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Forum Index : Electronics : How to repair frayed power cables?
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LadyN Guru  Joined: 26/01/2019 Location: United StatesPosts: 408 |
My brother being a construction worker comes across good deals all the time. Today, we are looking at 90' worth of 10GA multi strand, PURE copper, 3 core cables for $20, which I think is an amazing deal, but: These have had the outer insulation torn up and also some of the insulation on the core cables have torn up too, to the point I can see the multi strand copper that the insulation should have been protecting. Of course, this is why it's cheap - the construction company does not want anyone getting electrocuted or the job site burning down so they want to sell it for scrap and it's really VERY heavy. I think $20 is just above scrap price for just the copper - about 30lb my brother estimates. These are meant to carry power to BIG tools that need 2 phase 220v. BIG tools! I was thinking of applying heatshrink around the cores where theres damage and a larger heatshrink to wrap it up all around, BUT I would rather not cut the wires to get the heatshrink on them in the first place. Is there a way I'm not thinking of that this repair could be done? My brother is not going to let me buy this unless I present him a bulletproof plan to address the insulation issue. This will be scrapped today. If a picture helps, let me know and I will ask my brother to send me a few. |
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| Solar Mike Guru Joined: 08/02/2015 Location: New ZealandPosts: 1138 |
Depending on how many exposed breaks you have, potting compound comes to mind, its 2 pot stuff, mix together and sit the cable section in a plastic box or trough, pour over the resin and wait a few hours, will be 100% safe. Mike |
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| LadyN Guru Joined: 26/01/2019 Location: United StatesPosts: 408 |
Mike, could this work instead: https://www.harborfreight.com/super-strong-quick-drying-epoxy-92665.html .. or should I specifically get a certain potting compound? My concern with the epoxy is that it might become brittle over time or yellow and dry out in the sun which perhaps the potting compound is less likely to and hence provide better, lasting protection? |
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| Solar Mike Guru Joined: 08/02/2015 Location: New ZealandPosts: 1138 |
I would use the correct potting compound, it is very liquid when first mixed. Cable joiners use when joining high voltage under ground power cables. But does require the mold to contain it around the exposed wires. |
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| astroboy Newbie  Joined: 28/12/2014 Location: AustraliaPosts: 39 |
Hello N Would heat shrink tape be an option? For example: here There are many vidoes online about its use. I've got some but have not used it. Just an idea... John |
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| BenandAmber Guru Joined: 16/02/2019 Location: United StatesPosts: 961 |
How about liquid tape never used it but my wife bought me some of it be warned i am good parrot but Dumber than a box of rocks |
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renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678 |
Sorry N this may seem harsh, but if you can't afford to buy new cable that is safe to use you really shouldn't be tackling projects. Shrinktube or tape will not be anywhere as safe as the factory insulation. The last thing a project needs is sub standard dangerous parts used from the beginning. Sorry, but I would say this is a bad idea. Cheers Caveman Mark Off grid eastern Melb |
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mackoffgrid Guru Joined: 13/03/2017 Location: AustraliaPosts: 460 |
So thats 6mm2 cable ? 3 x 30ish metres of 6mm2 for $20. I would consider it but chop the ends off. That's a bullet proof plan for your brother. He's a good Brother. Either make good shorter leads from it or more likely use the good wire as a resource for winding transformers and choke etc. Make sure the freight etc doesn't tip the costs over the line. Cheers Andrew |
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| LadyN Guru Joined: 26/01/2019 Location: United StatesPosts: 408 |
We moved too slow and the 10ga cables were gone yesterday. The shift supervisor will keep an eye out for more and the brother says we will find some damaged 12GA cables, if not 10GA cables soon enough, which is the next time someone drives spinning blades over a cord at a construction site. Mark, please dont use sorry at all in advice to me. These are very valuable inputs! How would I learn otherwise? Andrew, OK, so you're advocating to retain portions of the cable that still has factory insulation or use this in an application where there's no need for plastic insulation at all? I am a very lucky girl. Was born in a great country. Got a wonderful family and always find good mentors. I am trying to do justice to my luck and fortune. |
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| renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678 |
N, sometimes you can get as new looking cable from metal scrap yards/dealers. One close to me stopped people coming in for safety reasons, but sometimes literally as new looking cable would be in the bins there for re processing. Pity really as it all gets melted down and all the insulation getting melted would give off nasty fumes. If even 10% of that could get re purposed that would be much better for the environment. Less fumes emitted and less energy wasted in melting. Some clearly came from UPS installs, I got some 3 metre 70mm2 battery cables once with the lugs on the ends, they looked absolutely brand new. So ring around a few scrap yards and ask if they could put aside any decent cable. Probably in the USA with the propensity for people to sue, the scrap dealers would be even more cautious there, but it doesn't hurt to ask. Cheers Caveman Mark Off grid eastern Melb |
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| BenandAmber Guru Joined: 16/02/2019 Location: United StatesPosts: 961 |
 I got a pretty good deal on a 130 lb new 8 6 and 2 gauge wire today be warned i am good parrot but Dumber than a box of rocks |
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| mackoffgrid Guru Joined: 13/03/2017 Location: AustraliaPosts: 460 |
Yes, exactly. Copper is expensive so if you can pick it up cheaply - good. I admit I have never tried scrap yards, might be interesting. |
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| BenandAmber Guru Joined: 16/02/2019 Location: United StatesPosts: 961 |
On these big commercial jobs like that pipeline coming through it is cheaper for them just to recycle all the extra batteries and the extra wire then to haul it to the next job That's how I got my big John Deere starting batteries for my bus also When you like to Tinker recycling center is your best friend be warned i am good parrot but Dumber than a box of rocks |
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