Project Overview: Restoring Buried Cable Integrity with Advanced Splicing

In this Nanaimo scenario, we tackled a severed multi-conductor cable—likely a direct-burial URD type for power or irrigation—damaged by mechanical excavation, leading to exposed strands and potential short circuits. The repair process initiated with non-invasive fault location using time-domain reflectometry (TDR) to pinpoint the break within centimeters, followed by careful excavation to expose a 12-18 inch section for splicing. We utilized a mechanical compression connector for high-conductivity joining, applying torque to 50 in-lbs for optimal contact pressure, and sealed with heat-shrink tubing infused with adhesive for IP68-rated waterproofing.

Technically, conductor preparation involved stripping insulation to 1 inch, abrading oxidized copper (evident from green patina) with emery cloth to achieve bright metal, and twisting strands for uniform insertion into the clamp. Voltage testing post-splice confirmed <0.5% drop under load, while insulation resistance was measured at >500 MΩ using a megger, verifying no leakage. This method not only reinstates service but enhances durability against soil moisture, reducing future corrosion risks in BC's wet climate.