Cable crimping

This article gives a practical description oI crimping Ior joining electrical cables in Iixed wiring
installations. The techniques shown are generally applicable to other Iields such as automotive
electrics. This is not, however, a recommended technique Ior extending Ilexible mains cables
connected to appliances.
It is recommended that you practice this procedure a Iew times beIore deploying it on a real
installation, to make sure the joints you create are mechanically strong. It is also a good idea to
get your practice in when you are not stuck upside down in some uncomIortable corner oI a
wiring cupboard or other "real liIe" situation.
Contents
|hide|
O Acceptable jointing methods
O Why Crimping?
O Required Tools and Materials
O The wrong tool Ior the job
O The crimping procedure
4 . Prepare the wire
4 . Fit insulation
4 . Select suitable crimps
4 . Crimp
4 . Test
4 .6 Heatshrink
O 6 See also
cceptable jointing methods
There are various situations where it may become necessary to join an electrical cable, such as
when eIIecting repairs and upgrades to installations. The wiring regulations basically allow Ior
Iour methods Ior making cable joints:
. Screw terminal connections
. Joints produced by a compression tool (i.e. crimped)
. Soldered Joints
. Welded Joints
) is most commonly used in electrical accessories such as switches and sockets. However this
method is only acceptable where the joint will remain accessible Ior Iuture inspection and
maintenance (see section |6-0-0| part (iii)), since screwed terminal connections can become
loose over time.
) Is not an option readily available in many domestic situations. Hence iI one needs to make a
joint that is robust, and can be saIely entombed into a building we are leIt with ) & ).
hy Crimping?
Crimping is a quick and reliable method oI jointing that is easy to deploy in the Iield since unlike
soldering it does not require time to be spent waiting Ior a soldering iron to heat up, and poses no
burn risk to the operator when working in conIined spaces.
Required Tools and Materials
For making reliable crimped joints the correct crimping tool must be used. Adequate crimping
tools are oI a substantial contruction and include a ratchet tightening mechanism that ensure
adequate pressure is applied to the crimp beIore it is released. Like this:

A suitable tool is available Irom most good tool shops and electrical retailers such as this||||.
Crimp terminals are available in a number oI sizes and two basic types: |Insulated| and
|Uninsulated|. Both types can be used, but the procedure is diIIerent, and uninsulated crimps
require the use oI a diIIerent crimp tool to insulated ones. For the purposes oI this article we will
use insulated crimps since these are the more commonly available, and require a little less work
to use.

In addition to a crimp tool you will need a Iew basic tools like wire cutters, and strippers. You
will also need some heatshrink tubing oI a size appropriate Ior the cable to be joined
The wrong tool for the job
Note that the cheap non ratchet crimp tools like this are not suitable:

II you have one oI these, save it Ior stripping wire and cropping small bolts.
The crimping procedure
Let's assume we need to join a section oI cable.
Prepare the wire
The Iirst job is to cut out any damaged sections or wire to leave sound wire to work with:

Strip the cable back a couple oI inches (about 0mm) on each side so that there is room to work.
To Reduce the size oI the overall crimp, and to make Ior a neater joint, the lengths oI wires can
be staggered so that the crimp terminals will not Iorm a bunch:

(It is better to stagger the joints even more than as shown in the photograph - such that there is no
overlap in the crimp terminal positions at all being ideal)
it insulation
BeIore going any Iurther Iit the insulation!
Cut some heatshrink to a length enough to not only cover the joint but also extend an inch oI two
down the cable. This will make the Iinal joint more moisture resistant. (II waterprooIing is
important then an adhesive lined heatshrink can be used):

For a .mm T&E cable use .7mm (0. inch) diameter heatshrink, Ior smaller cables 0mm
diameter will probably be a better Iit.
Also remember to Iit sleeving to the earth wires. Slide the heatshrink it up one oI the wires until
it is out oI the way:

$elect suitable crimps
For joining cables like this, the type oI crimp required is known as a "butt" crimp or splice.
The crimp selected needs to not only match the wire size in question, but also have enough
current carrying capacity Ior the circuit. The colour oI a crimp only indicates its size, they are not
designed to match any particular colour oI wire insulation.
The three most popular sizes / colours being:

Different crimp connections and their applications
Crimp colour Details pplication
Red O Area, wire
size
min:0.mm
O Area, wire
size
max:.6mm
O Current
rating:A
O Material,
contact:Coppe
mm and
.mm
T&E

r
O Material,
insulator:Colo
ured Vinyl
O Plating,
contact:Electr
o-tinned
O Temp, op.
max:8SC
O Temp, op.
min:-0SC
O Voltage rating,
AC:V
lue

O Area, wire
size
min:.0mm
O Area, wire
size
max:.6mm
O Current
rating:7A
O Material,
contact:Coppe
r
O Material,
insulator:Colo
ured Vinyl
O Plating,
contact:Electr
o-tinned
O Temp, op.
max:8SC
O Temp, op.
min:-0SC
O Voltage rating,
AC:V
.mm
T&E
ellow O Area, wire
size
min:.6mm
O Area, wire
size
max:6.6mm
O Current
.00mm
and
6.00mm
T&E

rating:8A
O Material,
contact:Coppe
r
O Material,
insulator:Colo
ured Vinyl
O Plating,
contact:Electr
o-tinned
O Temp, op.
max:8SC
O Temp, op.
min:-0SC
O Voltage rating,
AC:V

Crimp
Position the crimp in the jaws oI the crimp tool (in the recess marked with the same colour as the
crimp), and squeeze gently so as to grip the crimp without squashing it:

You should position the crimp so that the active part oI the jaws are directly over the metal part
oI the crimp, leaving the empty part oI the plastic insulation sticking out
You want the length oI exposed conductor to be roughly equal to halI the length oI the inner
metal part oI the crimp terminal ( - 8mm is usually about right), such that each wire Iills halI oI
the terminal. Note that butt splice crimp terminals like those shown in the picture do not usually
have any central stop to prevent the wire passing right through the terminal. With thinner wires it
does not matter iI the wires cross over, however with thicker wires there may not be enough
room in the terminal Ior this to happen - so iI you insert a wire too Iar Irom one side, you will not
be able to get the other wire Iar enough inserted on the other to make a reliable crimp.
Insert the wire such that the insulation is tucked inside the shrouded part oI the crimp:

Once the crimp is made, inspect the crimp to ensure it looks correctly compressed and the wire is
still in the correct place with no uninsulated section showing. Attempt to pull the wire out oI the
crimped connection to veriIy that it is held properly:

Repeat Ior the other wires in the cable:

Finally complete the crimp to the other cable:

Test
Once the cable is joined, you can test your work. As described above the Iirst test is mechanical:
that the wire should not pull Iree oI the crimp when applying reasonable Iorce. A visible
inspection should also be made to ensure that none oI the conductor is exposed at the ends oI the
insulation on the crimp connector.
To test electrically, Iind where the cable you have repaired connects to the existing circuit at both
ends. Disconnect both ends. At one end twist the phase, neutral and earth wires together. Now
use a multimeter on a low ohms range to measure the resistance between phase and neutral,
phase and earth, and neutral and earth at the untwisted end oI the cable. The two readings taken
with the earth wire ought to be equal, but larger than the phase/neutral one since the earth wire is
typically thinner than the phase/neutral wires.
Compare your results with the anticipated resistance values shown in the table here in the
Electrical Circuit Faults article. II all is well untwist the wires and reconnect both ends oI the
cable to the circuit ensuring the screw connections are well made and tight.





Wlre rexlxtunce tuble
W|re CSA]CC (mm) mChms ] metre L]N round tr|p (mChms) L]N + CC kound tr|p (mChms)
10 / 1 1810 3620 3620
13 / 1 1210 2420 3020
23 / 13 741 1482 1931
40 / 13 461 922 1671
60 / 23 308 616 1049
100 / 4 183 366 644
160 / 6 113 230 423
Table Notes
1 1he Wlre Cross SecLlon Area (CSA) column also lndlcaLes Lhe Lyplcal CSA of Lhe CC wlre used ln
a modern cable
2 1he mChms / MeLre value lndlcaLes Lhe reslsLance of a slngle lengLh of Lhe maln L or n
conducLor ln a cable
3 1he L/n round Lrlp value ls slmply double Lhe slngle lengLh value lL lndlcaLes Lhe expecLed
reslsLance readlng you would geL measurlng beLween L and n when you have placed a shorL aL
Lhe far end
4 1he L/n + CC value ls slmllar Lo (3) buL lnsLead lndlcaLes Lhe round Lrlp reslsLance expecLed lf
measurlng beLween L or n and CC wlLh a shorL beLween Lhese aL a dlsLanL polnL (Lhe CC
Lyplcally belng Lhlnner Lhan Lhe maln conducLors ralses Lhe value)