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newSchoolWorks.com › VoTechWorks › Building & Construction › Electrical Lineworker › Capstone Project: Overhead Distribution Line Installation › Lesson 2
BLD-LINE69-09 · Lesson 2 · 30 clock hours · lab

Integrated Field Installation: Climb, Rig, String, and Hang

Objective. Working in a two-person crew on the pole yard, the student climbs to working height, sets crossarm hardware, rigs and hoists a conductor segment using stringing blocks and a come-along, dead-ends the conductor with the correct sleeve or clamp, and positions a single-phase transformer for connection—all while maintaining 100% tie-off and following the JHA written in Lesson 1.

⚠ Pending professional review

This lesson, its worked examples and its practice questions has not yet been verified by a licensed professional engineer or master tradesperson or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.

VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.

Integrated Field Installation: Climb, Rig, String, and Hang

This lab brings together every skill you have practiced in isolation—climbing, hardware installation, conductor stringing, dead-ending, and transformer handling—into a single, sequenced field evolution. You and your partner will rotate between the aloft and ground roles so that both of you complete every major task. The job hazard analysis (JHA) you wrote in Lesson 1 governs this work. Read it before you put on your first piece of PPE.

PPE Inspection and Donning

No task begins until PPE is inspected and properly donned. Work through each item in order:

Document your inspection on the as-built log before climbing. Any defective item is pulled from service—never use it and flag it for replacement.

Climbing and Establishing a Working Position

Approach the class-H training pole and position your body squarely in front of it. Set your gaffs into the wood with each step before shifting your weight. Keep your hips away from the pole so your gaffs dig in at the correct angle—this is the single most common cause of a gaff-out.

100% tie-off is mandatory from the moment you leave the ground. On a wood pole with a single lanyard, the technique is a continuous climbing tie-off: your safety strap is repositioned above each obstacle before you unclip from below. Never have both ends of your tie-off disconnected at the same time. Your instructor's observation checklist will record every moment of tie-off status.

At crossarm height, set your body belt or harness lanyard around the pole and lean back to your working position. Test the position by taking both hands off the pole briefly—you must be stable and hands-free before handling hardware.

Crossarm and Pin Insulator Installation

Install the crossarm at the marked location using the hardware kit provided. Start all bolts by hand before applying torque, and torque bolted hardware to the manufacturer's specification using the calibrated torque wrench. Record the torque value on the as-built log immediately—this is your quality record and mirrors what a utility crew produces on a real job.

Thread the pin insulator onto the crossarm pin, turning clockwise until snug. Do not over-tighten porcelain or polymer insulators; follow the manufacturer's guidance.

Rigging, Stringing, and Dead-Ending the Conductor

From the ground, rig a snatch block at the crossarm bracket according to the rigging diagram in your reference materials. Attach the come-along to a rated anchor point. Feed the conductor through the stringing block, then pull the conductor through using the come-along until the sag matches the value specified in the simulated sag table for the given span length and conductor type. Sag is a safety-critical dimension: too little tension can violate ground clearance; too much can overload structures.

Apply the dead-end using whichever method your tooling supports:

After the dead-end is set, record the hardware lot number and torque or crimp values on the as-built log.

Transformer Positioning (Aloft Worker)

For the second evolution, you are the aloft worker. Your partner on the ground attaches the transformer bail to the hand line using a proper hitch—confirm this verbally before the lift begins. Guide the transformer in as your partner hauls the hand line; never allow the load to swing freely beneath you.

Set the transformer on the crossarm bracket with the primary bushing facing the source side as shown on the standard drawing. This orientation is not optional—reversing it creates a wiring error that could cause a fault or personnel hazard during energization. Secure all mounting hardware and torque to specification. Announce clearly when the transformer is secured so your partner can release the hand line.

Simultaneously, the ground worker lays out secondary rack hardware and applies phase-identification tape to each secondary conductor per the project drawing. Color-coding must match utility convention for your region; your instructor will specify the standard in use.

Closing Safety Points

Key terms10

100% tie-offA climbing safety practice in which the worker is connected to the structure by at least one approved lanyard or safety strap at every moment while aloft; no gap in fall protection is permitted.
Gaff-outAn uncontrolled slip of a climbing hook (gaff) out of the pole wood, typically caused by insufficient hip-out posture or a dull gaff point; a leading cause of climbing falls.
Snatch blockA pulley with a side plate that opens so a rope or line can be placed in the sheave without threading the end; used to redirect pulling force during conductor stringing and transformer lifts.
Preformed dead-endA helical wire grip that wraps around the conductor to terminate it at a structure; installed without special tooling by spiraling rods outward from a center mark.
Compression dead-end sleeveA metal sleeve into which the conductor is fully inserted and then crimped with a hydraulic or mechanical tool to create a permanent termination; crimp sequence is specified by the manufacturer.
SagThe vertical distance between the attachment points of a conductor span and the lowest point of the conductor curve; controlled during stringing to meet ground-clearance and tension design requirements.
Come-alongA hand-operated ratchet hoist used to pull and tension conductor or other loads; must be rated at or above the maximum load it will carry.
Primary bushingThe high-voltage terminal on a distribution transformer through which line voltage is applied; must be oriented toward the source side of the circuit per the installation drawing.
As-built logA written record completed during installation that captures actual hardware used, torque or crimp values, and lot numbers; serves as the quality and traceability document for the completed work.
Class 00 rubber glovesElectrical insulating gloves rated for use at the lowest voltage class; must be air-tested before each use and worn with leather protectors to prevent puncture.

Worked examples4

1. The sag table for your training span specifies a sag of 18 inches for the given conductor and simulated temperature. After tensioning with the come-along, you measure the sag at 24 inches. How many additional inches of sag must you remove, and in which direction do you adjust the come-along?
  1. Identify the target sag: 18 inches.
  2. Identify the measured sag: 24 inches.
  3. Calculate the difference: 24 − 18 = 6 inches of excess sag.
  4. To reduce sag, the conductor must be pulled tighter—advance (take up) the come-along to shorten the effective conductor length in the span.
  5. After each adjustment, re-measure sag before advancing further; overpulling increases tension and can overload hardware.
Answer: You must remove 6 inches of sag by advancing (taking up) the come-along to increase conductor tension.
2. The crossarm through-bolt manufacturer specifies a torque of 60 ft-lb. Your calibrated torque wrench is set and you apply force to the handle. The wrench clicks before the nut appears fully seated. What do you record on the as-built log, and what action do you take next?
  1. A torque wrench click indicates the preset torque value has been reached—stop applying force immediately; continuing past the click does not add accurate torque and can overload the fastener.
  2. The torque value to record is the wrench setting: 60 ft-lb.
  3. Visually confirm the bolt and nut are fully threaded and the hardware is properly seated; if alignment appears incorrect, consult your instructor before disturbing the connection.
  4. Record '60 ft-lb, as specified' in the torque column of the as-built log along with the hardware lot number and your initials.
Answer: Record 60 ft-lb on the as-built log. The click means specified torque was achieved; no further tightening is needed.
3. Your come-along is rated for a working load limit of 2,000 lb. The conductor segment plus the weight of the stringing block and rigging hardware is estimated at 340 lb, and the pulling force needed to achieve the required sag tension is an additional 480 lb. Is the come-along within its rated capacity for this pull?
  1. Identify total load: conductor/hardware weight 340 lb + pull force needed 480 lb = 820 lb.
  2. Compare to the come-along's working load limit: 820 lb vs. 2,000 lb rated.
  3. 820 lb is less than 2,000 lb, so the come-along is within its rated capacity.
  4. Note: always use rated working load limit, not breaking strength, for this comparison.
Answer: Yes. The total load of 820 lb is well within the 2,000 lb working load limit of the come-along.
4. A preformed dead-end has a center mark. You begin wrapping the first helical rod at a point 4 inches past the center mark instead of at the center mark itself. Why is this an installation error, and what is the correct starting point?
  1. The center mark on a preformed dead-end indicates the midpoint of the helix, ensuring that equal grip length is applied in each direction from that point.
  2. Starting 4 inches off-center means one side of the dead-end grip is shorter than designed, reducing the total grip length on that side.
  3. Reduced grip length decreases the rated holding strength of the dead-end, which could allow the conductor to pull through under load.
  4. Correct action: remove the partially applied rods, realign the center mark with the correct position on the conductor, and begin wrapping from the center mark outward in both directions per the manufacturer's instruction.
Answer: Starting off-center reduces grip length and holding strength. The correct starting point is exactly at the center mark, wrapping outward in both directions equally.

The math in this lesson1

Learners measure conductor sag, compare 24 inches to an 18-inch target, and remove 6 inches.
N-Q.3
Brush up in the math halls at newSchoolWorks.com:
In class: Don and inspect all required PPE (climbing hooks, safety strap, hard hat, safety glasses, rubber gloves with leather protectors, high-visibility vest); climb a class-H frame training pole to crossarm height, demonstrate a secure working position, install a crossarm and pin insulator, then descend—instructor completes a standardized climb observation checklist for each student in real time. · From the ground position, rig a snatch block at the crossarm, attach a come-along to the anchor, feed conductor through the block, and tension the conductor to the simulated sag table specification provided; apply a preformed dead-end or compression dead-end sleeve (per available tooling) and torque bolted hardware to manufacturer spec using a calibrated torque wrench—record values on the as-built log. · As the aloft worker (second evolution, roles swapped with partner), receive the transformer bail from a ground worker using a hand line and block, position the transformer on the crossarm bracket, verify that the primary bushing faces the correct direction per the standard drawing, and secure all mounting hardware; ground worker simultaneously lays out secondary rack hardware and labels each secondary conductor with phase tape per the project drawing.
Materials: Pole yard with minimum two class-H training poles, climbing hooks (gaffs) and safety straps (one set per student, sized and inspected), Class 00 rubber gloves with leather protectors, hard hats, safety glasses, high-visibility vests, crossarm and hardware kit, pin insulators, preformed or compression dead-end sleeves, come-along rated for conductor load, snatch blocks, stringing blocks, hand line, single-phase distribution transformer (de-energized training unit), transformer bracket and mounting hardware, calibrated torque wrench, as-built log forms, NCCER Power Line Worker Levels reference
Check: Instructor uses a 40-point performance observation checklist (adapted from NCCER task sheets) scored in real time; passing is 32/40 (80%). Automatic resubmit triggers: any moment of zero tie-off aloft, use of a tool or hardware outside its rated capacity, or failure to inspect PPE before donning. Students who trigger an automatic resubmit complete remediation during scheduled open-lab time and repeat the observed task the following day.

Practice check8

Answer each question, then check it. Nothing is recorded; this is your own practice.

OSHA 10 – PPE and Personal Protective Equipment
1. During PPE inspection before a climb, a student rolls the cuff of a Class 00 rubber glove and it immediately deflates. What is the correct action?
NCCER Power Line Worker – Climbing Safety
2. A lineworker is aloft on a wood pole and must reposition the safety strap above a through-bolt. Which sequence maintains 100% tie-off?
NCCER Power Line Worker – Conductor Stringing
3. After tensioning a conductor with a come-along, you measure a sag of 14 inches but the sag table calls for 20 inches. What adjustment is needed?
NCCER Power Line Worker – Hardware Installation
4. When installing a compression dead-end sleeve, the manufacturer specifies crimping from the conductor end toward the eye. A student crimps from the eye end toward the conductor end instead. What is the most likely consequence?
NCCER Power Line Worker – Rigging and Material Handling
5. Before the ground worker hauls a transformer up to the aloft worker using a hand line, what must both workers confirm?
NCCER Power Line Worker – Transformer Installation
6. The project drawing shows the transformer primary bushing must face the source side. After positioning the transformer, the aloft worker notices the primary bushing faces the load side. What is the correct immediate action?
OSHA 10 – Fall Protection
7. Which condition is an automatic resubmit trigger during this lab's performance observation?
NCCER Power Line Worker – Rigging Safety
8. A come-along has a working load limit (WLL) of 1,500 lb. The estimated conductor and rigging weight is 290 lb, and achieving the required sag tension requires an additional pull force of 1,260 lb. Can this come-along be used safely for this pull?
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