How to splice OPGW and OPPC optical cables

Splicing OPGW and OPPC cables involves careful safety preparation, precise cable stripping, fusion splicing of fibers, and secure closure installation to maintain both optical and electrical functions.

Safety and Site Preparation

Before starting, establish an equal potential zone to prevent electrical hazards, especially when working on live transmission lines. Install temporary grounding cables, use conductive mats, and wear protective equipment such as gloves, face shields, and insulated tools. Ensure the work area is stable and free from wind or other environmental hazards that could compromise safety or cable integrity .

Cable Preparation

1. Straighten and Mark the Cable: Stretch the cable over at least 2–2.5 meters and mark the section to be stripped. Wrap tape at the marking points to secure the strands during cutting .
2. Remove Armor Layers: Using a metal saw or mini grinder, carefully cut and remove the outer aluminum strands circumferentially. Then remove the inner strands if present. For cables with metal loose tubes, leave the inner strands about 10 mm longer than the outer strands to expose the fiber tubes .
3. Expose Fiber Tubes: If fibers are in a plastic or metal tube, carefully remove the tube covering. For metal tubes, install transportation tubes to protect fibers during handling .

Fiber Splicing

1. Access the Fibers: Open the fiber tubes and clean the fibers with appropriate solvents to remove any debris or coating residue.
2. Fusion Splicing: Use a fusion splicer to join the fibers. Align the fiber cores precisely to minimize splice loss. Follow the splicer manufacturer's instructions for optimal arc settings and splice parameters .
3. Protect the Splice: Place a heat-shrink sleeve over the splice to provide mechanical protection and environmental sealing .

Closure Installation

1. Select a Suitable Closure: Use an optical closure rated for outdoor and high-voltage environments (e.g., IP67-rated joint boxes) to protect the spliced fibers from moisture and mechanical stress .
2. Secure the Cable: Insert the prepared cable ends into the closure, ensuring proper strain relief and alignment. Tighten clamps or adapters to prevent movement.
3. Seal and Test: Close the enclosure and perform OTDR testing to verify splice quality and optical continuity .

Post-Splice Considerations

• Ensure the cable maintains its mechanical and electrical integrity, especially for OPGW, which also functions as a grounding conductor.
• Follow manufacturer guidelines for tension, bending radius, and environmental exposure to prevent long-term damage .
• Document splice locations and test results for maintenance and troubleshooting. By following these steps carefully, OPGW and OPPC splicing can be performed safely and reliably, ensuring both optical communication and electrical grounding functions remain intact.