Unequal Gauge Wire Splicing: Hidden Risk in Utility Networks

In electrical distribution systems, splicing wires of different gauges presents a serious risk—often overlooked, yet responsible for fires, outages, and costly failures.

📊 Key findings:

⚠️ 15–20% of splice failures involve gauge mismatches
🔥 Fire-related damages average $375,000 per incident
⏳ Failures can occur anywhere from 1–20 years post-install due to degradation, with the majority of failures occurring between 10 and 20 years post-install

🛠️ The solution? A 3-pillar approach:

Engineering controls (ampacity protection, proper connectors)
Certified installation practices
Advanced detection using IR & RF technologies
Together, these reduce fire incidents by up to 90%

💡 At nfoldROI, we’ve developed a data-driven solution that supports utilities in proactively identifying and managing these splice risks. Our 4D-Utilities Service Offering combines targeted inspection, predictive maintenance, and visual validation—improving safety and reducing emergency repairs.

As networks age, splice integrity must be a priority. We’re here to help you address it—with precision and foresight.

#Utilities #DigitalTwin #GIS #SmartGrid #AssetManagement #ElectricalSafety #InfraredThermography #RFMonitoring #PreventativeMaintenance #DistributionNetworks #nfoldROI #SpliceManagement