Company Directive

STANDARD TECHNIQUE: CA1D/6

Relating to the Procedures for making

Low Voltage Mains Cable Straight Joints

This Standard Technique Document contains all the approved LV mains cable straight joints,
which shall be implemented in conjunction with the appropriate General Requirements
contained in ST: CA1C.

This ST has not been written as a training document. It is not intended to be exhaustive in
content and you must refer to your supervisor if you require training or instruction.

You shall work safely and skilfully, utilising the training/instruction you have already received,
relating to the contents of this document and its cross-references.

You must make sure that you understand your job instructions and that you have the
necessary tools and equipment for the job.

Author: Richard Summers

Implementation Date: November 2022

Approved by

Carl Ketley-Lowe
Engineering Policy Manager

Date: 25th November 2022

Target Staff Group Jointers, Team Managers and Technicians who are involved in the jointing
activity
Impact of Change Green – No major impact

Planned Assurance checks The position of the BCNE connector will be checked as part of the Field Check
or Site Safety Visits

NOTE: The current version of this document is stored in the NGED Corporate Information Database. Any other
copy in electronic or printed format may be out of date. Copyright 2022 National Grid Electricity Distribution

ST: CA1D/6 November 2022 - 1 of 118 -

 IMPLEMENTATION PLAN

Introduction

This document details the general tasks and procedures required to complete low voltage
straight jointing and must be read in conjunction with specific STs for jointing techniques.

Main Changes

BCNE connector position changed to fit on the side of the PILC main.

Impact of Changes

No major impact.

Implementation Actions

To be implemented via training school roadshows.

Implementation Timetable

Implemented after briefing.

ST: CA1D/6 November 2022 - 2 of 118 -

 REVISION HISTORY

Document Revision & Review Table

Date Comments Author
November 2022  BCNE connector position changed to fit on the side Richard Summers
of the PILC main.
 Twine and 70 tape replaced with black adhesive
tape for paper terminations.

August 2020  Ex-DC cable straight joint added. Richard Summers

ST: CA1D/6 November 2022 - 3 of 118 -

 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINTS

INTRODUCTION

This Standard Technique Document contains all the approved LV Mains cable straight joints,
which shall be implemented in conjunction with the appropriate General Requirements
contained in ST: CA1C, including: -

1. General Cleanliness and Accident Prevention

2. General Jointing Procedures - Dead Cables

3. General Jointing Procedures and Safety Precautions - Live Cables

If the need arises to undertake a Mains Straight Joint configuration (i.e. non-standard) not
covered within this Standard Technique the Policy Manager is to be consulted.

CONTENTS

7.101 Three Core Wavecon - Three Core Wavecon

7.102 Three Core Wavecon - Three Core Wavecon including Services

7.103 Three Core Wavecon - Consac

7.104 Three Core Wavecon - Consac including Services

7.105 Three Core Wavecon - PILC

7.106 Three Core Wavecon - PILC including Services

7.107 Three Core Wavecon - Four Core Wavecon

7.108 Three Core Wavecon - Four Core Wavecon including Services

7.109 Four Core Wavecon - Four Core Wavecon

7.110 Four Core Wavecon - Four Core Wavecon including Services

7.111 Four Core Wavecon - Four Core Wavecon including Services (CNE)

7.112 Four Core Wavecon - PILC

7.113 Four Core Wavecon - PILC including Services

ST: CA1D/6 November 2022 - 4 of 118 -

 CONTENTS (Continued).

7.114 Four Core Wavecon - PILC including Services (CNE)

7.115 Single Core Solidal - Single Core Solidal

7.116 Single Core Solidal - Single Core PILC

7.117 Four Core Wavecon – 3x Single Core PILC (Ex DC cables)

Note: - Any reference to hybrid equally applies to plain concentric.

ST: CA1D/6 November 2022 - 5 of 118 -

 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.101

THREE CORE WAVECON – WAVECON MAINS CABLE

STRAIGHT JOINT

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C/4 Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 6 of 118 -

 JOINTING PROCEDURE 7.101

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

FROM TO STRAIGHT JOINT
95W MS1
95W 185W MS2
300W MS3
185W MS2
185W
300W MS3
300W 300W MS3

Note: - 70mm² and 120mm² Wavecon used in South Wales will be sized
as 95mm² (70) and 185mm² (120).

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 7 of 118 -

 JOINTING PROCEDURE 7.101

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 BCNE 3 LVCU 1700/5
MS1 1 2 3 2 1
MS2 1 1 2 3 2 1
MS3 1 3 2 3 2 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
Tinned copper braid (15 x 1.5)
16 swg tinned copper wire
PVC tape
De-solvit 1000FD
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 8 of 118 -

 JOINTING PROCEDURE 7.101

Actions General Requirements

(ST: CA1C)

Refer to Drawings LVJ 7.101.1, 7.101.2 whilst undertaking this Jointing Procedure.

1. Set up and mark cables 4

2. Open and cut cables in accordance with General Requirement 6.14 14

3. Prepare neutral/earth wires for jointing 8

4. Set cores in joint position 27

5. Connect neutral/earth wires on far side of joint including 29

equalisation bond

6. Remove temporary earth connection applied in 2 --

7. Apply temporary shrouding 21

8. Make and insulate phase connections 29/30

9. Remove temporary shrouding applied in 7 --

10. Connect remaining neutral/earth wires including equalisation 29

bond and copper earth tail

11. Form neutral/earth wires into their final positions --

12. Abrade and build up oversheaths 32

13. Thoroughly degrease the joint 35

14. Apply mastic waterblock to copper earth tail 33

15. Remove temporary binders --

16. Prepare and fit shell ensuring 15mm clearance 36

17. Mix and pour resin 37

ST: CA1D/6 November 2022 - 9 of 118 -

ST: CA1D/6 November 2022 - 10 of 118 -
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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.102

THREE CORE WAVECON – WAVECON THREE CORE

MAINS CABLE STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 12 of 118 -

 JOINTING PROCEDURE 7.102

JOINT KIT REFERENCES

MAINS CABLE JOINT KIT REFERENCES

ST JT WITH HYBRID SERVICES
FROM TO
1 x 1 ph 2 x 1 ph 1 x 3 ph
95W MSS 1 MSS 4 MSS 7
95W 185W MSS 2 MSS 5 MSS 8
300W MSS 3 MSS 6 MSS 9
185W MSS 2 MSS 5 MSS 8
185W
300W MSS 3 MSS 6 MSS 9
300W 300W MSS 3 MSS 6 MSS 9

Note: - 70mm² and 120mm² Wavecon used in South Wales will be sized as 95mm² (70)
and 185mm² (120).

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 13 of 118 -

 JOINTING PROCEDURE 7.102

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 USB 95 T1 USB 185T1 USB 300T1 BCNE 3 LVCU 1700/5
MSS 1 1 2 3 1 3 1
MSS 2 1 1 2 3 1 3 1
MSS 3 1 3 2 3 1 3 1
MSS 4 1 2 3 2 3 1
MSS 5 1 1 2 3 2 3 1
MSS 6 1 3 2 3 2 3 1
MSS 7 1 2 3 3 3 1
MSS 8 1 1 2 3 3 3 1
MSS 9 1 3 2 3 3 3 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
Tinned copper braid (15 x 1.5)
16 swg tinned copper wire
PVC tape
Emery cloth
De-solvit 1000FD
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 14 of 118 -

 JOINTING PROCEDURE 7.102

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.102.1, 7.102.2 whilst undertaking this Jointing Procedure.

1. Set up and mark cables 4

WAVECON CABLE - Preparation

2. Open and cut the cables in accordance with General Requirement 6.14 14

PVC SERVICE CABLE - Preparation

3. Open and cut the cable(s) in accordance with General Requirement 6.17 17

COMPLETION OF JOINT

4. Prepare neutral/earth wires for jointing 8

5. Set cores in joint position 27

6. Connect neutral/earth wires on far side of joint including 29

equalisation bond

7. Remove temporary earth connection applied in 2 --

8. Connect neutral/earth wires of service cable(s) 2

9. Apply temporary shrouding 21

10. Make and insulate phase connections 29/30

11. Remove temporary shrouding applied in 9 --

12. Connect remaining neutral/earth wires including equalisation 29

bond and copper earth tail

13. Form neutral/earth wires into their final positions --

14. Abrade and build up oversheaths 32

ST: CA1D/6 November 2022 - 15 of 118 -

 JOINTING PROCEDURE 7.102 – Continued

Actions General Requirements

(ST: CA1C)

15. Thoroughly degrease the joint 35

16. Apply mastic waterblock to copper earth tail 33

17. Remove temporary binders --

18. Prepare and fit shell ensuring 15mm clearance 36

19. Mix and pour resin 37

ST: CA1D/6 November 2022 - 16 of 118 -

ST: CA1D/6 November 2022 - 17 of 118 -
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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.103

THREE CORE WAVECON – CONSAC MAINS CABLE

STRAIGHT JOINT

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 19 of 118 -

 JOINTING PROCEDURE 7.103

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

FROM TO STRAIGHT JOINT
95C MS4
95W 185C MS 5
240C MS 6
95C MS 5
185W 185C MS 5
240C MS 6
95C MS 6
300W 185C MS 6
240 C MS 6

Key: - 95W = 95mm² Wavecon

95C = 95mm² Consac
185W = 185mm² Wavecon
185C = 185mm² Consac
240C = 240mm² Consac
300W = 300mm² Wavecon

Note: - 240mm² Consac is only to be found in the Midlands Region of NGED.

ST: CA1D/6 November 2022 - 20 of 118 -

 JOINTING PROCEDURE 7.103

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 TA1 TA2 BCNE 3 LVCU 1700/5
MS 4 1 2 3 1 1 1
MS 5 1 1 2 3 1 1 1
MS 6 1 3 2 3 1 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
‘H’ metal
Abrasive metal
PVC tape
De-solvit 1000FD
De-solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 21 of 118 -

 JOINTING PROCEDURE 7.103

Actions General Requirements

(ST: CA1C)

Refer to Drawings LVJ 7.103.1, 7.103.2 whilst undertaking this Jointing Procedure.

1. Set up and mark cables 4

CONSAC CABLE - Preparation

2. Open and cut cable in accordance with General Requirement 6.15 15

3. Carry out moisture test 19

4. Prepare neutral/earth sheath for jointing --

5. Apply core protection 25

WAVECON CABLE - Preparation

6. Open and cut cable in accordance with General Requirement 6.14 14

7. Prepare neutral/earth wires for jointing 8

COMPLETION OF JOINT

8. Set cores in joint position 27

9. Connect neutral/earth wires to neutral/earth sheath 29

10. Remove temporary earth connections applied in 2 and 6 --

11. Apply temporary shrouding 21

12. Make and insulate phase connections 29/30

13. Remove temporary shrouding applied in 11 --

14. Form neutral/earth wires and neutral/earth sheath into their 31

final position

15. Connect copper earth tail to neutral/earth wires 29

ST: CA1D/6 November 2022 - 22 of 118 -

 JOINTING PROCEDURE 7.103 – Continued

Actions General Requirements

(ST: CA1C)

16. Abrade and build up oversheaths 32

17. Thoroughly degrease the joint 35

18. Apply mastic water blocks to copper earth tail and Consac 33
PVC oversheath termination

19. Remove all temporary binders --

20. Prepare and fit shell ensuring 15mm clearance 36

21. Mix and pour resin 37

ST: CA1D/6 November 2022 - 23 of 118 -

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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.104

THREE CORE WAVECON – CONSAC MAINS CABLE

STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 26 of 118 -

 JOINTING PROCEDURE 7.104

JOINT KIT REFERENCES

MAINS CABLE JOINT KIT REFERENCES

ST JT WITH HYBRID SERVICES
FROM TO
1 x 1ph 2 x 1ph 1 x 3ph
95C MSS 10 MSS 13 MSS 16
95W 185C MSS 11 MSS 14 MSS 17
240C MSS 12 MSS 15 MSS 18
95C MSS 11 MSS 14 MSS 17
185W 185C MSS 11 MSS 14 MSS 17
240C MSS 12 MSS 15 MSS 18
95C MSS 12 MSS 15 MSS 18
300W 185C MSS 12 MSS 15 MSS 18
240C MSS 12 MSS 15 MSS 18

Key: - 95W = 95mm² Wavecon

95C = 95mm² Consac
185W = 185mm² Wavecon
185C = 185mm² Consac
300W = 300mm² Wavecon

Note: - 240mm² Consac is only to be found in the Midlands Region of NGED.

ST: CA1D/6 November 2022 - 27 of 118 -

 JOINTING PROCEDURE 7.104

JOINT KIT MATERIALS

EARTH
SHELL RESIN CONNECTORS
KIT TAIL
REF. 6.5 LVCU 1700/5
1586 1585 1584 5 litre UST 95 UST 185 UST 300 USB 95TI USB 185TI USB 300TI TA1 TA2 BCNE 3
litre
MSS 10 1 2 3 1 1 1 1
MSS 11 1 1 2 3 1 1 1 1
MSS 12 1 3 2 3 1 1 1 1
MSS 13 1 2 3 2 1 1 1
MSS 14 1 1 2 3 2 1 1 1
MSS 15 1 3 2 3 2 1 1 1
MSS 16 1 2 3 3 1 1 1
MSS 17 1 1 2 3 3 1 1 1
MSS 18 1 3 2 3 3 1 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
‘H’ metal
Abrasive metal
PVC tape
Emery cloth
De-solvit 1000FD
De-solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual

ST: CA1D/6 November 2022 - 28 of 118 -

 JOINTING PROCEDURE 7.104

Actions General Requirements

(ST: CA1C)

Refer to Drawings LVJ 7.104.1, 7.104.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

CONSAC CABLE - Preparation

2. Open and cut the cable 15

3. Carry out moisture test 19

4. Prepare neutral/earth sheath for jointing --

5. Apply core protection 25

WAVECON CABLE - Preparation

6. Open and cut the cable 14

PVC SERVICE CABLE - Preparation

7. Open and cut the cable(s) 17

COMPLETION OF JOINT

8. Prepare neutral/earth wires for jointing 8

9. Set cores in joint position 27

10. Connect Wavecon neutral/earth wires to neutral/earth sheath 29

11. Remove temporary earth connections applied in 2 and 6 --

12. Connect neutral/earth wires of service cable(s) 29

13. Apply temporary shrouding 21

14. Make and insulate phase connections 29/30

ST: CA1D/6 November 2022 - 29 of 118 -

 JOINTING PROCEDURE 7.104 – Continued

Actions General Requirements

(ST: CA1C)

15. Remove temporary shrouding applied in 13 --

16. Form neutral/earth wires and neutral/earth sheath into their 31

final position

17. Connect copper earth tail to neutral/earth wires 29

18. Abrade and build up oversheaths 32

19. Thoroughly degrease the joint 35

20. Apply mastic water blocks to copper earth tail and Consac 33
PVC oversheath termination

21. Remove all temporary binders --

22. Prepare and fit shell ensuring 15mm clearance 36

23. Mix and pour resin 37

ST: CA1D/6 November 2022 - 30 of 118 -

ST: CA1D/6 November 2022 - 31 of 118 -
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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.105

THREE CORE WAVECON – PILC

MAINS CABLE STRAIGHT JOINT

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 33 of 118 -

 JOINTING PROCEDURE 7.105

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

FROM TO STRAIGHT JOINT
Up to 95 PILC MS 7
95W Up to 185 PILC MS 8
Up to 300 PILC MS 9
Up to 185 PILC MS 8
185W
Up to 300 PILC MS 9
300W Up to 300 PILC MS 9

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 34 of 118 -

 JOINTING PROCEDURE 7.105

JOINT KIT MATERIALS

EARTH EARTH
KIT SHELL RESIN CONNECTORS
BOND TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 LVEB 08 LVCU 1700/5
MS 7 1 2 4 1 1
MS 8 1 1 2 4 1 1
MS 9 1 3 2 4 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
PVC tape
35mm² PVC sheathed (green/yellow) copper
De-Solvit 1000FD
De-Solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 35 of 118 -

 JOINTING PROCEDURE 7.105

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.105.1, 7.105.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

PILC CABLE - Preparation

2. Open and cut the cable 16

3. Carry out moisture test 19

4. Apply core protection 25

5. Apply armour bond 22

6. Apply lead sheath bond 23

WAVECON CABLE – Preparation

7. Open and cut the cable 14

8. Prepare neutral/earth wires for jointing 8

COMPLETION OF JOINT

9. Set cores in joint position 27

10. Connect 35mm² neutral/earth bond to lead sheath bond including 23

copper earth tail

11. Connect neutral/earth wires and 35mm² neutral/earth bond to 29/30

neutral core and insulate

12. Remove temporary earth connection applied in 7 --

13. Apply temporary shrouding 21

14. Make and insulate phase connections 29/30

15. Remove temporary shrouding applied in 13 --

ST: CA1D/6 November 2022 - 36 of 118 -

 JOINTING PROCEDURE 7.105 – Continued

Actions General Requirements

(ST: CA1C)

16. Abrade and build up oversheaths 32

17. Thoroughly degrease the joint 35

18. Apply mastic water blocks to lead sheath and copper 33

earth tail

19. Remove temporary binders --

20. Prepare and fit shell ensuring 15mm clearance 36

21. Mix and pour resin 37

ST: CA1D/6 November 2022 - 37 of 118 -

ST: CA1D/6 November 2022 - 38 of 118 -
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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.106

THREE CORE WAVECON – PILC MAINS CABLE

STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 40 of 118 -

 JOINTING PROCEDURE 7.106

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

ST JT WITH HYBRID SERVICES
FROM TO
1 x 1ph 2 x 1ph 1 x 3ph
Up to 95 PILC MSS 19 MSS 22 MSS 25
95W
Up to 185 PILC MSS 20 MSS 23 MSS 26
Up to 300 PILC MSS 21 MSS 24 MSS 27
185W Up to 185 PILC MSS 20 MSS 23 MSS 26
Up to 300 PILC MSS 21 MSS 24 MSS 27
300W Up to 300 PILC MSS 21 MSS 24 MSS 27

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 41 of 118 -

 JOINTING PROCEDURE 7.106

JOINT KIT MATERIALS

EARTH EARTH
SHELL RESIN CONNECTORS BOND
KIT TAIL
REF. 6.5
1586 1585 1584 5 litre UST 95 UST 185 UST 300 USB 95TI USB 185TI USB 300TI BCNE 3 LVEB 08 LVCU 1700/5
litre
MSS 19 1 2 4 1 1 1 1
MSS 20 1 1 2 4 1 1 1 1
MSS 21 1 3 2 4 1 1 1 1
MSS 22 1 2 4 2 1 1 1
MSS 23 1 1 2 4 2 1 1 1
MSS 24 1 3 2 4 2 1 1 1
MSS 25 1 2 4 3 1 1 1
MSS 26 1 1 2 4 3 1 1 1
MSS 27 1 3 2 4 3 1 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
PVC tape
35mm² PVC sheathed (green/yellow) copper
Emery cloth
De-solvit 1000
Workhorse dry wipes
Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.
ST: CA1D/6 November 2022 - 42 of 118 -
 JOINTING PROCEDURE 7.106

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.106.1, 7.106.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

PILC CABLE - Preparation

2. Open and cut the cable 16

3. Carry out moisture test 19

4. Apply core protection 25

5. Apply armour bond 22

6. Apply lead sheath bond 23

WAVECON CABLE – Preparation

7. Open and cut the cable 14

PVC SERVICE CABLE - Preparation

8. Open and cut the cable(s) 17

COMPLETION OF JOINT

9. Prepare neutral/earth wires for jointing 8

10. Set cores in joint position 27

11. Connect 35mm² neutral/earth bond to lead sheath bond including 23

copper earth tail

12. Connect neutral/earth wires and 35mm² neutral/earth bond to neutral 29/30
core and insulate

13. Remove temporary earth connection applied in 7 --

14. Apply temporary shrouding 21

ST: CA1D/6 November 2022 - 43 of 118 -

 JOINTING PROCEDURE 7.106 – Continued

Actions General Requirements

(ST: CA1C)

15. Make and insulate phase connections 29/30

16. Remove temporary shrouding applied in 14 --

17. Abrade and build up oversheaths 32

18. Thoroughly degrease the joint 35

19. Apply mastic water blocks to lead sheath and copper earth tail 33

20. Remove temporary binders --

21. Prepare and fit shell ensuring 15mm clearance 36

22. Mix and pour resin 37

ST: CA1D/6 November 2022 - 44 of 118 -

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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.107

THREE CORE WAVECON – FOUR CORE

WAVECON MAINS CABLE STRAIGHT JOINT

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 47 of 118 -

 JOINTING PROCEDURE 7.107

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

FROM TO
STRAIGHT JOINT
3/4 CORE 3/4 CORE
95W MS 10
95W 185W MS 11
300W MS 12
185W MS 11
185W
300W MS 12
300W 300W MS 12

Note: - 70mm² and 120mm² Wavecon used in South Wales will be sized as
95mm² (70) and 185mm² (120).

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 48 of 118 -

 JOINTING PROCEDURE 7.107

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 lt 6.5 lt UST 95 UST 185 UST 300 BCNE 3 LVCU 1700/5
MS 10 1 2 4 1 1
MS 11 1 1 2 4 1 1
MS 12 1 3 2 4 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
PVC tape
De-solvit 1000FD
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 49 of 118 -

 JOINTING PROCEDURE 7.107

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.107.1, 7.107.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

2. Open and cut the cables 14

3. Prepare neutral/earth and earth wires for jointing 8

4. Set cores in joint position 27

5. Connect neutral/earth wires to neutral core and insulate 29/30

6. Remove temporary earth connection applied in 2 --

7. Connect earth wires to neutral/earth wires including copper 29

earth tail

8. Apply temporary shrouding 21

9. Make and insulate phase connections 29/30

10. Remove temporary shrouding applied in 8 --

11. Form neutral/earth wires into their final positions --

12. Abrade and build up oversheaths 32

13. Thoroughly degrease the joint 35

14. Apply mastic waterblock to copper earth tail 33

15. Remove temporary binders --

16. Prepare and fit shell ensure 15mm clearance 36

17. Mix and pour resin 37

ST: CA1D/6 November 2022 - 50 of 118 -

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ST: CA1D/6 November 2022 - 52 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.108

THREE CORE WAVECON – FOUR CORE WAVECON

MAINS CABLES STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 53 of 118 -

 JOINTING PROCEDURE 7.108

JOINT KIT REFERENCES

MAINS CABLE JOINT KIT REFERENCES

FROM TO ST JT WITH HYBRID SERVICES
3/4 CORE 3/4 CORE 1 x 1ph 2 x 1ph 1 x 3ph
95W MSS 28 MSS 31 MSS 34
95W 185W MSS 29 MSS 32 MSS 35
300W MSS 30 MSS 33 MSS 36
185W MSS 29 MSS 32 MSS 35
185W
300W MSS 30 MSS 33 MSS 36
300W 300W MSS 30 MSS 33 MSS 36

Note: - 70mm² and 120mm² Wavecon used in South Wales will be sized as
95mm² (70) and 185mm² (120).

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 54 of 118 -

 JOINTING PROCEDURE 7.108

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 USB 95TI USB185TI USB 300TI BCNE 3 LVCU 1700/5
MSS 28 1 2 4 1 2 1
MSS 29 1 1 2 4 1 2 1
MSS 30 1 3 2 4 1 2 1
MSS 31 1 2 4 2 2 1
MSS 32 1 1 2 4 2 2 1
MSS 33 1 3 2 4 2 2 1
MSS 34 1 2 4 3 2 1
MSS 35 1 1 2 4 3 2 1
MSS 36 1 3 2 4 3 2 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation Patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
PVC tape
Emery cloth
De-solvit 1000FD
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 55 of 118 -

 JOINTING PROCEDURE 7.108

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.108.1, 7.108.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

WAVECON CABLE - Preparation

2. Open and cut the cables 14

PVC SERVICE CABLE – Preparation

3. Open and cut the cable(s) 17

COMPLETION OF JOINT

4. Prepare neutral/earth and earth wires for jointing 8

5. Set cores in joint position 27

6. Connect Wavecon neutral/earth wires to neutral core and insulate 29/30

7. Remove temporary earth connection applied in 2 --

8. Connect the Wavecon earth wires to the Wavecon neutral/earth wires 29

9. Connect neutral/earth wires of service cable(s) including copper 29

earth tail

10. Apply temporary shrouding 21

11. Make and insulate phase connections 29/30

12. Remove temporary shrouding applied in 10 --

13. Form neutral/earth wires into their final positions --

14. Abrade and build up oversheaths 32

15. Thoroughly degrease the joint 35

ST: CA1D/6 November 2022 - 56 of 118 -

 JOINTING PROCEDURE 7.108 - Continued

Actions General Requirements

(ST: CA1)

16. Apply mastic waterblock to copper earth tail 33

17. Remove temporary binders --

18. Prepare and fit shell ensuring 15mm clearance 36

19. Mix and pour resin 37

ST: CA1D/6 November 2022 - 57 of 118 -

ST: CA1D/6 November 2022 - 58 of 118 -
ST: CA1D/6 November 2022 - 59 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.109

FOUR CORE WAVECON – FOUR CORE WAVECON

MAINS CABLE STRAIGHT JOINT

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 60 of 118 -

 JOINTING PROCEDURE 7.109

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

FROM TO STRAIGHT JOINT
95W MS 13
95W 185W MS 14
300W MS 15
185W MS 14
185W
300W MS 15
300W 300W MS 15

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 61 of 118 -

 JOINTING PROCEDURE 7.109

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 BCNE 3 LVCU 1700/5
MS 13 1 2 4 2 1
MS 14 1 1 2 4 2 1
MS 15 1 3 2 4 2 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patches
Black cotton tape
Sealing putty
Cable ties
Shell support
Tinned copper braid (15 x 1.5)
16 swg tinned copper wire
PVC tape
De-solvit 1000FD
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 62 of 118 -

 JOINTING PROCEDURE 7.109

Actions General Requirements

(ST: CA1C)

Refer to Drawings LVJ 7.109.1, 7.109.2 whilst under taking this Jointing Procedure

1. Set up and mark cables 4

2. Open and cut the cables 14

3. Prepare earth wires for jointing 8

4. Set cores in joint position 27

5. Connect earth wires on far side of joint including equalisation 28

bond

6. Apply temporary shrouding 21

7. Make and insulate neutral connection 29/30

8. Make and insulate phase connections 29/30

9. Remove temporary shrouding applied in 6 --

10. Connect remaining earth wires including equalisation bond 29

and copper earth tail

11. From earth/wires into their final position --

12. Abrade and build up oversheaths 32

13. Thoroughly degrease the joint 35

14. Apply mastic waterblock to copper earth tail 33

15. Remove temporary binders --

16. Prepare and fit shell ensuring 15mm clearance 36

17. Mix and pour resin 37

ST: CA1D/6 November 2022 - 63 of 118 -

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ST: CA1D/6 November 2022 - 65 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.110

FOUR CORE WAVECON – FOUR CORE WAVECON

MAINS CABLE STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 66 of 118 -

 JOINTING PROCEDURE 7.110

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

ST JT WITH SPLIT CONC
FROM TO SERVICES
1 x 1ph 2 x 1ph 1 x 3ph
95W MSS 36 MSS 39 MSS 42
95W 185W MSS 37 MSS 40 MSS 43
300W MSS 38 MSS 41 MSS 44
185W MSS 37 MSS 40 MSS 43
185W
300W MSS 38 MSS 41 MSS 44
300W 300W MSS 38 MSS 41 MSS 44

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 67 of 118 -

 JOINTING PROCEDURE 7.110

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 USB 95TI USB185TI USB 300TI BCNE 3 LVCU 1700/5
MSS 36 1 2 4 2 2 1
MSS 37 1 1 2 4 2 2 1
MSS 38 1 3 2 4 2 2 1
MSS 39 1 2 4 3 2 1
MSS 40 1 1 2 4 3 2 1
MSS 41 1 3 2 4 3 2 1
MSS 42 1 2 4 4 2 1
MSS 43 1 1 2 4 4 2 1
MSS 44 1 3 2 4 4 2 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation Patches
Black cotton tape
Sealing putty
Cable ties
Shell support
Tinned copper braid (15 x 1.5)
16 swg tinned copper wire
PVC tape
Emery cloth
Desolvit 1000FD
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 68 of 118 -

 JOINTING PROCEDURE 7.110

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.110.1, 7.110.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

WAVECON CABLE – Preparation

2. Open and cut the cables 14

PVC SERVICE CABLE – Preparation

3. Open and cut the cable(s) 17

COMPLETION OF JOINT

4. Prepare earth wires for jointing 8

5. Set cores in joint position 27

6. Connect earth wires on far side of joint including equalisation 29

bond

7. Connect earth wires of service cable 29

8. Apply temporary shrouding 21

9. Make and insulate neutral connections 29/30

10. Make and insulate phase connections 29/30

11. Remove temporary shrouding applied in 8 --

12. Make remaining earth wire connection including equalisation 29

bond and copper earth tail

13. Form earth wires into their final position --

14. Abrade and build up oversheaths 32

ST: CA1D/6 November 2022 - 69 of 118 -

 JOINTING PROCEDURE 7.110 – Continued

Actions General Requirements

(ST: CA1C)

15. Thoroughly degrease the joint 35

16. Apply mastic waterblock to copper earth tail 33

17. Remove temporary binders --

18. Prepare and fit shell ensure 15mm clearance 36

19. Mix and pour resin 37

ST: CA1D/6 November 2022 - 70 of 118 -

ST: CA1D/6 November 2022 - 71 of 118 -
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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.111

FOUR CORE WAVECON – FOUR CORE WAVECON CNE

MAINS CABLE STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 73 of 118 -

 JOINTING PROCEDURE 7.111

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

ST JT WITH HYBRID SERVICES
FROM TO
1 x 1 ph 2 x 1 ph 1 x 3 ph
95W MSS 45 MSS 48 MSS 51
95W 185W MSS 46 MSS 49 MSS 52
300W MSS 47 MSS 50 MSS 53
185W MSS 46 MSS 49 MSS 52
185W
300W MSS 47 MSS 50 MSS 53
300W 300W MSS 47 MSS 50 MSS 53

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 74 of 118 -

 JOINTING PROCEDURE 7.111

JOINT KIT MATERIALS

EARTH
KIT SHELL RESIN CONNECTORS
TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 USB 95TI USB185TI USB 300TI BCNE 3 LVCU 1700/5
MSS 45 1 2 4 2 1 1
MSS 46 1 1 2 4 2 1 1
MSS 47 1 3 2 4 2 1 1
MSS 48 1 2 4 3 1 1
MSS 49 1 1 2 4 3 1 1
MSS 50 1 3 2 4 3 1 1
MSS 51 1 2 4 4 1 1
MSS 52 1 1 2 4 4 1 1
MSS 53 1 3 2 4 4 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
PVC tape
Emery cloth
De-solvit 1000FD
De-solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 - Part I of the Jointing Manual.
ST: CA1D/6 November 2022 - 75 of 118 -
 JOINTING PROCEDURE 7.111

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.111.1, 7.111.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

WAVECON CABLE – Preparation

2. Open and cut the cables 14

PVC SERVICE CABLE – Preparation

3. Open and cut the cable 17

COMPLETION OF JOINT

4. Prepare earth wires for jointing 8

5. Set cores in joint position 27

6. Connect earth wires on far side of joint including 35mm² copper 29

neutral/earth bond and equalisation bond

7. Connect neutral/earth wires of service cable(s) 29

8. Make and insulate neutral connections including 35mm² 29/30

neutral/earth bond

8. Apply temporary shrouding 21

10. Make and insulate phase connections 29/30

11. Remove temporary shrouding applied in 8 --

12. Make remaining earth wire connection including equalisation 29

bond and copper earth tail

13. Form neutral/earth wires into their final position --

14. Abrade and build up oversheaths 32

ST: CA1D/6 November 2022 - 76 of 118 -

 JOINTING PROCEDURE 7.111 – Continued

Actions General Requirements

(ST: CA1C)

15. Thoroughly degrease the joint 35

16. Apply mastic waterblock to copper earth tail 33

17. Remove temporary binders --

18. Prepare and fit shell ensure 15mm clearance 36

19. Mix and pour resin 37

ST: CA1D/6 November 2022 - 77 of 118 -

ST: CA1D/6 November 2022 - 78 of 118 -
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 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.112

FOUR CORE WAVECON – PILC MAINS CABLE

STRAIGHT JOINT

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 80 of 118 -

 JOINTING PROCEDURE 7.112

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCES

FROM TO STRAIGHT JOINT
Up to 95 PILC MS 16
95W Up to 185 PILC MS 17
Up to 300 PILC MS 18
Up to 185 PILC MS 17
185W
Up to 300 PILC MS 18
300W Up to 300 PILC MS 18

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 81 of 118 -

 JOINTING PROCEDURE 7.112

JOINT KIT MATERIALS

EARTH EARTH
KIT SHELL RESIN CONNECTORS
BOND TAIL
REF.
1586 1585 1584 5 litre 6.5 litre UST 95 UST 185 UST 300 LVEB 08 LVCU 1700/5
MS 16 1 2 4 1 1
MS 17 1 1 2 4 1 1
MS 18 1 3 2 4 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
PVC tape
De-solvit 1000FD
De-solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 82 of 118 -

 JOINTING PROCEDURE 7.112

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.112.1, 7.112.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

PILC CABLE – Preparation

2. Open and cut the cable 16

3. Carry out moisture test 19

4. Apply core protection 25

5. Apply armour bond 22

6. Apply lead sheath bond 23

WAVECON CABLE – Preparation

7. Open and cut the cable 14

8. Prepare earth wires for jointing 8

COMPLETION OF JOINT

9. Set cores in joint position 27

10. Connect earth wires to lead sheath bond including copper earth tail 23

11. Apply temporary shrouding 21

12. Make and insulate neutral connection 29/30

13. Make and insulate phase connections 29/30

14. Remove temporary shrouding applied in 11 --

15. Abrade and build up oversheaths 32

16. Thoroughly degrease the joint 35

ST: CA1D/6 November 2022 - 83 of 118 -

 JOINTING PROCEDURE 7.112 – Continued

Actions General Requirements

(ST: CA1C)

17. Apply mastic water blocks to lead sheath and copper earth tail 33

18. Remove temporary binders --

19. Prepare and fit shell ensuring 15mm clearance 36

20. Mix and pour resin 37

ST: CA1D/6 November 2022 - 84 of 118 -

ST: CA1D/6 November 2022 - 85 of 118 -
ST: CA1D/6 November 2022 - 86 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.113

FOUR CORE WAVECON – PILC MAINS CABLE

STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 87 of 118 -

 JOINTING PROCEDURE 7.113

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCE

ST JT WITH SPLIT CONC
FROM TO SERVICES
1 x 1 ph 2 x 1 ph 1 x 3 ph
Up to 95 PILC MSS 54 MSS 57 MSS 60
95W Up to 185 PILC MSS 55 MSS 58 MSS 61
Up to 300 PILC MSS 56 MSS 59 MSS 62
Up to 185 PILC MSS 55 MSS 58 MSS 61
185W
Up to 300 PILC MSS 56 MSS 59 MSS 62
300W Up to 300 PILC MSS 56 MSS 59 MSS 62

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 88 of 118 -

 JOINTING PROCEDURE 7.113

JOINT KIT MATERIALS

EARTH EARTH
SHELL RESIN CONNECTORS
KIT BOND TAIL
REF. 6.5
1586 1585 1584 5 litre UST 95 UST 185 UST 300 USB 95TI USB 185TI USB 300TI BCNE 3 LVEB 08 LVCU 1700/5
litre
MSS 45 1 2 4 2 1 1 1
MSS 46 1 1 2 4 2 1 1 1
MSS 47 1 3 2 4 2 1 1 1
MSS 48 1 2 4 3 1 1 1
MSS 49 1 1 2 4 3 1 1 1
MSS 50 1 3 2 4 3 1 1 1
MSS 51 1 2 4 4 1 1 1
MSS 52 1 1 2 4 4 1 1 1
MSS 53 1 3 2 4 4 1 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
PVC tape
Emery cloth
De-solvit 1000FD
De-solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 89 of 118 -

 JOINTING PROCEDURE 7.113

Actions General Requirements

(ST: CA1C)

Refer to Drawings LVJ 7.113.1, 7.113.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

PILC CABLE - Preparation

2. Open and cut the cable 16

3. Carry out moisture test 19

4. Apply core protection 25

5. Apply armour bond 22

6. Apply lead sheath bond 23

WAVECON CABLE – Preparation

7. Open and cut the cable 14

PVC SERVICE CABLE – Preparation

8. Open and cut the cable(s) 17

COMPLETION OF JOINT

9. Prepare earth wires for jointing 8

10. Set cores in joint position 27

11. Connect Wavecon earth wires to lead sheath bond including 23

copper earth tail

12. Connect earth wires of service cable 29

13. Apply temporary shrouding 21

14. Make and insulate neutral connections 29/30

ST: CA1D/6 November 2022 - 90 of 118 -

 JOINTING PROCEDURE 7.113 – Continued

Actions General Requirements

(ST: CA1C)

15. Make and insulate phase connections 29/30

16. Remove temporary shrouding applied in 13 --

17. Form earth wires into their final position --

18. Abrade and build up oversheaths 32

19. Thoroughly degrease the joint 35

20. Apply mastic water blocks to lead sheath and copper earth tail 33

21. Remove temporary binders --

22. Prepare and fit shell ensuring 15mm clearance 36

23. Mix and pour resin 37

ST: CA1D/6 November 2022 - 91 of 118 -

ST: CA1D/6 November 2022 - 92 of 118 -
ST: CA1D/6 November 2022 - 93 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.114

FOUR CORE WAVECON – PILC CNE MAINS CABLE

STRAIGHT JOINT INCLUDING SERVICES

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 94 of 118 -

 JOINTING PROCEDURE 7.114

JOINT KIT REFERENCES

CABLE SIZE JOINT KIT REFERENCE

ST JT WITH HYBRID
FROM TO SERVICES
1 x 1 ph 2 x 1 ph 1 x 3 ph
Up to 95 PILC MSS 63 MSS 66 MSS 69
95W Up to 185 PILC MSS 64 MSS 67 MSS 70
Up to 300 PILC MSS 65 MSS 68 MSS 71
Up to 185 PILC MSS 64 MSS 67 MSS 70
185W
Up to 300 PILC MSS 65 MSS 68 MSS 71
300W Up to 300 PILC MSS 65 MSS 68 MSS 71

Key: - 95W = 95mm² Wavecon

185W = 185mm² Wavecon
300W = 300mm² Wavecon

ST: CA1D/6 November 2022 - 95 of 118 -

 JOINTING PROCEDURE 7.114

JOINT KIT MATERIALS

EARTH EARTH
SHELL RESIN CONNECTORS
KIT BOND TAIL
REF. 6.5
1586 1585 1584 5 litre UST 95 UST 185 UST 300 USB 95TI USB 185TI USB 300TI BCNE 3 LVEB 08 LVCU 1700/5
litre
MSS 1 2 4 2 1 1 1
MSS 1 1 2 4 2 1 1 1
MSS 1 3 2 4 2 1 1 1
MSS 1 2 4 3 1 1 1
MSS 1 1 2 4 3 1 1 1
MSS 1 3 2 4 3 1 1 1
MSS 1 2 4 4 1 1 1
MSS 1 1 2 4 4 1 1 1
MSS 1 3 2 4 4 1 1 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
Whipping thread
PVC tape
Emery cloth
De-solvit 1000FD
De-solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 96 of 118 -

 JOINTING PROCEDURE 7.114

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.114.1, 7.114.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

PILC CABLE – Preparation

2. Open and cut the cable 16

3. Carry out moisture test 19

4. Apply core protection 25

5. Apply armour bond 22

6. Apply lead sheath bond 23

WAVECON CABLE – Preparation

7. Open and cut the cable 14

PVC SERVICE CABLE – Preparation

8. Open and cut the 17

COMPLETION OF JOINT

9. Prepare earth wires for jointing 8

10. Set cores in joint position 27

11. Connect Wavecon earth wires to lead sheath bond including 23

35mm² neutral/earth bond and copper earth tail.

12. Connect neutral/earth wires of service cable(s) 29

13. Make and insulate neutral connections including 35mm² 29/30

neutral/earth bond

ST: CA1D/6 November 2022 - 97 of 118 -

 JOINTING PROCEDURE 7.114 – Continued

Actions General Requirements

(ST: CA1C)

14. Apply temporary shrouding 21

15. Make and insulate phase connections 29/30

16. Remove temporary shrouding applied in 14 --

17. Form neutral/earth wires into their final position --

18. Abrade and build up oversheaths 32

19. Thoroughly degrease the joint 35

20. Apply mastic water blocks to lead sheath and copper earth tail 33

21. Remove temporary binders --

22. Prepare and fit shell ensuring 15mm clearance 36

23. Mix and pour resin 37

ST: CA1D/6 November 2022 - 98 of 118 -

ST: CA1D/6 November 2022 - 99 of 118 -
ST: CA1D/6 November 2022 - 100 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.115

SINGLE CORE SOLIDAL AWA

MAINS CABLE STRAIGHT JOINT

DEAD WORKING ONLY

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 101 of 118 -

 JOINTING PROCEDURE 7.115

MATERIALS LIST

CABLE SIZE – 600 Solidal

Item Quantity

Shell 1581 1
Resin 16 lt (2 x 5lt + 1 x 6.5lt)
Connector MF7 1
Connector BCNE 3 2
Copper Earth Tail 1

740 Solidal

Shell 1581 1
Resin 16 lt (2 x 5lt + 1 x 6.5lt)
Connector MF8 1
Connector BCNE 3 2
Copper Earth Tail 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
Tinned copper braid (15 x 1.5)
16 swg tinned copper wire
PVC tape
Emery cloth
De-solvit 1000FD
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I
of the LV Jointing Manual.

ST: CA1D/6 November 2022 - 102 of 118 -

 JOINTING PROCEDURE 7.115

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.115.1, 7.115.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

2. Remove PVC oversheaths 6

3. Prepare aluminium armour wires for jointing. 8

Note: - The armour may be flat aluminium strip, treat as aluminium wire.

4. Abrade core insulation --

5. Make and insulate phase connection 29

6. Connect aluminium armour wires including equalisation bond 29

and copper earth tail

7. Form aluminium armour wires into their final position --

8. Abrade and build up oversheaths --

9. Thoroughly degrease the joint 35

10. Apply mastic water block to copper earth tail 33

11. Remove temporary binders --

12. Prepare and fit shell ensuring 15mm clearance 36

13. Mix and pour resin 37

ST: CA1D/6 November 2022 - 103 of 118 -

ST: CA1D/6 November 2022 - 104 of 118 -
ST: CA1D/6 November 2022 - 105 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.116

SINGLE CORE SOLIDAL AWA - PILC

MAINS CABLE STRAIGHT JOINT

DEAD WORKING ONLY

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 106 of 118 -

 JOINTING PROCEDURE 7.116

MATERIALS LIST

CABLE SIZE – 600 Solidal - .75 PILC

Item Quantity

Shell 1581 1
Resin 16 lt (2 x 5lt + 1 x 6.5lt)
Connector MF7 1
Connector BCNE 3 2
Earth Bond LVEB 08 1
Copper Earth Tail 1

ADDITIONAL ITEMS FOR EACH JOINT

Insulation patch
Black cotton tape
Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
PVC tape
35mm² PVC sheathed copper (green/yellow)
Emery cloth
De-solvit 1000FD
De-solvit 1000
Workhorse dry wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the
LV Jointing Manual.

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 JOINTING PROCEDURE 7.116

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.116.1, 7.116.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

PILC CABLE – Preparation

2. Remove serving, (armour if fitted) and bedding and thoroughly 10

clean the lead sheath

3. Remove lead sheath 13

4. Carry out moisture test 19

5. Apply core protection 25

6. Apply armour bond (where applicable) 22

7. Apply lead sheath bond 23

SOLIDAL CABLE – Preparation

8. Remove PVC oversheath 6

9. Prepare aluminium armour wires for jointing 8

Note: The armour may be flat aluminium strip treat as aluminium wire

10. Abrade core insulation --

COMPLETION OF JOINT

11. Make and insulate phase connection 29

12. Connect aluminium armour wires to 35mm² earth wire --

13. Connect 35mm² earth wire to lead sheath bond including 29

the copper earth tail

14. Form aluminium armour wires into their final position --

15. Abrade and build up oversheaths 32

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 JOINTING PROCEDURE 7.116 – Continued

Actions General Requirements

(ST: CA1C)

16. Thoroughly degrease the joint 35

17. Apply mastic water blocks to lead sheath copper earth tail 33

11. Remove temporary binder --

12. Prepare and fit shell ensuring 15mm clearance 36

13. Mix and pour resin 37

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ST: CA1D/6 November 2022 - 111 of 118 -
 ST: CA1D/6 PROCEDURES FOR MAKING LV MAINS CABLE
STRAIGHT JOINT

JOINTING PROCEDURE 7.117

FOUR CORE WAVECON – 3X SINGLE CORE PILC

MAINS CABLE STRAIGHT JOINT
(EX DC CABLES)

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA1C Section 6 Pt 1
of the LV Jointing Manual

ST: CA1D/6 November 2022 - 112 of 118 -

 JOINTING PROCEDURE 7.117

MATERIALS LIST

CABLE SIZE – 95mm 4c Waveform - .up to 0.1sq” 3x 1c PILC

Item Quantity

Shell 1585 1 (39053)

Resin 13 lt (2 x 6.5lt) (31096)
Connector UST 95 3 (30888)
Connector UBRD 95 1 (39090)
Earth Bond LVEB 08 1
Copper Earth Tail 1

ADDITIONAL ITEMS FOR EACH JOINT

Black cotton tape

Sealing putty
Cable ties
Shell support
16 swg tinned copper wire
Heatshrink tubing
PVC tape
35mm² PVC sheathed copper (green/yellow)
Emery cloth
Degreasing wipes

Note: - Individual material item numbers (E5) are to be found in Section 4 – Part I of the
LV Jointing Manual.

ST: CA1D/6 November 2022 - 113 of 118 -

 JOINTING PROCEDURE 7.117

Actions General Requirements

(ST: CA1C)

Refer to Drawing LVJ 7.117.1, 7.117.2 whilst undertaking this Jointing Procedure

1. Set up and mark cables 4

PILC CABLE – Preparation

2. Remove serving, and bedding and thoroughly clean the lead sheath 10
from all 3 single core cables

3. Fit temporary earth bonds to all three cables

4. Remove lead sheath from all 3 single core cables 13

5. Carry out moisture test 19

6. Apply core protection 25

7. Identify and mark Neutral, L1, L2 or L3 as applicable 22

8. Fit lead sheaths bond to all 3 single core cables 23

9. Shroud all exposed metalwork

WAVECON CABLE – Preparation

10. Set up and mark cables 4

11. Open and cut the cables 14

12. Prepare earth wires for jointing 8

13. Set cores in joint position 27

14. Connect earth wires on far side of joint including equalisation 28

bond

15. Apply temporary shrouding 21

ST: CA1D/6 November 2022 - 114 of 118 -

 MAKING THE JOINT

16. Make and insulate neutral connection using the USTD connector 29/30

17. Make and insulate phase connections using the UST connectors 29/30

18. Remove temporary shrouding --

19. From earth/wires into their final position --

20. Abrade and build up oversheaths 32

21. Thoroughly degrease the joint 35

22. Apply mastic waterblock to copper earth tail 33

23. Remove temporary binders --

24 Prepare and fit shell ensuring 15mm clearance 36

25. Mix and pour resin 37

ST: CA1D/6 November 2022 - 115 of 118 -

ST: CA1D/6 November 2022 - 116 of 118 -
ST: CA1D/6 November 2022 - 117 of 118 -
 APPENDIX A

SUPERSEDED DOCUMENTATION

This Standard Technique supersedes ST: CA1D/5 dated August 2020 which has now been
withdrawn.

APPENDIX B

RECORD OF COMMENT DURING CONSULTATION

No comments received.

APPENDIX C

ASSOCIATED DOCUMENTATION

ST: CA1B, ST: CA1C, ST: CA1E, ST: CA1F, ST: CA1G, ST: CA1H, ST: CA1I, ST: CA1U, ST: CA1W,
ST: CA1X, ST: CA1Y, ST: CA1Z, ST: CA1AA, ST: CA1AB, ST: CA7A, ST: CA7B, ST: CA7C, ST: CA7D.

APPENDIX D

KEY WORDS

LV Mains straight joints

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