Automatic Deadend Clamp for Overhead Power Line

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Product details

Automatic Splices and Deadends | ANSI C119.4 Full-Tension Connectors | Automatic Deadend Clamp

Yokelink Automatic Splices and Deadends provide rapid, high-reliability mechanical and electrical terminations for bare ACSR, AAC, and AAAC overhead conductors. Designed for emergency restorations and standard utility line construction, these tension-activated connectors install in seconds without specialized compression tools or crimpers.

Tapered Jaw Locking Mechanism:

The connector utilizes precision-machined internal aluminum alloy or bronze jaw wedges backed by heavy-duty stainless steel springs. When the conductor is pushed into the funnel, the spring forces the serrated jaws to grip the wire. As line tension increases, the tapered internal shell drives the jaws tighter into the conductor, delivering a mechanical grip exceeding 95% of the conductor's Rated Breaking Strength (RBS).

ANSI C119.4 Electrical and Mechanical Integrity:

Engineered strictly to ANSI C119.4 (Class A) full-tension standards, each assembly is pre-filled with high-grade electrical inhibitor grease to prevent oxidation and ensure low electrical contact resistance. Available in both inline full-tension splices and bail-type automatic deadends with stainless steel or galvanized bails.

Automatic Splices and Deadends for ACSR Conductor (4)

Key Technical Features of Automatic Splices and Deadends:

Tool-Less Installation: Push-in design slashes field assembly time and labor costs.

Full Tension Rating: Holds over 95% of conductor RBS per ANSI C119.4.

Spring-Loaded Serrated Jaws: Ensures immediate bite and long-term dynamic tension grip.

Factory Pre-Inhibited: Pre-filled with oxide inhibitor compound for long electrical service life.

Bail Configurations: Flexible and rigid stainless steel bails available for primary/secondary deadends.

Production Process of Automatic Splices and Deadends:

The production process of automatic splices and deadends starts with raw‑material inspection of aluminum alloy or steel bars, followed by cutting, hot forging or extrusion, CNC machining to form precise inner and outer dimensions, deburring and surface finishing, hot‑dip galvanizing or other anti‑corrosion surface treatment, dimensional checking and visual inspection, assembly of accessory parts, performance tests including slip‑load test, tensile strength test and electrical conductivity test, final quality re‑inspection and marking, and finished‑product packaging for shipment.

Automatic Splices and Deadends production

Yokelink Quality Control and Testing Equipments:

We don't just reference standards; we also verify them in practice: each batch of products undergoes destructive tensile testing in our internal laboratory to ensure load performance exceeds the minimum requirements of IEEE C135.2 or CSA C83 specification; we use optical comparators to ensure the geometric accuracy of chamfered tips and rolled threads, enabling convenient on-site installation; at the same time, we conduct comprehensive testing on Rockwell hardness, coating thickness, and other parameters, and each shipment is accompanied by the original manufacturer's material specifications (MTRs) and quality inspection reports, with all data traceable back to the raw material furnace number.

Automatic Splices and Deadends Quality Inspec

Application of Automatic Splices and Deadends：

Automatic splices and deadends are widely applied in overhead transmission and distribution power‑line projects. They are mainly used for connecting, splicing and fixing aluminum conductors, steel‑reinforced aluminum conductors and overhead cables. These fittings can securely grip the conductor ends, transfer mechanical tension and conduct electric current. They are suitable for new power‑line construction, line renovation and maintenance work in power grids, and can operate stably under various outdoor weather conditions.

Automatic Splices and Deadends application

Automatic Splices and Deadends Technical Specification Sheet：

Technical Parameter	Value
Material	Aluminum Alloy
Applicable Conductor	AAC / AAAC / ACSR
Installation	Automatic Wedge Gripping
Application Voltage	Medium & High Voltage Overhead Lines
Feature	High Tensile Strength & Reliable Connection

Automatic Splices and Deadends technical reference

Yokelink Product Quality Inspection Report

We provide comprehensive inspection services for machine bolts, including SGS test bolts and formal Production Part Inspect Report (PPIR). The SGS tests verify the bolts’ compliance with international standards like ASTM A307 and IEEE C135.80, covering mechanical properties and corrosion resistance. The PPIR details all inspection items, ensuring each machine bolt meets dimensional, performance and quality requirements, providing reliable quality assurance for overhead line and industrial applications.

Technical Specifications of Automatic Splices and Deadends：

Part NO.	Conductor Range		Decimal Range	Color Code	Approximate Dimensions (in.)
Part NO.	AAAC	AAC	Decimal Range	Color Code	A	B	C
H10-42ZB	#4,#2	#4,#2	.232-.332	4 – Orange, 2 – Red	12-13/16	7-13/16	5-1/16
H10-1020ZB	1/0, 2/0	1/0, 2/0	.368–.461	1/0 – Yellow, 2/0 – Gray	14-1/2	9	4-15/16
H10-3040ZB	3/0, 4/0	3/0, 4/0	.461–.575	3/0 – Black, 4/0 – Pink	20-3/4	11-3/4	8-1/2
H10-266336ZB	266, 336	266, 336	.586–.684	Green	20-3/4	11-3/4	8-1/2
H10-397477ZB	397, 477	397, 477	.720–.858	Blue	20-3/4	11-3/4	8-1/2

Frequently Asked Questions (FAQ)

Q1: How does an Automatic Splice achieve full mechanical holding strength without crimping?

A: The connector operates on a mechanical wedge principle. Inside the tapered aluminum shell, spring-loaded serrated jaws bite into the conductor as soon as it is inserted. Once tension is applied to the line, the pulling force draws the jaws deeper into the internal taper, creating a radial clamping pressure that increases proportionally with line load, exceeding 95% of the conductor's rated breaking strength.

Q2: What is the significance of the ANSI C119.4 Class A rating?

A: ANSI C119.4 is the standard for overhead electrical connectors. A Class A rating verifies both full-tension mechanical holding capability and low electrical failures. It guarantees that the connector runs cooler than the conductor under full electrical load, eliminating hot spots and premature line.

Q3: Can an automatic splice or deadend be removed and reused?

A: No. Automatic splices and deadends are designed as single-use, permanent connections. During installation and tensioning, the serrated jaws bite directly into the conductor strands, and the internal components deform slightly under high load. Reusing a removed unit risks jaw slippage and catastrophic mechanical failure.

Q4: What preparation is required on the conductor before insertion?

A: The conductor must be cut cleanly and squarely, free of burrs or flared strands. The outer aluminum strands must be thoroughly wire-brushed to remove surface oxides. Insertion depth must follow the marked strip-gauge on the connector shell to ensure the conductor passes completely through the jaws and hits the center stop.

Q5: What is the difference between an Automatic Splice and an Automatic Deadend?

A: An Automatic Splice is an inline sleeve with two open ends, used to join two separate pieces of conductor under full line tension. An Automatic Deadend has one jaw chamber for conductor entry and an attached flexible or rigid bail on the opposite end, designed to hook onto a spool insulator, clevis, or anchor bracket at termination poles.

Value-Added Supply Chain Services

1. Blanket Order & Free Warehousing Yokelink VALUE ADDED SUPPLY CHAIN (3)

Yokelink offers Blanket Order programs: Place an annual order to lock prices, we manufacture your total volume and hold stock in our facility free of charge. Split Shipments: Schedule partial shipments (e.g., monthly or quarterly) based on your project progress. You get the benefits of just-in-time delivery without the risk of shortages.

2. DDP Shipping (USA Duties Included)Landed Cost Certainty:

We handle the complex logistics. Our DDP (Delivered Duty Paid) service covers sea freight, US Customs clearance, and Section 301 tariffs. The price we quote is the final price delivered to your door / Warehouse.

3. Free Sample Program

We offer Free Samples to qualified commercial buyers for testing and approval.

4. Empowering Latin America's Utility Infrastructure

We have established a robust supply chain and a proven track record across Brazil, Mexico, El Salvador, Honduras, Nicaragua, Ecuador, Bolivia, Chile, Peru, Uruguay, Guatemala, Argentina, and the Dominican Republic. From standard distribution lines to complex 34.5 kV double-circuit transmission projects, leading utility contractors trust Yokelink for uncompromising quality and on-time delivery.