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The products are widely used in transmission and distribution lines of electrical energy, optical cable lines and
high-speed railway lines.
| model | Scope of application | Weight | Material | Breaking Load |
| tangent tower | Used for the main material size of cable hanging point≤80mm | 3.0 | A3 steel | 70 |
| Used for the main material size of cable hanging point81mm~200mm | 3.4~5.0 | 70 | ||
| angle tower | Used for the main material size of cable hanging point≤100mm | 3.7 | 100 | |
| Used for the main material size of cable hanging point101mm~200mm | 4.0~4.9 | 100 | ||
| For rod | Used to installφ190~φ400 | 3.0~5.4 | 70 |
A Dead-End Tension Clamp is a specialized hardware component used to permanently terminate and secure the end of a conductor, cable, wire rope, or strand in an overhead or underground transmission/distribution system. Its primary function is to absorb and transfer the full mechanical tension (load) from the line to a supporting structure (pole, tower, anchor) while maintaining electrical continuity where required.
Overhead Power Lines: Termination at tangent poles, dead-end poles, corner poles, or at the interface with substations.
Guy Wire/Strand Anchoring: Terminating and anchoring guy wires that support utility poles, towers, or masts to ground anchors or foundations.
Railway & Catenary Systems: Terminating contact wires or messenger wires in electrified rail systems.
Telecommunications: Securing the ends of fiber optic or coaxial cables under tension.
Civil Engineering & Construction: Anchoring cable barriers, temporary guying systems, or suspension bridge strands.
The clamp operates by creating a secure mechanical grip on the conductor. When the conductor is pulled taut, the tension force is transferred through the clamp body to its mounting hardware (bolt, eye, socket), and finally to the support structure. The design ensures the grip strength exceeds the conductor's rated breaking strength, preventing slippage or pull-out.
By Conductor Type:
Strain/Dead-End Clamp for Bare Conductors: Used on ACSR (Aluminum Conductor Steel Reinforced), AAC, AAAC. Often features a saddle and keeper design (e.g., NEMA-type) or a helical preform rod design.
Guy/Ground Anchor Clamp: For steel strand (e.g., EHS strand). Typically a two-bolt or three-bolt parallel groove clamp.
Messenger/Figure-8 Clamp: For supporting bundled communication cables or secondary distribution lines.
Wedge-Type Dead-End: Uses an internal wedge that tightens under tension (common for guy strands and some distribution lines).
By Material:
Aluminum Alloy: For aluminum conductors to prevent galvanic corrosion.
Ductile Iron or Forged Steel: For high-strength applications like guy strands and large transmission conductors. Often hot-dip galvanized.
Copper or Bronze: Used in grounding or where high electrical conductivity is critical.
Selection is critical for safety and performance and must be based on:
Conductor Specifications: Exact type, diameter, cross-sectional area (e.g., 336.4 kcmil ACSR "Drake"), and rated breaking strength (RBS).
System Voltage & Electrical Requirements: Does it need to carry current (e.g., jumper connection integrated) or just provide mechanical termination?
Mechanical Loads: Maximum expected tension (including wind, ice loading, and a safety factor, per NESC or other standards).
Environmental Conditions: Corrosivity (C1-C5), presence of salt spray, industrial pollutants.
Compatibility with Fittings: Must match the associated clevis, ball socket, anchor rod, or pole band.
NEMA Standards: NEMA CC 1-4 for guy strand clamps, NEMA CV 7 for dead-ends.
ASTM International: Standards for material properties (e.g., ASTM A153 for galvanizing).
IEEE Standards: For electrical and mechanical testing.
National Electrical Safety Code (NESC): Governs installation and safety requirements.
Third-Party Testing: Products are typically proof-tested to 50%, 70%, or 100% of the conductor's RBS. Look for certification from labs like SEI (SEI Certs).
This is the minimum mechanical failing load the clamp assembly must withstand. It must be greater than the ultimate strength of the conductor it is designed for, with an appropriate safety margin (often 2:1 or more). Never use a clamp rated below the conductor's rated breaking strength.
Follow Manufacturer Instructions (IMPERATIVE): Each clamp has specific torque values and installation sequences.
Conductor Preparation: Clean the conductor section to be gripped. For helical rod dead-ends, follow exact wrapping patterns.
Alignment: Ensure the conductor sits correctly in the saddle or groove.
Torquing: Use a calibrated torque wrench to tighten bolts to the specified value in the specified pattern (e.g., criss-cross). Do not overtighten.
Final Inspection: Verify the conductor is seated, all bolts are torqued, and a positive "witness mark" is applied.
Mismatched Components: Using a clamp with an undersized or incorrect conductor.
Incorrect Torque: Under-torquing leads to slippage; over-torquing can crush the conductor or damage the clamp.
Improper Alignment: The conductor is not seated fully in the groove, creating a point of high stress.
Reusing Clamps: Never reuse a dead-end clamp that has been under load. The aluminum body may have yielded (permanently deformed).
Missing or Incorrect Hardware: Using non-grade-specified or ungalvanized nuts/bolts.
Initial Inspection: After installation and first application of load.
Regular Cyclical Inspections: Part of overall line maintenance. Check for:
Visible cracks or deformation in the clamp body.
Corrosion, especially at the bolt/clamp interface.
Loose hardware.
Slippage of the conductor (check against initial witness marks).
Thermographic Inspection (if current-carrying): To detect hot spots from poor connections.
With proper selection and installation, dead-end clamps should last the design life of the line (30-50+ years). Life is reduced by:
Exposure to severe corrosive environments.
Cyclic loading (vibration, galloping) leading to fatigue.
Overload events (severe storms).
Yes, they are commonly used for in-line repairs (splicing out a damaged section) or for converting a tangent pole to a dead-end pole. The new clamp must be rated for the existing conductor and the new, calculated tension loads.
To specify the correct part, provide:
Conductor Code & Diameter (e.g., "Partridge" 26/7 ACSR, 0.642" diameter).
Conductor Rated Breaking Strength (RBS) in lbs or kN.
Type of Termination Needed: e.g., eye type, clevis type, stub angle.
Quantity and Project Specifications (e.g., NESC Grade B Construction).
Catastrophic. Failure can lead to:
Dropped Conductors: Creating life-threatening electrocution and fire hazards.
Structural Collapse: Failure of a guyed pole or mast.
Major Power Outages.
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