Network Standard

Document No. Title:

NS125 Construction of low voltage overhead mains

Approved Date 9/05/2024 Revision 5

Lifecycle Stage Plan; Design; Construct Internal Use ☒ External Use ☒
Technical Approver Authorised By

Name Matthew Cupples Name Murray Chandler

Designation Senior Engineer Designation Head of Network
Strategy and Future
Grid

Revision

No Date Description Technical Approver Authorised By

0 28/05/2015 Conversion to new template. NA. Manager Engineering
Information and Services
1 24/06/2015 Clause on selection of conductors, Table on Matthew Cupples Chief Engineer
bare conductors, LV ABC identification and
connection including fittings, prevention of
conductor clashing, rail crossing, Waterway
crossing
2 1/12/2015 Revision date changed Matthew Cupples Head of AEP&S
3 2/10/2020 Full review of the NS Duminda Thenuwara Head of AEP&S
4 9/09/2022 LVABC is now mandatory when replacing Matthew Cupples Mark Ragusa
greater than 1 span of bare wire, and conversion
to new NS template.
5 9/05/2024 Amendments to crossarm material clause Matthew Cupples Murray Chandler

DISCLAIMER
This document is bound to the conditions set out in NS002 Network Standards Disclaimer.
Ausgrid maintains a copy of this and other Network Standards together with updates and amendments online at www.ausgrid.com.au.
This document is considered uncontrolled once printed.

UNCONTROLLED IF PRINTED
Table of Contents

Scope ................................................................................................................................................................. 3
Reference Documents...................................................................................................................................... 3
Ausgrid Documents ......................................................................................................................................... 3
Other Standards and Documents ................................................................................................................... 3
Acts and Regulations ....................................................................................................................................... 3
1 Conductor Selection and Details .......................................................................................................... 4
2 Crossarm Selection ............................................................................................................................... 5
3 Streetlighting Circuits ............................................................................................................................ 5
4 Clearance Criteria................................................................................................................................... 5
5 Construction ........................................................................................................................................... 5

List of Annexures
Annexure A Standard construction drawings .................................................................................................. A-1
Annexure B Connections to twin-and-twist ..................................................................................................... B-3
Annexure C Approved tools ............................................................................................................................C-4

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Scope
This Network Standard and the associated standard construction drawings set out Ausgrid’s requirements
for new construction, replacement, and refurbishment of existing low voltage overhead mains.
This standard does not apply to high voltage overhead mains, which are detailed in NS126 Construction of
High Voltage Overhead Mains and NS135 Construction of Overhead 33kV, 66kV and 132kV Overhead
Mains.
This standard does not apply to low voltage overhead services, which are detailed in NS124 Specification for
Overhead Connections up to 400 Amps.
Ausgrid’s requirements for overhead line design are detailed in NS220 Overhead Design Manual.

Reference Documents
All work covered in this document shall conform to all relevant Legislation, Standards, Codes of Practice and
Network Standards.

Ausgrid Documents
NS001 Glossary of Terms
NS109 Design Standards for Overhead Supply Developments and Distribution Centres
NS119 Public Lighting Design and Construction
NS124 Specification for Overhead Service Connections up to 400 Amps
NS179 Vegetation Management
NS220 Overhead Design Manual

Other Standards and Documents

AS/NZS 7000 – Overhead Line Design – Detailed procedures
ENA Doc 001-2019 National Electricity Network Safety Code
Service and Installation Rules of NSW
Relevant Industry and SafeWork NSW Guides and Codes of Practice

Acts and Regulations

Electricity Safety Act 1945
Electricity Supply General) Regulation 2014 (NSW)
Electricity Supply (Safety and Network Management) Regulation 2014
Electricity Supply (Safety Plans) Regulation 1997
Work Health and Safety Act 2011 and Regulation 2017

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Clause Standard Requirements

1 Conductor Selection and Details

1.1 Two types of low voltage overhead mains are used on Ausgrid’s network:
• Bare conductor; and
• Aerial Bundled Cable (LV ABC)
1.2 LV ABC shall be used for all:
• new overhead mains,
• extensions of existing overhead mains,
• replacement of existing overhead mains greater than one span; and
• infill of more than one span of street lighting mains where continuity of the circuit must be
maintained.
1.3 Low Voltage Aerial Bundled Cable (LV ABC)
1.3.1 Where LV ABC is used, cables shall be selected from those listed in Table 1. For current ratings
and other electrical properties of the conductors refer to NS220.

Table 1 - LV ABC conductors

Description Stockcode

2x25 mm² LV ABC H109298

2x95 mm² LV ABC H78279

4x25 mm² LV ABC H109280

4x95 mm² LV ABC 67959

4x150 mm² LV ABC 148080

1.4 Bare conductors

1.4.1 Where bare conductor is used, conductors shall be selected from those listed in Table 2.1

Table 2 - Bare conductors

Description Stockcode

7/4.50 AAC Mercury H13433

19/3.75 AAC Pluto H13459

6/1/3.00 ACSR/GZ Apple H13467

6/4.75+7/1.60 ACSR/GZ Cherry H13483

3/4/2.50 ACSR/GZ Raisin H13734

1Many other conductors exist on the network, and they may continue to be used for maintenance (such as replacement after a failure)
or minor work (such as a pole relocation where a short extension to the mains is required). For current ratings and other electrical
properties refer to NS220

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2 Crossarm Selection
2.1 Crossarm material
2.1.1 Composite crossarms shall be used where they are included as an option on the standard
construction drawing.
2.1.2 Some standard construction drawings do not include a composite crossarm in the length and
drilling pattern required. In these cases, a timber crossarm shall be used as shown on the
standard construction drawing.
2.2 Crossarm length
2.2.1 Crossarm lengths shall be chosen to meet the design requirements for midspan separation in
accordance with NS220 and AS/NZS 7000 – Overhead Line Design. The range of suitable
crossarms is shown on each standard construction drawing.
2.2.2 The minimum crossarm length that shall be used for new low voltage mains is 2.1m as per the
standard construction drawings.
2.3 Maintenance
2.3.1 Where an existing low voltage mains crossarm is replaced (due to maintenance or a pole
replacement), the new crossarm shall be at least 2.1m long in order to maximise conductor
separation.
2.3.2 An existing 1.8m crossarm may be replaced with a new crossarm of the same length if it prevents
encroachments, such as a breach of conductor clearances to buildings or assets crossing
property boundaries under static conditions.
2.3.3 If a 1.8m crossarm would result in encroachments, the mains shall be converted to LV ABC to
resolve all encroachments.

3 Streetlighting Circuits
3.1 As per NS119, all new street lighting luminaires shall be connected to the low voltage mains and
not to dedicated, switched street lighting circuits. Where continuity of an existing dedicated street
lighting circuit is required during maintenance, LV ABC may be installed between existing
sections.
3.2 During maintenance, legacy street lighting circuits (such as those using dedicated crossarms,
swan-neck insulators, or 5-wire arrangements) shall not be converted to any other legacy
arrangements. They shall be maintained as they were, converted to LV ABC for infill between
existing sections of dedicated street lighting circuits, or removed and the luminaires connected to
low voltage mains.
3.3 Where street lighting crossarms are replaced during maintenance, the same length crossarm may
be used.
3.4 Where the low voltage mains are converted to LV ABC, any dedicated street lighting circuit that
exists in the same span shall also be converted to LV ABC.

4 Clearance Criteria
4.1 All clearances shall be met at the time the network is built or altered in any way, including
construction of new overhead mains, pole replacements or relocations, conductor replacements,
and crossarm replacements. This includes the clearances to ground and structures in NS220 and
the vegetation clearances in NS179.

5 Construction
5.1 Overhead mains shall be constructed in accordance with the standard construction drawings
listed in Annexure A.
5.2 LV ABC installation by pulling-in
5.2.1 For LV ABC, the pulling tension shall not exceed 4 kN.

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5.3 Phasing/arrangement of conductors
5.3.1 LV ABC cables are to be arranged so that A phase is the conductor that has only one identifying
rib, B phase is the conductor that has two ribs, C phase is the conductor that has three ribs and
the Neutral is the multi-ribbed conductor.
5.3.2 Where four-core cable is used on a single-phase network, unused cores shall be capped and
remain de-energised.
5.3.3 Where open wire construction is used, it shall be arranged so that the neutral conductor is located
nearest to the property line.
5.3.4 Low voltage transposition structures shall not be created with bare mains. Where it is necessary
to transpose phases, at least one span shall be converted to LV ABC.
5.3.5 Where there are open points at a structure (including normally-open links, structures with open
bonds, and structures with spans terminating on each side of the pole) conductors in the same
position shall be of the same phase whether they can be electrically connected or not.
5.3.6 LV ABC Identification
Where the ends of the LV ABC are accessible, the end caps may be removed, and the probes
applied directly to the conductor. Where testing is required in the middle of a run of LV ABC, an
insulated test point (piercing G-clamp, stockcode H78444) shall be used and is the only method
permitted for gaining access to the conductor for testing.
5.4 Installation of spreaders in Bushfire Prone Areas
5.4.1 In bushfire prone areas, low voltage spreaders shall be installed on all spans of bare wires over
30m long as follows:
• Two-wire lines (horizontal construction) - where the shorter cross arm length in the span is
less than 1.8m - one spreader (mid-span) for span length between 30m and 45m, two
spreaders (spaced equally) for span lengths exceeding 45m.
• Two-wire lines (vertical construction) - where the vertical separation in the span is less than
1.5m - one spreader (mid-span) for span length between 30m and 45m, two spreaders
(spaced equally) for span lengths exceeding 45m.
• Three and four-wire lines (horizontal construction) and all vertical construction – as indicated
in the Table 3.

Table 3 - Low voltage spreader requirements for 3 and 4 wire lines.

(Horizontal Construction) (Vertical Construction) One spreader Two spreaders

Shorter cross arm length in Vertical separation (mid-span) (spaced equally)
span between outer conductors

1.8 ma 1.5 m Span 30-45 m Span > 45 m

2.1 m 1.75 m Span 45-90 m Span > 90 m

2.4 m or greater 2.0 m or greater Span 55-110 m Span > 110 m

a 1.8m crossarms exist on the network however shall not to be used for new constructions as per Clause 2.3.

5.5 Multiple LV circuits

5.5.1 Conductors of the same material installed in the same span shall have the same sag.
5.5.2 For the location of each attachment point on the structure, refer to the standard construction
drawings. Refer to NS220 for inter-circuit spacing.
5.6 Mid-span joints
5.6.1 New mains shall not use mid-span joints. Cables and conductors shall be joined at the non-
tension bond position of a pole top at erection.

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5.6.2 Mid-span joints are permitted for pole relocations and repairs to mains.
5.6.3 Where used on LV ABC, mid-span joints shall be staggered to allow the cores to fit closely
together.
5.6.4 To facilitate piecing-in of a conductor, up to two mid-span joints per phase are permitted in a
span. If there are existing joints in the span, a section of conductor and the associated joints may
need to be removed to comply with this requirement.
5.6.5 There shall be no full-tension joints on twin-and-twist conductors. For alternative installation
options see Annexure B.
5.7 Bonds
5.7.1 Bonds (also known as taps) are short pieces of conductor between two sections of conductor
under tension. They may be a continuation of the mains or a separate piece of conductor.
5.7.2 All bonds shall be insulated or covered. The rating of the bond shall equal or exceed the rating of
the highest rated mains to which it is connected.
5.7.3 Where the bond is not insulated, the conduits shown in Table 4 shall be used to cover the bond.

Table 4 – UV stable, grey plastic flexible conduit

Description Stockcode

13mm inside diameter 176565

16mm inside diameter 176564

20mm inside diameter 176566

5.7.4 Connections for bonds shall only be installed on conductors that are not under tension. Where this
is not possible and a connection to conductors under tension is required (such as a tee-off), the
conductors and bonds shall be the same material.
5.7.5 Bimetallic PG clamps shall not be used on mains under tension.
5.7.6 Vertical bonding for LV ABC
5.7.6.1 Vertical bonding must be installed with parallel LV ABC conductors of the same circuit at intervals
not exceeding 100 metres and at:
• substations,
• links,
• terminations, and
• tee connections.
5.7.7 Vertical bonding for bare conductors
5.7.7.1 Where vertical bonds are installed for parallel circuits of bare conductors, they shall be insulated
with a loop installed 150 mm below the bottom circuit to allow for the placement of temporary line
covers.
5.8 Temporary covers
5.8.1 Temporary covers include pipe-type covers (commonly known as Torapoli or tiger tails) and
drape-type covers. Before temporary covers are used, both the mains and temporary covers shall
be inspected for visual defects.
5.8.2 Mains must not be overloaded and must not sag below minimum clearances due to the addition of
temporary covers.
5.8.3 They shall be placed to maintain even sag, and spreaders shall be added if needed.

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5.9 LV ABC insulation integrity
5.9.1 To prevent corrosion of the aluminium conductor and maintain the fully insulated system, it is
essential that the XLPE insulation has no holes. Any holes in insulation must be repaired,
including those caused by G-Clamps or the removal of fittings.
5.9.2 Holes identified in the insulation must be carefully sealed with vinyl-backed mastic tape
(stockcode 69807) to restore the insulation and prevent moisture ingress. A single layer is
sufficient for holes left by G-Clamps, or 3 layers half-lapped for other damage.
5.9.3 Electrical tape is not suitable for reinstating the insulation or moisture barrier, and insulation
piercing connectors (IPCs) shall never be used to cover holes made by G-Clamps.
5.9.4 Cut ends of the cable that are not terminated with an electrical connector shall be individually
sealed with a cable end cap. This includes cable ends that will have electrical connectors added
at a later date.
5.9.5 The cut ends of the cable remaining on a drum shall be sealed.
5.10 Enclosed LV fuse-switch disconnectors
5.10.1 To prevent moisture ingress into the conductor strands, a drip loop shall be included in the
conductor near the termination onto the switch.
5.11 LV ABC piercing connections
5.11.1 Piercing connections shall not be made under electrical load.
5.11.2 IPCs are single use components and shall never be reused.
5.11.3 IPCs shall not be used for sealing holes left by other piercing connectors or test devices.
5.11.4 IPCs shall be installed in accordance with the manufacturer’s instructions. In addition to the tools
specified by the manufacturer, the tools in Annexure C may be used.
5.12 Redundant mains and hardware
5.12.1 Where overhead mains are redundant, the designer shall make provision in the design to remove
redundant assets when work is identified on the pole structure.
5.12.2 All redundant hardware, including connectors, shall be removed at the time it is made redundant.
Any other redundant hardware already present shall also be removed.
5.13 Stainless steel bolts and set-screws – lubrication of threads
5.13.1 Before installation of each stainless steel bolt or set-screw, the thread shall be lubricated with anti-
seize grease containing nickel (stockcode 177212).

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 CONSTRUCTION OF LOW VOLTAGE OVERHEAD MAINS

Annexure A Standard construction drawings

Table 5 - LV ABC construction drawings

Description Construction No. Drawing No.

LV ABC Intermediate Construction for 30° Maximum Angle 1-70 513981

LV ABC Termination Construction 1-71 513982

LV Open Wire to ABC Through Termination Construction 1-72 513983

LV ABC Intermediate Construction for 30° – 60° Maximum 1-73 514012

Angle

LV ABC Through Termination Construction 1-74 514013

LV ABC Corner Pole Construction 60° – 150° Angle 1-75 514014

LV ABC Through Mains Corner Construction 1-76 514015

LV ABC Through Termination Construction with Tee-off 1-77 514016

LV ABC Intermediate Construction with Tee-off 1-78 514017

LV ABC Through Termination Construction with Links 1-79 514052

LV ABC intermediate construction on 500mm standoff bracket 1-80 206544

for 0° to 30° deviation angle

LV ABC Offset Arm Construction for 0° to 30° Deviation Angle 1-81 232175

LV ABC Offset Twin Arm Construction for 0° to 30° Deviation 1-82 244670
Angle

LV ABC Intermediate Construction on 500mm Standoff Bracket 1-83 206546

for 30° – 60° Maximum Angle

LV Horizontal Pin Construction with LV ABC Tee Off 1-84 206624

Construction

LV Open wire to ABC Through Termination Construction with 1-89 206623

Links

LV ABC Parallel Circuit Bonding Arrangements - 186336

LV ABC Constructed on Conductive Poles Below High Voltage - 565720

Supply

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 CONSTRUCTION OF LOW VOLTAGE OVERHEAD MAINS

Table 6 - Bare overhead construction drawings

Description Construction No. Drawing No.

LV Horizontal Pin Construction 1-1 513900

LV Offset Arm Arrangement 1-2 513901

LV Angle Arrangement 1-3 513902

LV Termination Arrangement 1-10 513903

LV Through Termination Arrangement 1-11 513904

LV Corner Pole Termination Arrangement 1-12 513940

LV Corner Pole Through Mains Construction 1-13 513905

LV Corner Pole (Tee-off) Termination Arrangement 1-14 513906

LV Railway Termination Construction 1-15 513945

LV Through Mains with Links 1-50 513971

HV, LV and communications crossarm details 228823

LV through termination for maintenance and legacy 1-11(A) 234378

replacements only

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 CONSTRUCTION OF LOW VOLTAGE OVERHEAD MAINS

Annexure B Connections to twin-and-twist

Electrical and mechanical connections to twin-and-twist conductors shall be performed as detailed
in Table 7.

Table 7 - Twin-and-twist conductor connection options

Connection Description

Bonds to copper conductors Connect insulated copper tails to the mains with split bolts. The split bolts
(including tails to switchgear, fully encapsulate both of the conductors as well as the bonding cable.
copper single UGOHs, PTs This eliminates slipping out of the side and shares the electrical load
etc.) between the conductors.

Wavecon UGOH’s All Wavecon UGOH’s shall be terminated into LV links or a LV ABC link
box. This allows for the tail between the link and the main to be covered
copper and can be connected to the main with the use of the split bolt
procedure mentioned above.

Bonds to aluminium Tails from aluminium conductors (both bare and LV ABC) cannot be
conductors connected directly to the copper twin-and-twist conductors. Instead,
connect insulated copper tails as described above, and then connect the
copper tail to the bare aluminium or LV ABC using PG clamps or IPCs
respectively.

Low voltage services Spread the two conductors and install a service connector on the larger
conductor. If there isn’t already a split bolt clamp around the two mains
conductors (such as from a bond), then install a split bolt no more than
300mm away from the service connector, but not so close that it bends
the conductor.

Straight through attachment Keeping both conductors together, locate them in the top or side groove
to pin insulators of the low voltage pin insulator as appropriate. Use a hand-tie around
both conductors together, treating them as one.

Terminations Keeping both conductors together, take them around the low voltage
shackle insulator and back adjacent to the conductor under tension. Use
pieces of tie wire to make a throat tie around both conductors together,
treating them as one. More detailed instructions are given on the
following page.

Mid-span full tension splices As McIntyre sleeves are no longer available, there is no available solution
for mid-span full tension connections. Instead, terminate the conductors
at the pole either side of the break, and replace with a single copper
conductor appropriately rated for the load and bonded as described
above. There shall be no mid span sleeving on twin-and-twist conductors.

Methods for tying twin-and-twist conductors to insulators are shown in Table 8.

Table 8 - Twin-and-twist conductor insulator tie drawings

Description Drawing No.

Termination tie for twin and twist conductors 251901

Side tie for twin and twist conductors 251902

Top tie for twin and twist conductors 251903

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 CONSTRUCTION OF LOW VOLTAGE OVERHEAD MAINS

Annexure C Approved tools

Table 9 - Battery powered tools for installing IPCs

Type Manufacturer Model Notes

Impact wrench Hilti SIW 6AT-A22 The tool shall be set to Level 3.
The tool shall only be used on connectors
involving 95mm² or 150mm² LV ABC mains.

Drill driver Any Any The tool shall be set or limited to a rotational
speed of less than 500 rpm.
The tool shall not use any impact or hammer
action.

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