Splice failures are a major concern for power line maintenance and are most often caused by improper installation or material incompatibility. The most common issues include:

• Improper Compression: Insufficient or uneven compression during installation can create air gaps between the splice and the conductor. This leads to increased electrical resistance, which causes the splice to overheat and degrade over time.

• Corrosion: Galvanic corrosion can occur if the splice material is not compatible with the conductor material (e.g., using a copper splice on an aluminum conductor without a bimetallic interface). Contaminants and moisture can also accelerate this process.

• Vibration and Fatigue: Constant motion from wind (aeolian vibration) can cause fatigue breakage of conductor strands, particularly at the ends of rigid splices. This is a common failure point for both splices and dead-ends.

Preventing these issues starts with using the right tools and equipment. Our products, from hydraulic crimping tools with precise die sets to tension stringing equipment that minimizes conductor damage, are designed to ensure every splice is installed correctly. Proper cleaning and preparation of the conductor surfaces are also essential for a low-resistance, durable connection.