How to Select a Dead End Clamp for ABC and Covered Conductors

ABC and covered-conductor dead ends fail most often at the RFQ stage: the buyer lists “tension clamp,” skips messenger diameter, and then wonders why a 50 mm² body will not grip a 13 mm insulated messenger. A dead end clamp has one job—anchor the conductor at terminals, angles, and section points without crushing the jacket. Selection starts with cross-section, messenger diameter, and breaking load, not with the product photo.

This guide shows how to select a CONWELL dead end clamp (metal or plastic tension clamp) for LV-ABC and covered conductors, using published model windows and NFC / EN references from the product pages.

What the clamp must do on ABC and covered lines

On insulated aerial bundled cable and covered conductors, the dead end clamp terminates the span and transfers axial tension into the pole hardware while the UV-resistant wedges grip the insulation evenly. CONWELL’s category notes call out aluminum-alloy bodies, stainless hardware, polymer wedges, NFC33-042 and EN50483-3 compliance, an operating window of −20°C to 90°C, and typical conductor coverage from about 16 mm² to 150 mm² across the metal tension range. These clamps are single-use: once installed under load, do not plan to reopen and reuse the same unit.

Keep the location clear. Dead ends belong on terminal poles, major angles, and section points. Intermediate straight poles take suspension clamps. Mixing the two is a design error, not a field improvisation.

Step 1: Lock conductor size and messenger diameter

Read both numbers on the cable datasheet—phase or messenger cross-section in mm² and outer messenger diameter in mm. CONWELL tension clamps publish both. If either value sits outside the printed window, change the model; do not force a smaller body onto a heavier insulated messenger.

For a common 50–70 mm² insulated messenger around 11–13 mm OD, shortlist PAL1500 when the span needs a 15 kN metal anchor, or PA1500 when a polymer body and 6 kN class match the design load. Step up to the PAL2000 category row (70–150 mm², 18 kN) or PA2000 (70–95 mm², 12.8–14.8 mm messenger) when the messenger grows. Small covered drops land on PA25.

Step 2: Match breaking load to the span design

Breaking load is not a shopping badge. It must sit above the design tension for that dead-end or angle pole. PAL1500 at 15 kN and PA1500 at 6 kN can cover overlapping mm² windows and still be wrong for each other if the sag-tension calc calls for the higher class. Ask the designer for the required kN (or design tension) before you freeze a cheaper plastic body on a long span or river-crossing terminal.

Step 3: Choose metal vs plastic body for the site

Metal PAL clamps (aluminum alloy, stainless hardware) are the default when mechanical class and corrosion life dominate the package—PAL1500 is the clear mid-range example with a published 10–13 mm messenger window. Plastic PA clamps use high-strength insulating housings, open-bail or anti-slip fastening, and self-tightening wedges; PA1500 and PA2000 pages reference NFC77-042 and tool-free install for LV insulated overhead cable. Pick plastic when the utility accepts the published kN class and wants jacket-safe, fast stringing. Pick metal when the load table pushes you toward 12–18 kN on the PAL rows.

Step 4: Confirm standards and insulation protection

Put NFC33-042 and EN50483-3 on dead-end datasheet requests for the CONWELL tension range, and keep third-party test reports in the vendor pack—CONWELL states those reports are available for the dead-end line. The grip must use UV-resistant plastic wedges that hold covered or ABC insulation without cutting it. If the drawing still shows a bare-conductor compression dead end, stop and re-check the cable type; that hardware is not a drop-in for insulated messenger ABC.

Practical selection path

Write the BOM by pole function first: dead-end quantity equals terminals plus hard angles, not total poles. Size each clamp by messenger mm² and diameter, then by required kN, then by metal vs plastic. Keep insulation piercing connectors and suspension clamps as separate lines under aerial cable accessories—a dead end does not make a branch tap, and a suspension clamp does not anchor a terminal.

FAQ

Can one dead end clamp cover every ABC size on a mixed feeder?

No. Cross-section and messenger diameter windows differ by model. Stock at least two sizes when small covered drops and mid-size messengers share the route.

Are CONWELL dead end clamps reusable?

No. They are single-use so clamping force and insulation protection stay consistent after the first install.

Which model should I shortlist for a 50 mm² insulated messenger around 11–12 mm OD?

Compare PAL1500 (35–70 mm², 10–13 mm, 15 kN) with PA1500 (50–70 mm², 11.2–12.8 mm, 6 kN). Choose from the design breaking load, not from which photo looks larger.

What standards should appear on the supplier datasheet?

Ask for NFC33-042 and EN50483-3 with the model’s cross-section, messenger diameter, and breaking load. Plastic PA pages also reference NFC77-042 for the tension-clamp install practice.

Where should these clamps be installed on the line?

At terminals, major direction changes, and section points. Use suspension clamps on intermediate straight-line poles.

What three data points should I send CONWELL for a fast quote?

Messenger or conductor size (mm²) plus outer diameter, required breaking load or span class, and metal vs plastic preference with quantity by pole type.

Practical Takeaway

Select the dead end clamp by messenger size, diameter, and kN first. For mid-size LV-ABC and covered-conductor anchors, shortlist PAL1500 when you need a 15 kN metal body, or PA1500 / PA2000 when a plastic tension clamp matches the load table. Send CONWELL those three fields—mm², messenger OD, and required kN—and ask for datasheets on the exact models before stringing starts.