MEC/Mechanical/TBT-MEC-013

Cable Pulling and Termination

MEICA Works › Mechanical › Cable Pulling and Termination

Presenter		Project
Location		Date

Cable pulling routes power, control, and instrumentation cables from panels to equipment in MEICA installations.
Large power cables can weigh hundreds of kilograms per drum, requiring mechanical aids for pulling and handling.
Cable drums must be positioned securely on jacks or stands that allow controlled unreeling during the pull.
The pulling force must not exceed the cable manufacturer's maximum to prevent conductor and insulation damage.
Cable lubricant reduces friction in ducts but can create slip hazards on floors and hands.
Working at height is needed when pulling cables into elevated trays, ladder racks, and gland plates.
Termination involves stripping insulation, crimping lugs, and torquing connections — all requiring hand dexterity.
Cable glands must be correctly sized and tightened to maintain the IP rating of the enclosure.
Verification of cable identification at both ends is essential before termination to prevent cross-connections.
All terminations must be tested for continuity, insulation resistance, and correct polarity before energisation.

Manual handling	Heavy cable drums and long cable runs cause back, shoulder, and hand injuries during pulling operations.
Cable damage	Exceeding pull forces or bending radii damages insulation and conductors, causing faults and fire risk.
Electrical safety	Incorrect termination causes loose connections, overheating, arc flash, and equipment malfunction.

Don't

Use mechanical cable pulling equipment for heavy or long cable runs
Check the cable manufacturer's maximum pulling tension before starting the pull
Secure cable drums on jacks or stands that allow controlled unreeling
Apply cable lubricant where needed and clean up any spillage to prevent slips
Verify cable identification tags at both ends before starting termination
Use calibrated torque tools for all gland and terminal connection tightening
Test continuity, insulation resistance, and polarity before any cable is energised
Coordinate pulling operations with teams at each end using radio communication
Use safe working platforms for termination work at elevated panel and tray positions
Record all cable installation and test results for the handover documentation

DON'T pull cables by hand where mechanical pulling equipment is available
DON'T exceed the manufacturer's maximum pulling tension — it damages the cable
DON'T allow cable drums to unreel uncontrolled during the pulling operation
DON'T bend cables tighter than the specified minimum bend radius for the cable type
DON'T terminate cables without verifying identification at both ends first
DON'T leave glands under-tightened — water and dust ingress causes equipment failure
DON'T energise cables before completing continuity and insulation resistance tests
DON'T step on cables routed across walkways — protect them with ramps or overhead routing
DON'T use incorrect crimp tools or terminal sizes — poor crimps cause overheating
DON'T leave cable lubricant on floor surfaces where it creates a slip hazard

See also: MEICA Safety Awareness | Cable Pulling Safety

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