For decades the electrician had few choices when confronted with the need to 
splice electrical cables. Recent innovations in low voltage (1000 V) electrical splicing offer many new cable splicing and jacket repair alternatives to electrical contractors and facilities maintenance personnel.
PRE-INSULATED MECHANICAL CONNECTORS:
DIRECT BURIAL & SUBMERSIBLE
PRODUCT: POLARIS BLUE™
Introduced in 2006 by NSi Industries, Polaris Blue™ is UL listed for direct burial and submersible applications. The product is available in two configurations: A single conductor in-line splice for wire sizes ranging from #6 through 250 MCM and a multi-port configuration for feed/tap as well as stub applications. The multi-port submersible product is also available from #6 through 250 MCM.
These connectors are UL listed for use with all cable constructions suitable for wet/damp locations such as THHN, XHHW, USE and others. They are not recommended for use with extra-flexible cables.
HOW IT WORKS:
Polaris Blue™ incorporates a traditional dual-rated aluminum mechanical set screw connector and a high-strength dielectric plastisol vinyl insulation. Cable entry points utilize an elongated plastisol sleeve to seal the connector from the external environment. These connectors are rated for application up to 600 volts and in conjunction with 90 DC rated cables. Rated for use down to -45 degrees C, they are highly abrasion-, UV- and chemical-resistant and will not support combustion. The splice is reusable/re-enterable. Custom configurations are available.
HOW TO INSTALL:
The splice is accomplished by simply inserting the stripped conductor into the cable entry sleeve and tightening down the hex head set screw to the recommended torque value. After replacing the access plugs in both the set screw access points and any unused cable access points, the connection is complete and ready for submersion or burial.
HOW IT HELPS:
These connectors eliminate the need for expensive and time consuming resin based splice kits, heat shrink, or rubber and vinyl taping in submersible applications, lowering installation costs and allowing for easy re-entry into the splice for service.
You will want to keep these on the truck for the inevitable broken/damaged cable emergencies.
PRODUCT: MULTI-SEAL®
A similar technology is offered to the electrician by companies such as The Homac Companies and CMC (Connector Manufacturing Co.). Homac’s Multi-Seal® products utilize injection molded EPDM rubber or thermoplastic elastomer insulation over a dual-rated mechanical connector. They are available in both in-line and multi-port configurations. These connectors offer a range-taking feature in a submersible & direct burial splice.
HOW IT WORKS:
Homac’s Multi-Seal® RAB 350 Series incorporates through-hole cable ports and translucent inspection windows to ensure proper cable insertion. Tethered screw plugs prevent plug loss during installation. Services may be removed and the connection is easily resealed with the attached plug feature.
These splice connectors are rated for direct burial, submersible and/or overhead applications to 600V and available from #12 through 1000 MCM conductor sizes.
HOW TO INSTALL:
To complete the splice, the installer must strip the conductor, remove the entry sleeve cone and nip out the section of cone equivalent to the conductor OD. Then the installer places the conductor into the cone, inserts the conductor under the set screw and tightens down to the recommended torque value. They then insert the cone into the entry sleeve. Last, the installer must replace all access plugs.
HOW IT HELPS:
In a variation on this theme, Homac offers an insulation displacement version of the pre-insulated submersible connector in both in-line and stub splice configurations.
Homac’s Barracuda® series is designed to pierce the insulation and penetrate the conductor eliminating the need to strip the insulation prior to installing. The connector includes a shear-head breakaway torque screw feature that ensures a properly installed connection every time.
These connectors accommodate conductor sizes from #10 through 350 MCM and are 600 V rated.
PRE-INSULATED MECHANICAL CONNECTORS FOR MOTORS
PRODUCT: POLARIS GREY™
Polaris Grey™ is UL listed for fine stranded flexible and extra-flexible copper cable constructions such as DLO cable, type G, type W, G-GC, SHD-GC and motor lead wire from #14 thru 3/0.
HOW IT WORKS:
Polaris Grey™ is a pre-insulated mechanical connector that includes a ferrule under the set-screw to ensure that the cable strands are tightly bundled and properly crimped to ensure a gas-tight termination of fine stranded wire. These connectors are re-useable and replacement ferrules are available.
HOW TO INSTALL:
To terminate simply insert the conductor into the ferrule located under the set screw and tighten the hex head set-screw to the proper torque value. Replace access plugs.
HOW IT HELPS:
An excellent alternative to taping wire nuts, split bolts or compression stub splices, lowering installed costs and allowing for easy access for motor service.
These connectors are not appropriate for direct burial or outdoor applications.
PRE-INSULATED MECHANICAL CONNECTORS – code cable constructions
PRODUCT: PRE-INSULATED CONNECTORS
Pre-insulated connectors have revolutionized how the electrical industry terminates and splices electrical cables in trough, wireway and junction boxes. These connectors/splices are available as in-line splice, multi-port feed/tap and stub configurations for cable sizes from #14 thru 750 MCM.
These connectors are appropriate for most copper and aluminum cable constructions. They are 600V rated for 90˚ C cable and suitable for use at temperatures down to -45˚ C
HOW IT WORKS:
For splicing and tapping of both copper and aluminum cable constructions. Pre-insulated connectors have eliminated the need for time-consuming splicing and tapping with split bolts, mechanical or compression connectors and tape, allowing for easy re-entry for service or moves, adds and changes.
HOW TO INSTALL:
Pre-insulated connectors have become an extremely popular solution for distribution in troughs, junction boxes and pull boxes. Pre-insulated connectors save time in the field; simply strip the wire, insert the cable under the set screw and tighten down the set screw to the recommended torque value.
Resin Splice Kits: Direct Burial & Submersible
PRODUCT: SHAKE N’ SEAL 
For those electricians who prefer resin style splicing, Dover, NH based Uraseal has introduced a new and improved technology called
SHAKE N’ SEAL which utilizes a two part urethane encapsulant provided in a tube form. UL listed for direct burial and submersible applications up to 600 volts and for conductor sizes from #18 through 250 MCM. Larger kits accommodating conductor sizes through 750 MCM and 5KV are available but are not UL listed.
HOW TO INSTALL:
To complete the splice, simply flip the wafer in the tube and shake from 30 to 60 seconds. Next, open tube by cutting the crimped end, remove the wafer and insert the splice into the tube. For certain through splices a hinged mold is supplied that is snapped into place, then the urethane encapsulant is poured into the mold.
HOW IT HELPS:
Total resin set-up time is 3 to 5 minutes. Total installation time averages 10 to 15 minutes as compared to 30 to 45 minutes for traditional epoxy resin kits. These products significantly reduce both the material cost and installation time associated with traditional epoxy resin splice kits. They actually make resin splice kits easy to use!
PRODUCT: FLOOD-SEAL® SPLICE KIT
For a convenient, economical and reliable installation, Homac’s Flood-Seal® splice kit line sets the standard. Kits include both mechanical and compression copper or aluminum splices, packaged with slip-on rubber insulating covers. Aluminum connectors are pre-filled with oxide inhibitor. The rubber insulating sleeves provide a sealed connection and feature cut rings that accommodate a wide range of cable sizes.
Suitable for direct burial/submersible applications, these splice kits are UL Listed and available for cable sizes from #14 thru 1000 MCM.
COLD-APPLIED Splicing
PRODUCT: ROLL-ON SPLICING
Introduced in 1986cold-applied roll-on direct burial splice kits offer a fast, simple and inexpensive alternative to cold shrink, labor-intensive tapes, heat shrink and resin kits.
HOW IT WORKS:
Each kit is range taking. For example, the smallest splice covers a conductor range from #8 through 2/0, reducing the number of SKU’s required for inventory. These splices are UL486D listed and are suitable for installations as low as -15˚ F (-25˚ C). They are compatible with standard polymeric and elastomeric insulated cables. Suitable for direct burial in up to 1000V applications and available for cable sizes from #8 thru 1000 MCM.
HOW TO INSTALL:
The roll-on splice kits are a fast, simple and durable splice for low voltage compression connector applications. Simply roll the EPDM elastomeric sleeve onto one side of the cable, complete the splice, apply mastic, and roll the sleeve back over the connector, centering the elastomeric sleeve over the connector.
HOW IT HELPS:
These splices are as simple as splicing gets, and will save time and simplify life in the field.
PRODUCT: Roll-ON Motor Stub Kit
In a variation of the elastomeric Roll-On splice kit mentioned above, a Roll-On stub kit offers a quick, easy method of insulating and sealing stub connections in motors or street lighting.
HOW TO INSTALL:
Simply roll the stub splice cover over the connection. If sealing from the environment is required, wrap the mastic material provided in the kit between and around the legs of the phase prior to installing the Roll-On cover. Three covers are provided in each kit. These splices are easily re-enterable for motor service and re-useable.
Available from conductor size #14 through 500 MCM for applications up to 1000V, these kits are UL listed for direct burial and comply with the ANSI 119.1 1986 underground splicing standard when used with the mastic provided in the kit.
PRODUCT: COLD-APPLIED GEL SPLICE KITS 
In 1998, cold-applied silicone gel splicing technologies were introduced to the utility and transportation industries, and are becoming popular in the traditional construction and industrial electrical markets.
HOW IT WORKS:
Available in several forms for a variety of splicing and stub applications, the silicone gel material completely encapsulates the connection and seals out moisture. The sealing material remains pliable for the life of the cable. Silicone Gel has the added benefit of preventing corrosion and oxidation via the encapsulation process and wetting action of the gel on the cable and connector surfaces.
HOW IT HELPS:
This technology combines the benefits of resin type splices, fast installation and reduced splice failures due to installation variables. They eliminate the need for taping, complicated resin molds or the use of a torch in splicing and tapping.
PRODUCT: Wrap-Around Gel Splice kits
HOW IT WORKS:
This gel closure sleeve is a stretchable hardened plastic outer jacket combined with an internal layer of Silicone Gel that conforms to the splice and cable jacket, sealing out moisture and other contaminants in direct burial and manhole applications.
HOW TO INSTALL:
Installation is simple; after installing the connector the closure sleeve is centered, wrapped around the connector, and snapped shut. Finally, two cable ties are installed on each end of the closure sleeve and cinched tight. The splice is complete and ready for burial.
These gel closures are suitable for in-line compression and mechanical splices up to 1000V and for conductor sizes from #14 through 750 MCM.
They are UL listed for direct burial up to 4/0 and ANSI C119.1 1986 compliant for underground applications through 750 MCM.
PRODUCT: Gel closures
These clamshell style closures use the same Gel technology as the Wrap-Around products, making splicing as simple as placing the finished splice in the closure and snapping it shut.
The hinged closure is molded out of UV and impact resistant polypropylene and filled with insulating silicone gel material. The closure includes a frangible finger design at the conductor entry/exit point to ensure a tight environmental seal.
These closures come in three varieties: in-line mechanical splices for #2 to 4/0 conductors, mechanical splice/taps from #14 to 2/0, and H-frame compression connectors from #14 through 350 MCM.
PRODUCT: Gel stub kits
Available in both street lighting and motor termination kits gel stub kits offer a low cost, durable, re-enterable alternative to taping, heat shrink or resin kits. Appropriate for use in a variety of applications including street lighting and outdoor lighting, motor terminations, irrigation applications, sealing around wire nuts, and HVAC terminations.
HOW IT WORKS:
The stub kits are made up of a UV and abrasion resistant flexible outer cap filled with a silicone gel sealant, and a locking collar. The gel seals out the environment and insulates.
HOW TO INSTALL:
To install, simply push the gel cover down over the connection and snap the collar shut, ensuring that the connector is located below the collar and locked in place.
PRODUCT: Street Lighting Stub Kit
Gel stub kits for street lighting are available for #14 thru 2/0 feeds and #14 thru #6 taps. 1000V rated. Suitable for use in temperatures from 140D C to 105 D C. UL listed.
PRODUCT: Motor Stub Kits
Gel Motor stub kits are available for conductor sizes from#16 thru 500 MCM. Rated for up to 1000V. UL listed. Motor stub kits include three gel covers per kit.
New Technologies are available to help the electrician save time, effort and money when the inevitable “ Uh Oh” broken or damaged cable emergency happens. These products are readily available through your local electrical distributor.
