Cable Joint Kit
A comprehensive kit containing all materials and components required for splicing and repairing AGL primary and secondary cables. Includes heat‑shrink tubing, insulation tape, mechanical connectors, epoxy resins, and protective sleeves to create waterproof, electrically insulated, and mechanically robust cable joints that meet airfield standards.
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What Is It?
A Cable Joint Kit is a pre‑assembled collection of materials and components specifically designed for splicing, repairing, and terminating airfield ground lighting (AGL) primary and secondary cables. These kits provide everything needed to create a reliable, waterproof, and electrically sound cable joint in the field, eliminating the need to source individual components separately.
Typical contents of a cable joint kit include:
- Heat‑shrink tubing: Dual‑wall adhesive‑lined tubing that provides electrical insulation, mechanical protection, and a watertight seal when heated.
- Mechanical connectors: Copper or brass crimp connectors, split bolts, or compression lugs for securely joining cable conductors.
- Insulation tape: High‑voltage self‑amalgamating tape or PVC tape for insulation and moisture sealing.
- Epoxy resin or gel: Two‑part resins or encapsulating compounds for filling joint enclosures and creating a waterproof seal.
- Protective sleeves: Flexible or rigid sleeves that provide mechanical protection and abrasion resistance.
- Heat shrink end caps: For sealing cable ends and providing strain relief.
The kit is designed for use with specific cable types and sizes, ensuring compatibility and ease of installation. It meets the requirements of international standards for AGL cable joints and is approved for use on airfields worldwide.
Purpose & Function
The cable joint kit's purpose is to make a field splice as electrically sound and as watertight as the continuous cable on either side of it, rather than leaving that outcome to whatever materials happen to be on hand at the time of repair. A buried AGL primary cable will occasionally need repair after mechanical damage or during circuit extension work, and a poorly executed improvised splice is one of the more common sources of intermittent series-circuit faults, since a marginal joint can pass current initially and only fail once moisture works its way in over subsequent seasons. By bundling matched connectors, sealing tape, resin, and heat-shrink components to a tested combination, the kit removes the guesswork from what would otherwise be an ad hoc repair.
Where Is It Used?
The cable joint kit is used throughout the airfield wherever cable splicing or repair is required, including:
- Primary Series Cable Splicing: Joining sections of primary cable in the series loop, including repairs after damage or during system expansion.
- Secondary Cable Connections: Connecting isolating transformers to light fixtures and signs, and repairing secondary cable runs.
- Connector Installation: Terminating cables with L‑823 connectors or other primary/secondary connectors.
- Junction Box Cable Entries: Sealing and protecting cable entries into junction boxes, handholes, and distribution panels.
- Emergency Repairs: Quick, reliable repair of damaged cables to restore AGL system functionality with minimal downtime.
The kit is suitable for use in buried, elevated, and pit‑mounted installations, and is compatible with both copper and aluminium conductors. It is designed to withstand the harsh airfield environment, including moisture, temperature extremes, chemical exposure, and mechanical stress.
Installation & Location
A joint is made at the excavated or exposed section of cable where a splice or repair is required, with the work area cleaned and kept dry before assembly begins, since moisture trapped inside the joint is the most common cause of later failure. The cable ends are prepared, conductors joined with the kit's connector, and the completed splice built up in layers — insulation tape or resin, then a heat-shrink sleeve — so the finished joint restores both the electrical insulation and the mechanical protection of the original cable. Once complete, the joint is generally housed in a below-grade splice pit, handhole, or joint enclosure rather than left directly in open ground, giving future maintenance access without re-excavating the full run. Where the joint sits in a wet or frequently flooded location, the kit's components are selected and layered to give a fully submersible result, matched to the IP rating of the surrounding pit or enclosure.
How Does It Work?
The cable joint kit provides all components necessary to create a reliable, waterproof, and electrically sound cable joint using standard field‑installation techniques. The typical installation process involves:
- Cable Preparation: Stripping the cable jacket and insulation to the specified lengths, cleaning the conductors, and preparing the cable ends for termination.
- Conductor Connection: Joining the cable conductors using mechanical connectors (crimp connectors, split bolts, or compression lugs) to create a low‑resistance, gas‑tight electrical joint.
- Insulation and Sealing: Applying self‑amalgamating tape, heat‑shrink tubing, or epoxy resin to insulate the joint and provide a watertight seal. Dual‑wall heat‑shrink tubing with adhesive liner is often used to ensure a moisture‑proof seal.
- Mechanical Protection: Encasing the joint in a protective sleeve or jacket to provide mechanical strength and resistance to abrasion, impact, and environmental stress.
- Testing: After installation, the joint is typically tested for insulation resistance and continuity to verify the quality of the connection.
The kit is designed to be installed by trained personnel using standard tools (e.g., cable strippers, crimping tools, heat guns). The materials are selected for compatibility with AGL cables and to meet the rigorous performance requirements of airfield installations, including IP68 watertight integrity.
System Architecture & Control Logic
A cable joint is an inline splice in the series circuit loop, so it carries the full commanded current of the CCR just like an unbroken length of primary cable — the ALCMS and CCR have no way to distinguish a joint from a continuous run, and neither device is aware the joint exists as a discrete component. It is not individually addressable or monitored; its performance is folded entirely into the loop's overall resistance budget that the CCR tracks as voltage against commanded current. A well-made joint adds negligible resistance and is invisible to the control system. A poor connection — an under-crimped conductor, an incomplete heat-shrink seal that later admits moisture — raises loop resistance and shows up to the CCR as elevated loop voltage at a given current step, or, if the joint fails completely, as a full open-circuit loop fault. Because loop-level monitoring cannot localise the fault to the joint itself, confirming a suspect joint still requires physically sectionalising the loop and testing insulation resistance and continuity at each candidate location.
ALCMS → CCR → Series Circuit Loop → Cable Joint (inline splice) → Loop continues (with loop-level feedback)
Field Joint Assembly Sequence
Cable Preparation
Jacket and insulation stripped to spec; conductors cleaned
Conductor Connection
Crimp connectors, split bolts, or compression lugs form a low-resistance, gas-tight joint
Insulation & Sealing
Tape, heat-shrink tubing, or epoxy resin restore the insulation and watertight barrier
Mechanical Protection
Protective sleeve adds resistance to abrasion, impact, and environmental stress
Testing
Insulation resistance and continuity checked before the joint is buried or closed up
A Single Field Joint Reproduces Every Protective Layer of the Original Cable — Electrical, Watertight, and Mechanical
Physical Construction
The kit is built as a layered assembly rather than a single part: at its core sit the mechanical connectors (copper or brass crimp barrels, split bolts, or compression lugs) that physically rejoin the severed conductors, sized to match the specific cable's conductor cross‑section. Around each rejoined conductor, self‑amalgamating or high‑voltage tape rebuilds the conductor insulation, followed by a length of dual‑wall, adhesive‑lined heat‑shrink tubing sized to overlap the original cable jacket on both sides of the joint; when heated with a torch or heat gun, the tubing shrinks tight around the joint while its internal adhesive liner melts and flows to form a continuous, watertight seal bonded to the cable sheath. For larger primary joints, a two‑part epoxy resin or gel is poured into an outer moulded shell or sleeve surrounding the whole assembly, encapsulating the connectors and tubing in a solid, waterproof block once cured. Heat‑shrink end caps seal any spare or unused cable cores, and the completed joint is protected by a rigid or flexible outer sleeve before being reburied or reinstated in its enclosure.
Technical Parameters
| Parameter | Typical Value |
|---|---|
| Cable Compatibility | Primary: 6mm² to 16mm² (AWG 10 to 6); Secondary: 1.5mm² to 4mm² (AWG 16 to 12) |
| Voltage Rating | Up to 5kV (transient), 600V continuous (primary); Up to 1kV (secondary) |
| Insulation Material | XLPE, PVC, or EPR (compatible with cable insulation types) |
| Heat‑Shrink Tubing Type | Dual‑wall adhesive‑lined (polyolefin or PVDF) |
| Connector Material | Tin‑plated copper, brass, or aluminium (compatible with conductor type) |
| Sealing Material | Self‑amalgamating tape, epoxy resin, or silicone gel |
| Protection Class (installed) | IP68 (submersible, continuous) |
| Operating Temperature | -40°C to +85°C (ambient) |
| Shrink Ratio (heat‑shrink) | 3:1 or 4:1 (depending on cable diameter) |
| Mechanical Strength | ≥ 70% of cable tensile strength (with mechanical protection sleeve) |
| Standards | IEC 60502, IEEE 404, FAA AC 150/5345‑7 (cable), AC 150/5345‑26 (connectors) |
Electrical Requirements
| Requirement | Typical Value |
|---|---|
| Circuit Position | In-line joint within series circuit or secondary cable run |
| Rated Current (Pass-through) | 6.6A series circuit standard (matched to jointed cable size) |
| Voltage Withstand (Joint) | Up to 5kV transient, 600V continuous (primary); up to 1kV (secondary) |
| Insulation Resistance (post-joint) | ≥ 50 MΩ (megger test, joint-to-ground) |
| Dielectric Withstand | No breakdown at rated voltage + safety margin (per IEC 60502) |
| Conductor Continuity | No measurable increase in loop resistance across joint |
| Fault Protection | Joint failure detected as CCR ground fault or open-circuit |
Applicable Standards
IEC 60502
Power cables with extruded insulation and their accessories for rated voltages from 1 kV to 30 kV
IEEE 404
Standard for extruded and laminated dielectric shielded cable joints rated 2.5 kV to 500 kV
FAA AC 150/5345‑7
Specification for L-824 Underground Electrical Cable
FAA AC 150/5345‑26
Specification for L-823 Plug and Receptacle, Cable Connectors
ICAO Annex 14
General requirements for AGL circuit components and cable installations
Installation Requirements
Clean, Dry Work Area
FitClean and keep the work area dry before assembly begins, since moisture trapped inside the joint is the most common cause of later failure.
Connector Sizing
FitMatch the kit's crimp barrels, split bolts, or compression lugs to the specific cable's conductor cross-section before joining, since an undersized connector produces a weak or high-resistance joint.
Layered Build-Up
FitBuild the joint up in the specified layers — insulation tape or resin, then heat-shrink sleeve — so the finished joint restores both electrical insulation and mechanical protection of the original cable.
Heat-Shrink Application
FitHeat the dual-wall, adhesive-lined tubing evenly with a torch or heat gun until the internal adhesive liner melts and flows, forming a continuous, watertight seal bonded to the cable sheath.
Submersible-Grade Selection
FitWhere the joint sits in a wet or frequently flooded location, select and layer kit components to give a fully submersible result, matched to the IP rating of the surrounding pit or enclosure.
Enclosure Housing
FitHouse the completed joint in a below-grade splice pit, handhole, or joint enclosure rather than leaving it directly in open ground, giving future maintenance access without re-excavating the full run.
Pre-Energisation Sign-off
DocumentationRecord joint location, connector type, and IP rating achieved before backfill, since the completed joint is not inspectable once reburied or reinstated in its enclosure.
Testing & Commissioning
Insulation Resistance Test Across Joint
Pre-EnergisationMegger-test through the completed joint before backfill, confirming the jointed insulation resistance is no lower than the parent cable.
Joint Continuity & Resistance Test
Pre-EnergisationVerify conductor continuity through the joint and record resistance, ruling out a poorly made crimp or incomplete reinstatement of the screen.
High-Voltage Withstand Test
Pre-EnergisationApply a proof voltage across the completed joint for the specified duration to confirm the reinstated insulation withstands it without breakdown.
Visual & Dimensional Inspection
Pre-EnergisationInspect the cured joint body for correct dimensions, absence of voids, and proper overlap of insulation and screen tapes or mouldings.
Moisture Ingress / Seal Integrity Check
Pre-EnergisationConfirm end seals and any water-blocking components are correctly fitted before the joint is backfilled or bandaged.
Documentation & As-Built Sign-off
Final AcceptanceRecord insulation, hi-pot, and continuity readings alongside the joint's as-built location in the commissioning dossier for handover.
Inspection & Maintenance
Post-Installation Testing
At installTest insulation resistance with a 500V or 1000V megohmmeter and verify continuity immediately after jointing to catch undetected faults before backfilling.
Insulation Resistance Retest
AnnualRe-test insulation resistance at the joint on the regular AGL circuit test schedule to catch gradual seal degradation before it causes a fault.
Excavation Spot-Check
As neededIf a circuit fault is suspected near a joint, excavate to visually confirm the heat-shrink seal and mechanical protection sleeve remain intact.
Ground Disturbance Review
As neededAfter nearby excavation, resurfacing, or heavy vehicle traffic over a buried joint, check for signs of ground movement that could stress the joint.
Documentation Review
OngoingKeep joint location, date, and test results on record so future maintenance and fault-finding can quickly locate and assess each joint.
Common Field Issues
Inadequate Cable Stripping
Improper stripping of the cable jacket or insulation can leave exposed conductors, cause nicks in the conductor, or result in insufficient insertion depth. Use the correct stripping tools and follow the manufacturer's strip length instructions.
Incomplete Heat‑Shrink Application
If the heat‑shrink tubing is not heated evenly or to the correct temperature, it may not fully shrink or seal, compromising watertight integrity. Use a heat gun with temperature control and ensure even heating until the adhesive flows from both ends.
Incorrect Crimping or Torque
Over‑crimping or under‑crimping mechanical connectors can result in high‑resistance joints that overheat. Use the correct crimping tool and dies, and follow the manufacturer's torque specifications for bolted connections.
Contamination of Joint Area
Dirt, oil, or moisture on the conductors or joint materials can prevent proper adhesion of tape and heat‑shrink, compromising insulation and sealing. Clean conductors with isopropyl alcohol and ensure the joint area is dry before starting.
Incompatibility of Materials
Using materials that are not compatible with the cable insulation (e.g., using PVC tape on EPR insulation) can cause degradation over time. Always use materials that are specifically designed for AGL cables and are compatible with the cable type.
Inadequate Mechanical Protection
In buried installations, the joint may be subject to ground movement, rocks, or heavy loads if not properly protected with a mechanical sleeve or armouring. Use the protective sleeve provided in the kit and ensure the joint is properly bedded in sand or gravel.
Failure to Test After Installation
Not performing insulation resistance and continuity tests after jointing can leave undetected faults that cause system failures later. Always test the joint using a megohmmeter (500V or 1000V) and a continuity tester.
Troubleshooting Guide
Joint Fails Insulation Resistance Test After Installation
Water Ingress at the Joint Over Time
Joint Running Warm or Showing Discoloration
Joint Displaced or Damaged After Backfilling
Intermittent Fault Traced to a Buried Joint
Failure Modes & Root Causes
Contamination-Induced Insulation Failure
Incomplete Heat-Shrink Adhesive Flow
Over- or Under-Crimped Mechanical Connector
Inadequate Mechanical Protection
Untested Joint (Latent Defect)
Safety & Operational Notes
De-Energise Before Opening the Joint
Electrical SafetyNever cut into or remake a joint on a live series circuit; de-energise and lock out the CCR and verify zero energy at the cable ends before exposing the conductors.
Excavation & Buried Services
OperationalLocate and mark all buried services before excavating to expose a joint, and hand-dig within the tolerance zone of the marked cable to avoid an accidental strike on the circuit or on adjacent utilities.
Heat-Shrink Torch Handling
Personnel SafetyUse the torch or heat gun away from dry vegetation and confined spaces, keep it clear of skin and clothing during shrink-down, and allow the joint to cool before handling.
Contamination Control
WorkmanshipKeep conductors, connector, and insulation components clean and dry throughout the make-up; do not open sealed kit components until immediately before use, and pause the work if groundwater intrudes on the joint area.
Insulation Test Before Backfill
Electrical SafetyMegger and continuity-test the completed joint before backfilling and before re-energising the circuit; a fault found after backfill means re-excavating the joint.
PPE & Grounding
Personnel SafetyUse insulated tools and appropriate PPE when handling series-circuit conductors, and confirm the circuit is bonded/grounded per the electrical design before reconnecting the loop.
Bedding & FOD Control
OperationalBed the joint properly and use its protective sleeve before backfilling, and account for all tools, offcuts, and packaging at the excavation to prevent foreign object debris on or near the movement area.
Record & Restore to Compliant State
ComplianceLog the insulation resistance and continuity results at commissioning, and confirm the circuit is restored to full compliance before closing out the work and cancelling any associated NOTAM.
Engineering & Expert Notes
Trend Insulation Readings From This Joint Specifically
TroubleshootingA joint's insulation resistance value at commissioning is the real baseline for that location; comparing future readings only to a generic spec threshold, rather than to this joint's own history, can miss a slow degrading trend years before it trips the CCR.
Groundwater Table Dictates the Right Kit, Not Just the Cable Size
DurabilityAn inline joint installed above the seasonal high water table may pass every test at commissioning yet flood every wet season; specify a kit rated for permanent submersion whenever there's any doubt about drainage at the joint location.
Resin or Gel Cure Time Isn't Negotiable in Cold Weather
WorkmanshipResin and gel-filled joint kits cure more slowly at low ambient temperature; backfilling or re-energising before full cure can leave voids in the encapsulant that later become moisture paths, even though the joint looked complete at close-up.
Fewer Joints Beats Perfect Joints
DesignEvery inline joint is a future failure point regardless of workmanship quality; where a run can be pulled through in one length instead of jointed at a convenient access point, the long-term reliability case usually favours the longer pull.
Record As-Built Joint Locations, Not Just Depths
OperationalA joint's GPS location and depth recorded at installation saves hours of hand-digging on the next fault-find; a joint located only by "approximately halfway between two cans" is effectively unlocated once ground features change.
Match the Kit to the Circuit Voltage Class, Not Just the Cable Gauge
ComplianceA joint kit rated for the wrong voltage class can pass an initial megger test yet break down under the CCR's actual series-circuit voltage over time; always confirm kit rating against circuit voltage, not just conductor size.
Airport Lighting Cable Joint
An airport lighting cable joint is the repaired or extended point in a primary or secondary cable. It must restore the conductor, the insulation and the watertight seal. Most insulation faults in a loop start at a joint, so a joint made with the right kit, in dry conditions, and followed by an insulation test is one of the best ways to prevent later faults.
Record the position of every joint on the as-built drawings. For the connector-based alternative, see the primary cable joint splice connector.
Related Components
Frequently Asked Questions
Short answers about AGL cable joint kits: contents, jointing method, ratings, testing, standards and mistakes.
Q1What is an AGL cable joint kit?
A cable joint kit is a pre-assembled set of materials for splicing, repairing and terminating AGL primary and secondary cables. It typically includes dual-wall adhesive-lined heat-shrink tubing, mechanical connectors (crimp connectors, split bolts or compression lugs), insulation tape, epoxy resin or gel, protective sleeves and heat-shrink end caps.
Q2Why use a proper joint kit instead of improvised materials?
The kit makes a field splice as electrically sound and watertight as the continuous cable either side of it. A poorly executed improvised splice is a common source of intermittent series-circuit faults, because a marginal joint can pass current at first and only fail once moisture works in over later seasons.
Q3Where are cable joint kits used?
For splicing primary series cable (repairs and system expansion), secondary connections from isolating transformers to fixtures and signs, terminating cables with L-823 connectors, sealing cable entries into junction boxes and handholes, and emergency repairs. They suit buried, elevated and pit-mounted installations and both copper and aluminium conductors.
Q4How is a cable joint made?
Prepare the cable by stripping the jacket and insulation to specification and cleaning the conductors. Join the conductors with a mechanical connector, insulate and seal with tape, heat-shrink or epoxy, add a protective sleeve for mechanical strength, then test insulation resistance and continuity before burying or closing up.
Q5What cable sizes and ratings does a joint kit cover?
Typically primary cable of 6 mm² to 16 mm² (AWG 10 to 6) and secondary cable of 1.5 mm² to 4 mm² (AWG 16 to 12). Voltage rating is up to 5 kV transient and 600 V continuous for primary, and up to 1 kV for secondary. Installed protection class is IP68, and the operating range is -40°C to +85°C.
Q6What insulation resistance should a finished joint achieve?
At least 50 MΩ joint-to-ground on a megger test, with no measurable increase in loop resistance across the joint. Test immediately after jointing with a 500 V or 1000 V megohmmeter, before backfilling.
Q7Which standards apply to AGL cable joints?
The main references are IEC 60502, IEEE 404, FAA AC 150/5345-7 (L-824 underground cable), FAA AC 150/5345-26 (L-823 plug and receptacle connectors) and ICAO Annex 14. Always verify the current edition and your aerodrome's approved requirements.
Q8How often should cable joints be tested?
Test at installation, then retest insulation resistance annually on the regular AGL circuit test schedule. Excavate to inspect if a fault is suspected near a joint, and check after nearby excavation, resurfacing or heavy vehicle traffic. Keep joint location, date and test results on record.
Q9What are the most common cable jointing mistakes?
Inadequate stripping, uneven or incomplete heat-shrink application, over- or under-crimping connectors, contamination by dirt, oil or moisture, incompatible materials (for example PVC tape on EPR insulation), inadequate mechanical protection in buried installations, and failing to test after installation.
Q10What should I do if a new joint fails its insulation test?
The likely cause is contamination on the conductors or joint materials, or incompatible materials. Re-test at the specified voltage, and if the reading is still low, cut out and remake the joint, cleaning the conductors with isopropyl alcohol and using materials rated for the cable's insulation type.
Q11What safety steps apply when making or repairing a joint?
Never cut into a joint on a live series circuit: de-energise and lock out the CCR and verify zero energy. Locate and mark buried services before excavating, use the heat gun away from vegetation and confined spaces, keep materials clean and dry, megger and continuity-test before backfilling, and bed the joint with its protective sleeve.
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Please read before relying on any content on this page.
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