench measurements will not same for all, depending on the voltage rating, cable size, laying location, and other vicinity factors cable ducts or trenches' depth and width vary.

 

According to low, medium, and high voltage cables, the open trench depth and width vary. Usually the higher the voltage range the higher the depth and width of the cable trench.

At the bending point, the cable trench must be followed an adequate size as per the cable manufacturer's recommendation, which means the trench width must be sufficient to bend the cable without overexciting mechanical stress to the cable. The cable bending diameter depends on cable flexibility, and cable flexibility depends on cable-constructed materials.  The corrugated aluminum metallic sheath is used to get more flexibility for high and extra–high voltage cables.

The cable trench should be sufficient to move the installer to install the cables and allow the cables to be installed within specified cable pulling dimensions and without damaging the cable sheaths considering bending radii.

Equipment Required For  Cable Laying In Trench 

 

Key equipment for cable laying in the trench with a brief description is as below:

1. Cable Winch
2. Winch Wire Rope
3. Cable Pulling Swivel
4. Cable Socks
5. Cable Rollers
6. Corner Rollers
7. Draw Off Rollers
8. Cable Drum Trailer

Cable Winch– A cable winch is a mechanical device that is used to pull in (up) the cable or let out the cable or adjust the cable pulling tension. It consists of a spool and an attached hand crank.

During cable, the cable winch is placed at the end of the cable trench which provides smooth and controlled actual pulling of the cables through the trench. There are various cable winches depending on the types of cable to pull, like- telecommunications, heavy power cables, and lightweight small power cabling, etc.

Winch Wire Rope– Winch wire rope is nothing but a metal wire rope twisted into a helix formatting a composite rope. Larger diameter winch rope consists of multiple number of wire strands to provide larger pulling strength.

During cable pulling in a cable trench, the winch wire rope is attached to the cable end eye bolt to be pulled through the winch rope.  This winch wire rope allows for heavier cables to pull through the trench and gives extra strength.

Cable Pulling Swivel–The cable pulling swivel is a connecting device that connects the grip (cable) and the pulling rope or winch wire. The cable pulling swivel is designed in such a way that used to allow the winch wire to rotate when being pulled and avoid kinking or twisting the cable core and protect from damage.

The impertinence to selecting the cable pulling swivel is to mind the maximum pulling capacity at or above the pulling force of the cable puller.

Depending on the cable types and pulling purposes swivels or connectors may be different types, like- Clevis pins, Line swivels, Rope connectors, Breakaway swivels and connectors,  shackle and connectors, Wire rope bridle slings, etc.

Cable Socks–A cable pulling sock is a kind of cable installation tool that high tensile galvanized steel wire shock that ensures an efficient method of supporting for cable pulling.

Cable socks are also called cable grips or cable shocking. This is the most handy and efficient tool to pull the cable in trenches, ducts, or buildings. This is high tensile galvanized steel wire, also available in stainless steel or Kevlar constructed.

Cable Roller– A cable roller is a simple cable-pulling tool that is used to roll or pull the cable on it. It is placed 3 to 4 m apart and at corners to allow for the bending radius of the cable. The cable easily moves on it without any scratch on it and the cable puller feels less weight on it. The cable roller is mainly two types according to its using location.

1. Straight Line Cable Rollers
2. Corner Cable Rollers 
3. Draw Off Rollers

The straight-line cable rollers are used at the straight part of the cable trench. Normally 3m to 4m apart be used, also consider the cable weight and diameter. Straight cable rollers protect the cable to touch the bottom and soil surface which may cause scratches on cable outer jacket. 

Corner Rollers are to be used within the cable trench where there is a bend in the cable trench. Actually, corner cable rollers are incorporated vertical and horizontal cable rollers to allow cable pulling safely without any damage. Actually, the corner roller protects the cable from extra stress on the cable outer jacket due to trench bending.

Draw Off Roller is one kind of cable-pulling roller that is used near the cable drum during cable is pulled off from the drum to the trench. It is used to direct or guide the cable to the trench in a straight line.

 Cable Drum Trailer- The cable drum trailers sense to transport the cable drum from one place to another on-site, on the other hand, a cable trailer is also meant to stabilize the cable drum while the cable is being pulled through the cable trench or cable ducts. A cable drum trailer used to stabilize the drum during cable pulling is commonly used as a Cable jack.

Cable Jointing Tools & Equipment

To prepare the Cable to join each other or for the cable sealing end, many special tools and equipment are necessary for a cable jointer. It also varies from types of cable and types of jointing accessories. A very common tools list is to be used for cable jointing and termination works.

List of Common Tools Used for Cable Jointing and Sealing End Termination
Sl. No.	Name of Item	Qty(pcs)	Item Code	Remarks
1	Al Sheath Cutter	1	T3201-005
2	Band Saw	1	J3041-017
3	Temperature Control Box	1	J1090-066
4	SRC & Slip-on Insert Tool	1	T1020-031	50 Ф -140Ф
5	Hydraulic Compression Pump	1	J3061-064	Small
6	Hydraulic Compression Tool	1	J3074-054	Small
7	Hydraulic Punching Tool	1	T3001-038
8	Electric De-humidifier	1	J1120-033
9	Vernier Calipers	1	M2064-062	Damage
10	Belt Sander	1	T1042-073
11	Humidity Meter	1	M2120-054
12	High Voltage Insulator Tester	1	M2032-028
13	Torque Wrench	1	M2014-014
14	Pressure Gauge	1	C1220-062
15	Rubber Sleeve Installation Machine (132KV)	1	J1132-009
16	Hydraulic Compression Pump	1	J3060-050	Big
17	Hydraulic Compression Head	1	J3072-055	Big
18	Hydraulic Compression Tool Set	1	T3092-046	Small
19	Impact (Big)	1
20	Impact (Small)	1
21	Red Box	1		25 & 26 missing
22	Jack saw	1		Damage
23	Hammer Drill	1
24	Heat Gun	1
25	Drier	1
26	Vacuum Cleaner	1
27	Lever Block
	0.8 Ton	6
	0.5 Ton	8
	0.25 Ton	6
28	Hand Lamp	4
29	Soldering Iron	2
30	Heating Belt	15
31	Extension Cord	3
32	Heat Belt Power Cable	14
33	Thermometer	4
34	Oil Gate Valve	2
35	Ratchet Belt	16
36	Saw Cutter	1
37	Gas Torch	1
38	Cylinder (Big)	1
39	Cylinder(Small)	1
40	Burner	4
41	Aluminum Angle	9		1.5m
42	Nose Cone (132KV 500sq.mm)	1
43	Eye Bolt
	M-16	4
	M-12	6
	M-10	4
44	300 Scale	3
45	600 Scale	1
46	Transformer	1
47	Blower	1
48	OFC Material Box	1
Consumable Item for Use During Cable Joint and Termination
Sl. No.	Item Name	Qty	Item Code	Remarks
1	Wrap	30 Pcs
2	Aluminum Foil	30 Pcs
3	P.E Tube (1800 mm)	1 Role
4	P.E Tube (600 mm)	3 Role
5	Hand Gloves	20 Bundle
6	130 C tape	30 Pcs

Safety is of utmost importance when working with cable jointing tools and equipment. Failure to follow safety guidelines can result in accidents, injuries, or damage to equipment. Here's a safety guide for working with cable jointing tools and equipment:

Training and Qualifications:

• Ensure that all personnel working with cable jointing tools and equipment are properly trained and qualified for the job.
• Training should include both theoretical knowledge and practical skills.

Personal Protective Equipment (PPE):

• Always wear appropriate PPE, which may include safety goggles, gloves, insulated tools, hard hats, and insulated footwear.
• Use fire-resistant clothing when working with live cables or in potentially hazardous environments.

Work Area Inspection:

• Before starting work, inspect the work area to identify potential hazards such as live cables, sharp objects, or flammable materials.
• Ensure proper lighting for clear visibility.

De-Energize the System:

• Before performing cable jointing work, de-energize the electrical system. Follow lockout/tagout procedures to prevent accidental re-energization.

Isolation and Disconnection:

• Confirm that the cables are isolated and disconnected before beginning any cable jointing work.
• Use appropriate testing equipment to verify that the cables are de-energized.

Tools and Equipment Inspection:

• Regularly inspect cable jointing tools and equipment for signs of wear, damage, or defects.
• Replace or repair any damaged tools or equipment immediately.

Proper Tool Selection:

• Use the right tools and equipment for the specific cable jointing task.
• Insulated tools should be used for work on live cables.

Working with Live Cables:

• When working on live cables is necessary, follow the relevant safety procedures, such as using insulated tools and maintaining a safe distance.
• Always have a qualified observer present when working with live cables.

Ventilation:

• Ensure proper ventilation when working in confined spaces to prevent the buildup of harmful gases or fumes.

Fire Safety:

• Have fire extinguishing equipment readily available, especially when working near flammable materials.
• Avoid using tools or equipment that could create sparks in areas with flammable gases or liquids.

First Aid:

• Keep a well-stocked first aid kit on hand and ensure that all workers are trained in basic first aid procedures.

Emergency Procedures:

• Establish clear emergency procedures, including how to respond to electrical shocks or fires.
• Ensure that all workers know how to shut off power in case of an emergency.

Documentation:

• Maintain accurate records of all cable jointing work, including diagrams, test results, and safety procedures followed.

Environmental Considerations:

• Follow environmental regulations and guidelines when working with cable jointing materials, especially those that may be hazardous to the environment.

Continuous Learning:

• Stay up-to-date with the latest safety standards and guidelines related to cable jointing work.

Communication:

• Maintain clear communication among team members to ensure everyone is aware of the work being performed and any potential hazards.

Post-Work Inspection:

• After completing cable jointing work, inspect the area and equipment to ensure everything is in order and safe.

By following these safety guidelines, you can help prevent accidents and injuries while working with cable jointing tools and equipment. Always prioritize safety in all electrical and cable jointing work.