ASTM F1835-97(2023)
(Guide)Standard Guide for Cable Splicing Installations
Standard Guide for Cable Splicing Installations
SIGNIFICANCE AND USE
4.1 Splicing of cables in the shipbuilding industry, both in Navy and commercial undertakings, has been concentrated in repair, conversion, or overhaul programs. However, many commercial industries, including aerospace and nuclear power, have standards defining cable splicing methods and materials that establish the quality of the splice to prevent loss of power or signal, ensure circuit continuity, and avoid potential catastrophic failures. This guide presents cable splicing techniques and hardware for application to commercial and Navy shipbuilding to support the concept of modular ship construction.
4.2 This guide resulted from a study that evaluated the various methods of cable splicing, current technologies, prior studies and recommendations, performance testing, and the expertise of manufacturers and shipbuilders in actual cabling splicing techniques and procedures.
4.3 The use of this guide by a shipbuilder will establish cabling splicing systems that are: simple and safe to install; waterproof; corrosion- and impact-resistant; industry accepted with multiple suppliers available; low-cost methods; and suitable for marine, Navy, and IEC cables.
SCOPE
1.1 This guide provides direction and recommends cable splicing materials and methods that would satisfy the requirements of extensive cable splicing in modular ship construction and offers sufficient information and data to assist the shipbuilder in evaluating this option of cable splicing for future ship construction.
1.2 This guide deals with cable splicing at a generic level and details a method that will satisfy the vast majority of cable splicing applications.
1.3 This guide covers acceptable methods of cable splicing used in shipboard cable systems and provides information on current applicable technologies and additional information that the shipbuilder may use in decision making for the cost effectiveness of splicing in electrical cable installations.
1.4 This guide is limited to applications of 2000 V or less, but most of the materials and methods discussed are adaptable to higher voltages, such as 5-kV systems. The cables of this guide relate to all marine cables, domestic and foreign, commercial or U.S. Navy.
1.5 The values stated in SI units are to be regarded as standard. The values given in parentheses are mathematical conversions to inch-pound units that are provided for information only and are not considered standard.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.
1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
General Information
Relations
Standards Content (Sample)
This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: F1835 − 97 (Reapproved 2023) An American National Standard
Standard Guide for
Cable Splicing Installations
This standard is issued under the fixed designation F1835; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 2. Referenced Documents
1.1 This guide provides direction and recommends cable 2.1 ASTM Standards:
splicing materials and methods that would satisfy the require- B8 Specification for Concentric-Lay-Stranded Copper
Conductors, Hard, Medium-Hard, or Soft
ments of extensive cable splicing in modular ship construction
and offers sufficient information and data to assist the ship- D2671 Test Methods for Heat-Shrinkable Tubing for Elec-
trical Use
builder in evaluating this option of cable splicing for future
ship construction. 2.2 IEEE Standards:
IEEE 45 Recommended Practice for Electrical Installations
1.2 This guide deals with cable splicing at a generic level
on Shipboard
and details a method that will satisfy the vast majority of cable
2.3 UL Standards:
splicing applications.
UL STD 224 Extruded Insulating Tubing
1.3 This guide covers acceptable methods of cable splicing
UL STD 486A Wire Connectors and Soldering Lugs for Use
used in shipboard cable systems and provides information on
with Copper Conductors
current applicable technologies and additional information that
2.4 IEC Standards:
the shipbuilder may use in decision making for the cost
IEC 228 Conductors of Insulated Cables
effectiveness of splicing in electrical cable installations.
2.5 Federal Regulations:
Title 46 Code of Federal Regulations (CFR), Shipping
1.4 This guide is limited to applications of 2000 V or less,
2.6 Military Specifications:
but most of the materials and methods discussed are adaptable
MIL-T-16366 Terminals, Electric Lug and Conductor
to higher voltages, such as 5-kV systems. The cables of this
Splices, Crimp-Style
guide relate to all marine cables, domestic and foreign,
MIL-T-7928 Terminals, Lug, Splices, Conductors, Crimp-
commercial or U.S. Navy.
Style, Copper
1.5 The values stated in SI units are to be regarded as
standard. The values given in parentheses are mathematical
3. Terminology
conversions to inch-pound units that are provided for informa-
3.1 Definitions of Terms Specific to This Standard:
tion only and are not considered standard.
3.1.1 adhesive, n—a wide range of materials used exten-
1.6 This standard does not purport to address all of the
sively for bonding and sealing; coating added to the inner wall
safety concerns, if any, associated with its use. It is the
of heat-shrinkable tubing to seal the enclosed area against
responsibility of the user of this standard to establish appro-
moisture. Adhesive is for pressure retention and load-bearing
priate safety, health, and environmental practices and deter-
applications (see also sealant).
mine the applicability of regulatory limitations prior to use.
3.1.2 barrel, n—the portion of a terminal that is crimped;
1.7 This international standard was developed in accor-
designed to receive the conductor, it is called the wire barrel.
dance with internationally recognized principles on standard-
ization established in the Decision on Principles for the
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Development of International Standards, Guides and Recom-
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
mendations issued by the World Trade Organization Technical
Standards volume information, refer to the standard’s Document Summary page on
Barriers to Trade (TBT) Committee.
the ASTM website.
Available from Institute of Electrical and Electronics Engineers, Inc. (IEEE),
445 Hoes Ln., Piscataway, NJ 08854-4141, http://www.ieee.org.
Available from Underwriters Laboratories (UL), 2600 N.W. Lake Rd., Camas,
This guide is under the jurisdiction of ASTM Committee F25 on Ships and WA 98607-8542, http://www.ul.com.
Marine Technology and is the direct responsibility of Subcommittee F25.10 on Available from International Electrotechnical Commission (IEC), 3, rue de
Electrical. Varembé, 1st floor, P.O. Box 131, CH-1211, Geneva 20, Switzerland, https://
Current edition approved Dec. 1, 2023. Published December 2023. Originally www.iec.ch.
approved in 1997. Last previous edition approved in 2018 as F1835 – 97 (2018). Available from DLA Document Services, Building 4/D, 700 Robbins Ave.,
DOI: 10.1520/F1835-97R23. Philadelphia, PA 19111-5094, http://quicksearch.dla.mil.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F1835 − 97 (2023)
3.1.3 butt connector, n—a connector in which two conduc- expertise of manufacturers and shipbuilders in actual cabling
tors come together end to end with their axes in line, but do not splicing techniques and procedures.
overlap.
4.3 The use of this guide by a shipbuilder will establish
3.1.4 butt splice, n—device for joining conductors by butt- cabling splicing systems that are: simple and safe to install;
ing them end to end. waterproof; corrosion- and impact-resistant; industry accepted
with multiple suppliers available; low-cost methods; and suit-
3.1.5 circumferential crimp, n—final configuration of a
able for marine, Navy, and IEC cables.
barrel made when crimping dies completely surround the barrel
and form symmetrical indentations.
5. General Requirements for Cable Splicing
3.1.6 compression connector, n—connector crimped by an
5.1 Cable splicing requires that cable joints be insulated and
externally applied force; the conductor is also crimped by such
sealed with an insulation equal in electrical and mechanical
force inside the tube-like connector body.
properties to the original cable. Cable splicing shall consist of
3.1.7 cold-shrink tubing, n—tubular rubber sleeves that are
a conductor connector, replacement of conductor insulation,
factory expanded and assembled onto a removable core. No
replacement of the overall cable jacket, and where applicable,
heat is used in installation. Also known as prestretched tubing
reestablishment of shielding in shielded cables and electric
(PST).
continuity in the armor of armored cables.
3.1.8 crimp connectors, n—tubular copper connectors made
5.2 Nonsplice Applications—Unacceptable areas for cable
to match various wire sizes and fastened to the conductor ends
splices are established by regulations and concern the restric-
by means of a crimping tool.
tion of being unable to splice cables in defined hazardous areas.
3.1.9 crimping die, n—portion of the crimping tool that
Hazardous areas are locations in which fire or explosion
shapes the crimp.
hazards may exist as a result of flammable gases or vapors,
flammable liquids, combustible dust, or ignitable fibers or
3.1.10 crimping tool, n—a mechanical device, which is used
flyings.
to fasten electrical connectors to cable conductors by forcefully
compressing the connector onto the conductor. This tool may
6. Cable Splicing
have interchangeable dies or “jaws” to fit various size connec-
tors.
6.1 Cable splicing as presented in this guide uses a system
of compression-crimp, tubular-metal connectors for butt con-
3.1.11 heat-shrink tubing, n—electrical insulation tubing of
nection of cable conductors and insulating systems of shrink-
a polyolefin material, which shrink in diameter from an
able tubing to reinsulate the individual conductors and replace
expanded size to a predetermined size by the application of
the overall cable jacket.
heat. It is available in various diameter sizes.
6.2 Crimp Connectors—For splice connection of
3.1.12 primary insulation, n—the layer of material that is
conductors, compression-crimped connectors shall be used for
designed to do the electrical insulating, usually the first layer of
joining an electrical conductor (wire) to another conductor. The
material applied over the conductor.
joint requires proper compression to achieve good electrical
3.1.13 sealant, n—inner-wall coating optional to shrinkable
performance while not overcompressing and mechanically
tubing to prevent ingress of moisture to the enclosed area (see
damaging the conductor. Compression connections are accom-
also adhesive).
plished by applying a controlled force on a barrel sleeve to the
3.1.14 splice, n—a joint connecting conductors with good
conductor with special tools and precision dies.
mechanical strength and good conductivity.
6.3 Conductor Reinsulation—Thin-wall shrinkable tubing
3.1.15 tensile, n—amount of axial load required to break or
shall be used to reinsulate the conductor and the installed
pull wire from the crimped barrel of a terminal or splice.
connector. The insulation tubing, when shrunk or recovered,
shall be equal in electrical and mechanical properties to the
4. Significance and Use
original conductor insulation. Tubing used for conductor rein-
sulation does not require an interior adhesive sealant coating.
4.1 Splicing of cables in the shipbuilding industry, both in
Navy and commercial undertakings, has been concentrated in
6.4 Cable Jacket Reinsulation—Shrinkable tubing shall be
repair, conversion, or overhaul programs. However, many
used to envelop the overall splice. To satisfy more abusive
commercial industries, including aerospace and nuclear power,
conditions that cable jackets are exposed to, a flame-retardant,
have standards defining cable splicing methods and materials
thick-wall tubing construction with factory applied sealant
that establish the quality of the splice to prevent loss of power
shall be used.
or signal, ensure circuit continuity, and avoid potential cata-
strophic failures. This guide presents cable splicing techniques
7. Cable Preparation
and hardware for application to commercial and Navy ship-
7.1 Cables to be spliced shall be prepared to the dimensions
building to support the concept of modular ship construction.
specified in Fig. 1 and Fig. 2. Fig. 1 provides cable preparation
4.2 This guide resulted from a study that evaluated the for power cables from single to four conductor sizes. Dimen-
various methods of cable splicing, current technologies, prior sions for multiple conductor cables (conductor size of No. 14
studies and recommendations, performance testing, and the or less) are shown in Fig. 2.
F1835 − 97 (2023)
FIG. 1 Splice Dimensions for Power Cables
F1835 − 97 (2023)
FIG. 2 Splice Dimensions for Control-Multiple Conductor Cables
7.2 Care must be exercised when preparing the cable ends 7.2.1 Insulation cutting tools that limit depth of cut should
so that conductor insulation is not cut when removing the
be used to prepare cable ends so that underlying insulation is
overall cable jacket, shield, or cable armor, where applicable.
not cut. Similar care is required when removing the individual
Similar care is required when removing the individual shield or
conductor insulation to protect the conductor copper strands
insulation protecting the conductor to prevent cuts or nicks on
from nicks and cuts.
the individual conductor strands.
F1835 − 97 (2023)
7.2.2 Cable preparation shall result in stripping the indi- 8.1.1.6 Connector shall be color-coded in accordance with
vidual conductors so that the bare copper is long enough to Table 1 or Table 2.
reach the full depth of the butt connector plus 3.2 mm ( ⁄8 in.).
8.1.2 Conductor Reinsulating Material—To reinsulate the
conductor and the installed connector, heat-shrink tubing shall
7.3 Match the geometrical arrangement between cables to
be used (see Table 3).
be spliced using conductor color code identification to elimi-
8.1.2.1 When recovered or shrink, the tubing used shall be
nate crossovers or mismatch when splicing.
equal to or greater than the thickness of the original conductor
7.4 Cable ends shall be in or near their final position before
insulation.
being spliced.
8.1.2.2 Shrink tubing used for conductor reinsulation shall
8. Materials and Tools be heat-shrink tubing. The tubing shall be thin-wall cross-
linked polyolefin tubing, flame-retardant (FR-1) construction
8.1 Cable Splicing Materials—The following sections pro-
in accordance with UL STD 224 requirements. Performance
vide an overview of the various splice materials. In addition,
requirements shall include:
specific recommendations and suggested guidelines are offered
Shrink ratio 2:1
that would enhance the cable splicing process.
Operating temperature range –55 °C to +135 °C
8.1.1 Crimp-Type Connectors—Splice connectors shall be
Minimum shrinkage temperature +121 °C
compression-type, butt connectors conforming to the require-
Longitudinal shrinkage ±5 %
Electrical rating 600-V continuous operation
ments of UL STD 486A and shall be satisfactory to Section
Dielectric strength in accordance with 19.7 kV/mm (500 V/mil) min
20.11 of IEEE 45.
Test Methods D2671
8.1.1.1 Connector shall be seamless, tin-plated copper.
8.1.2.3 Shrink tubing to cover the connection of individual
8.1.1.2 Butt connector shall have positive center wire stops
conductors does not require an interior coating of adhesive
for proper depth of conductor insertion.
(mastic) sealant.
8.1.1.3 Connectors shall be marked with wire size for easy
8.1.3 Cable Jacket Replacement Materials—Several meth-
identification.
ods and a variety of materials are available that will provide the
8.1.1.4 Connector shall have inspection holes to allow
mechanical protection, moisture-sealing properties, and elec-
visual inspection for proper wire insertion.
trical performance characteristics needed in a cable splice. For
8.1.1.5 Butt connector for wire sizes No. 10 (AWG) or
a splice reliability and ease of installation replacement of cable
larger shall be the “long barrel” type to permit multiple crimps
jacket and to envelop the splice area, however, either the
on each side of the connector for greater tensile strength. The
heat-shrink or the cold-shrink (prestretched) type shall be used.
conductor ends shall be fully inserted to the “stop” at the center
of the connector. For smaller conductor sizes (No. 10 AWG or 8.1.3.1 The tubing used, when recovered or shrunk, shall be
less), a single crimp should be spaced half way between the equal to or greater than the thickness of the original conductor
end of the connecto
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