The double roller design is used to string distribution lines via helicopter. It is compatible with the ACRS-1000 mount base, which is included with the purchase or rental, allowing for angle adjustments in 15-degree increments without requiring removal from the distribution pole cross-arm. Constructed from 6061-T6 aircraft-grade billet aluminum, this design eliminates the need for linemen to be on the pole while helicopters fly the sock line/ conductor. A cross-arm mount ratchet assembly is included.

 

BTI Stringing blocks/Bases

 

Introducing the patented BTI stringing blocks and bases. Our products are designed with safety, quality, and efficiency in mind, developed in partnership with experienced journeyman linemen and industry pilots who currently use rollers for wire stringing. After years of stringing wire conventionally and with helicopters, they recognized the need for better tools for the job. BTI rollers have been established as leading-edge rollers and have been tested and utilized since 2016. Many years of testing and design changes have resulted in our current high-quality product. Our rollers suit nearly every scenario encountered in most distribution wire stringing applications. The TRWG-M-1000 is the only helicopter stringing block on the market featuring a double roller design. Our rollers have removable helicopter guides, allowing them to function in conventional wire strings. The extendable, bright orange helicopter guides are designed to provide more surface area and better visibility for pilots, creating a safer and more efficient environment. The double roller design can be used for every structure, eliminating concerns about uplift issues, which ultimately can cause wire or equipment damage during stringing operations. During helicopter wire stringing, the double roller design offers the aircraft greater latitude to gain altitude without worrying about conductor damage or hang-ups due to sock line/ conductor riding to the top of the roller. Our all-angle roller design is the only roller accommodating helicopter wire strings. These rollers perform exceptionally well in challenging angles where setting up standard rollers with a helicopter guide is tricky. These all-angle rollers can hold 180 degrees of swing, ensuring they find the “sweet spot” and roll smoothly for a successful wire string every time.

Every roller placed is only as good as its base, just as a house is as good as its foundation. We took this concept very seriously when developing a base that is not only universal but also extremely strong, unlike any other base on the market. While working with the Journeyman lineman, we quickly identified concerns regarding the strength and versatility of the competitors’ bases. We developed the ACRS-1000 base to stand apart. This base is machined from 6061-T6 aircraft-grade aluminum and features an adjustable slide and strap to accommodate different sizes of crossarms. Additionally, we designed a stronger and more adjustable platform for the roller to sit in, allowing the lineman to adjust the angle in 15-degree increments without removing the base from the arm. Our bases are designed so that the lineman can position them for the most effortless use of the ratchet strap, rather than the angle they need to achieve, resulting in a highly user-friendly base.

Safety:

Some of the hazards we identified were as follows:

A lineman is working on the pole while helicopters fly overhead.

Our theory is that people are the most essential part of any project. The more you can do to reduce their risk exposure, the better. These rollers create a scenario where the helicopter and the roller perform the work. We wanted to design rollers that eliminate the need for linemen to be on the pole while helicopters fly the sock line/conductor. The double roller design allows for this in every scenario. Straight through, up strain, angles- it does not matter; this roller can accommodate everything. The all-angle roller has covered angles or scenarios where the double roller doesn’t work.

A concern is that linemen must “hold the pull” to place the sock line or conductor into the stringing block.

As mentioned above, our goal was to eliminate linemen needing to climb up the pole during operations. Any time you have to hold the pull during wire stringing so the lineman can place the conductor in the roller, you expose the string to additional risk and, even worse, expose the lineman to more risk. Sock line bags to the ground, tensioners stop turning, wires start bouncing, among other issues. Incidents where linemen get their hands caught in rollers are eliminated because they do not need to be there!

Pilots must fly at lower than desired altitudes between structures at times. The terrain, congestion with homes, or other items create hazards on the ground that the pilots must pay close attention to. Having a double roller design at every structure allows the pilot to better manage altitude without being concerned about causing damage to the sock line/conductor, the roller, or any equipment on the structure. Once the sock line/conductor is in the roller, the pilot can depart each structure at a higher altitude, allowing for better clearance over terrain, existing conductors, and less rotor wash on the ground, which in turn will reduce exposure to the pilot, aircraft, and ultimately lower risk on the ground.

 

 

Pilots are having issues placing the sock line or conductor in the fly rollers:

Extendable guides give the pilot an advantage and reduce issues with the sock line or wire hanging up during the pull. Extending the guides gives the pilot a much larger surface area to land the sock line/conductor. The guides are painted bright orange to aid the pilot in visually identifying where to place the sock line or conductor. The better the pilot can see, the less likely there will be an issue with missing the roller.

 

 

 

 

 

Efficiencies:

During the development of this roller, one of the issues identified was the number of linemen and extra equipment it takes to string wire with helicopters. The issue was driven by the notion that no double roller on the market could accommodate helicopter stringing. Moreover, the available rollers did not meet the expectations of the linemen and pilots. Linemen were required to be up any poles with up-strain, angles, or in some cases, even straight through. This significantly increases personnel and equipment, leading to a much higher cost per wire string, not to mention the additional exposure to risk. Using the BTI roller will eliminate the need for all extra equipment and personnel. These rollers can perform tasks typically handled by linemen, allowing for a reduced workforce required or a redistribution of linemen to areas where they are more effective, thereby creating a safer and more efficient project.

Other concerns raised were related to go-backs on wire strings. At times, the conductor could be damaged, or the strands could be flattened due to the wire riding on the top of a standard roller (without a top roller). This can ultimately cost the utility or contractor money if the wire must be replaced due to insufficient rollers being used. BTI rollers were developed to reduce the likelihood of conductor damage and eliminate mistakes when placing rollers in uplift scenarios in any conventional or helicopter string. Occasionally, linemen may not identify certain sights as needing a double roller. Still, once the string is underway, it becomes apparent that the sock line/conductor may pull tighter than expected, creating a hazardous or damaging situation where the sock line/conductor is compromised. Linemen must hold the pull to change the roller to a double uplift roller. Using BTI rollers at every sight eliminates this concern.