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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:

  1. Engineering controls (ampacity protection, proper connectors)
  2. Certified installation practices
  3. 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.