OPGW Optical Cable Fiber Splicing Steps

Splicing OPGW cables involves careful preparation, fusion splicing, sealing, installation in closures, and post-splice testing to ensure both optical and grounding performance.1. Safety and Site PreparationBefore starting, establish an equal potential zone by installing temporary ground cables and using protective equipment such as hot-sticks, conductive mats, gloves, and face shields to prevent electrical hazards . Ensure the work area is stable, especially when working on transmission towers, and follow all utility safety protocols.2. Cable PreparationStraighten and mark the cable over 2–2.5 meters to identify the section for splicing .Remove the armor: Carefully cut and remove the outer aluminum strands using a metal saw or mini grinder, then remove inner strands if present. For cables with metal loose tubes, leave the inner strands slightly longer to expose the fiber tubes .Install heat-shrink or transportation tubes over the cable to protect fibers during handling .3. Fiber PreparationStrip the fiber coating using the three-character method: flat, stable, and fast. Hold the fiber horizontally, strip about 5 cm, and bend the remaining fiber to prevent slipping .Clean and cleave the fiber ends precisely to ensure a high-quality end face, which is critical for low-loss fusion splicing .4. Fusion SplicingUse a high-performance fusion splicer suitable for the fiber type. Set the correct pre-melting and main melting parameters according to fiber specifications .Align fibers in the splicer, monitor the arc, and ensure no bubbles, misalignment, or virtual melting occurs.After splicing, coil the fibers carefully to avoid stress and maintain bend radius.5. Sealing and ProtectionPlace a heat-shrink sleeve over the splice and apply heat evenly until the thermo-indicating paint changes color .For multiple loose tubes, additional sealing tubes may be applied for extra protection .6. Installation in ClosureClean the cable clamp and closure port, feed the cable through the designated ports, and align the heat-shrink sleeves properly .Secure the splice inside the closure, ensuring it is installed above 6 meters to prevent environmental damage .7. Post-Installation TestingUse an OTDR (Optical Time Domain Reflectometer) to verify splice quality, measure attenuation, and ensure the optical signal meets standards .Confirm that the cable's grounding functionality remains intact to maintain both communication and lightning protection capabilities .Tools and EquipmentFusion splicer with dust and windproof coverFiber cleaver and stripperHeat-shrink sleeves and transportation tubesGloves, face shield, hot-sticks, conductive matsOTDR for testing Following these steps meticulously ensures a reliable OPGW splice that maintains both optical performance and electrical grounding integrity, even in challenging high-voltage environments .