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Topband: Terminating old Phillystran with Spelter sockets

To: towertalk@contesting.com, topband@contesting.com
Subject: Topband: Terminating old Phillystran with Spelter sockets
From: Grant Saviers <grants2@pacbell.net>
Date: Thu, 19 Jun 2014 11:43:14 -0700
List-post: <topband@contesting.com">mailto:topband@contesting.com>
I recently concluded testing of wire rope clamps (clips) on "old" parallel Phillystran (PS). The old PS does not work with the current PS guy grip type of termination. These tests showed that clamps as a termination system has risks that are not acceptable to me.

Since the factory no longer supplies the socket type termination made for old PS, I undertook tension tests using off the shelf Crosby Spelter sockets made for steel wire rope. These sockets develop full breaking strength of the cable and the steel strands are held with epoxy in the tapered socket. The PS guy being tested is the 5/8" od 27,000# breaking strength and will be preloaded to a maximum of 600# and has a requirement of 6700# breaking strength for the tower in permitting.

Using West Marine series 105 epoxy, I was able to sustain 12,000# tension in the test sample with acceptable creep over a period of 5 days. This result is far superior to what I could obtain with cable clamps and a dubious clamp tightening procedure. With a Spelter socket there is no damage to the PS sheath and the termination completely encapsulates the Kevlar fiber from UV and weather.

There may be improvements to the system with alternative epoxies, which I may consider for further testing. However, at this point I have a termination system proven to my satisfaction for the tower guys I need using the 1800' of old PS I have.

I will gladly send a pdf copy of my new Spelter socket or prior cable clamp test reports to topbanders or towertalkians that request it off-line.

73,

Grant KZ1W
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