How to Tension Guy Wires

Guy wires are popular methods for stabilizing large poles and towers in various industries. From power and telecommunications lines to railway signals and wind turbines, guy wires play a crucial role in holding up many tall structures. 

Guy wire installation and maintenance involves tensioning the lines for optimal performance. The amount of tension needed for your applications depends on many factors, including the structure you're stabilizing and the wire length and strength you want to use. The first step in knowing how to tension guy wires is understanding the materials you're working with and the parameters for safe and effective methods.

The Importance of Guy Wire Tension

Guy wires transfer some of a tall structure's weight to the ground off to the side through their stress. One of the wire's ends connects to a high point on the structure, while the other anchors into the ground. The entire wire setup creates a diagonal line that helps secure the structure from the foundation all the way up. 

Historically, guy wires have been essential for stabilizing tall structures. The term “guy wire” derives from the French word “guie,” which means “to guide.” In the 1600s, Dutch sailors adopted the term “gei,” referring to the ropes that stabilized ship masts. The name later evolved into “guy.”

Guy wire usage expanded with advancements in materials like high-tensile steel. Since guy wires stabilize structures and transfer their weight, installing them at the proper tension is crucial. 

Tensioning wires too tight may cause compression failure in a structure, causing it to buckle and even collapse from too much pressure. High tension can also make the wires vibrate during heavy wind or earthquakes, inducing excessive wear and tear on wire and structure components. 

A wire that's too loose — meaning a sagging wire — can gallop or move with the wind and other weather events, which can become an issue if it contacts nearby objects or if the excessive movement places stress on the structure's operating components. Loose guy wires also raise the risk of mechanical failure and fatigue damage and can even cause structural insecurities.

For best tension results, only use high-quality products, and always enlist the help of a professional. Routinely check your guy wires' tensions to ensure your commercial structures are as stable as possible, and adjust the tension as needed.

Factors That Influence Tensioning

Several factors influence guy wire tensioning, including:

  • Environmental conditions: Strong winds can apply significant lateral forces on structures, requiring increased tension in guy wires to counteract these forces. Changes in temperatures can also cause wire material to expand or contract. Steel wires can become smaller and tighter in cold weather while becoming longer and thicker in heat, due to metals shrinking and expanding during these temperatures.
  • Load considerations: The weight of antennas, cables or other equipment attached to the structure will affect how much tension is needed in guy wires. Additionally, the accumulation of snow or ice can add extra weight, necessitating adjustments to the tension to ensure stability.
  • Installation angle: Guy wires' anchored angle will affect their effectiveness. A steeper angle generally provides better support but may require more tension.
  • Wire thickness: Thicker wires can handle more tension than thinner ones, as they contain more material to resist being pulled apart.
  • Wire length: Longer wires need more tension than shorter wires to keep the ends from pulling apart.
  • Flexibility: Wires made out of more flexible materials stretch rather than tighten when you pull on them.
  • Structural design: Taller structures typically require more robust tensioning solutions due to the increased leverage from wind and other forces. Guy wire configurations, whether in triangular or quadrilateral patterns, will impact how the forces and tension levels are distributed. The more force you apply, the more tension in the wire.
  • Maintenance history: Over time, wear on components can affect tension levels, requiring more regular inspections and adjustments.

Equipment Needed to Tension Guy Wires Safely

The first step in tensioning guy wire is to gather the correct equipment for safe maintenance. Once you have your guy wire, you'll need additional hardware to attach it to your structure with the correct tension.

Key guy wire tensioning equipment includes:

  • Guy grips: Also known as preformed guy grips, these feature gripping points that securely connect and clamp ground wires, conductors and fiber optic cables.
  • Dead-end guy grips: These grips determine the guy wire's end. They are often useful for overhead line transmission.
  • Guy assembly: A guy wire and all attachment hardware make up the general guy assembly. Big-grip dead ends, for instance, are one-time-use guy wire tensioners you can use during initial wire installation and reapply during new installations and re-tensioning. You'll also need wire rope clips, which are specialized fittings that clamp the loose ends of guy wires to secure eye loops. 
  • End sleeves: When tensioning guy wire with big-grip dead ends, end sleeves attach on the ends of the wires to prevent unraveling while the wires are at high tension. 
  • Wire-pulling grips: Wire-pulling grips create temporary tension on guy wires until the team tightens or loosens them to ideal levels. 
  • Come-along: A come-along is a hand-operated wire lifting device that helps adjust guy wire tension by pulling wire in or letting it out. 
  • Dynamometer: Dynamometers measure guy wire tension with built-in analog load cells or digital scales. Installers use them to determine when a guy wire reaches its target load. 
  • Guy clamp: Cable suspension clamps stabilize rods with anchors and cables on communication pole lines. They help secure steel strands.
  • Guy thimble: A wire rope thimble forms an oval wire eye that fixes to eyebolts and guy wire rods. These are often hot-dip galvanized for durability and corrosion resistance.
  • Turnbuckle: A turnbuckle adjusts tension by pulling together or pushing apart guy anchors.

How to Measure Guy Wire Tension

When installing structures with guy wires, raising them at the proper tension is crucial for optimal operations. Once you've installed the guy wire, routine tensioning can also help keep your structure in good condition over time. You can measure guy wire tension either directly or indirectly.

Direct Methods

Direct measurement involves attaching a dynamometer to a come-along and wire-pulling grip combination. This method can be very accurate, as it places the load cell directly in line with a guy wire's load path. 

Indirect Methods

Standard indirect methods for measuring guy wire tension are:

  • Pulse method: After making a guy wire pulse, or oscillate, you can measure the time it takes for the pulse to move up and down the wire. Trained professionals can accurately perform this test and the appropriate calculations.
  • Tangent intercept method: The tangent intercept method is a useful test for structures with larger guy wires managed by crews with specialized training. By sighting up a guy wire and finding an intercept point at the sag of the wire, professionals can calculate the tension based on where the direct line of sight intercepts the point where the guy attaches to the tower.
  • Shunt dynamometer method: The shunt dynamometer method uses a tool that attaches to the wire and applies force. This device measures the wire's deflection and converts this to a tension measurement.

Guy Wire Tensioning Procedure

As with any guy wire procedures, you should work with professionals who know how to tighten wire ropes, following all proper steps and safety procedures. Find a professional you trust to follow these parameters:

  • Safety: Crew safety should be everyone's top priority in any situation involving tensioned guy wires. When working in the vicinity of any electrical wires, installers should always note any live wires that could pose a safety risk. They should also wear proper personal protective equipment, including hard hats, rubber-soled boots and protective sleeves. 
  • Weather: Only install guy wires on dry days without wind when there's no chance of rain or electrical storms. Harsh weather can complicate guy wire installation and cause safety hazards.

To ensure these wires are properly tensioned and maintained for optimal stability and safety, professional teams typically follow these installation steps:

  1. Preparation: Confirm all wires and hardware are secure on the structure the crew is lifting.
  2. Using a gin pole: A gin pole is a common tool professionals use to raise and lower guy wire structures. Guy wires secure the gin pole to the ground, and raising or lowering the gin pole raises and lowers the structure it carries.
  3. Adjusting tension during lifting: As the team raises or lowers the structure, some of the gin pole's anchoring guy wires will tighten, while others will loosen. To keep each wire at optimal tension, check and adjust them as needed throughout the process until the structure is entirely in position.
  4. Attaching guy wires: One end of the wire is secured to the structure and the other to an anchor point on the ground. The crew connects three or four guy wires around the structure.
  5. Tensioning guy wires: Professionals know how to tighten cable equipment by using a come-along attached to a wire-pulling grip to draw in slack and tighten the wires. After the wire is tense enough, they employ turnbuckles to adjust the tension levels, ensuring they are taut but not overly tight for flexibility.
  6. Safety inspection: While checking for sagging, crew members inspect all connections for kinks, frays and the overall integrity of guy wires.
  7. Anchor installation: Lastly, the anchor devices are secured into the ground, ideally about two-thirds of the height of the tower structure.

The crew can follow their tightening methods in reverse to loosen guy wires, repeating these procedures as necessary to achieve the best results.

Partner With Bekaert as Your Guy Wire Supplier

Proper guy wire tensioning lets your supported structures achieve ideal operating conditions. Whether you're considering a new structure or want to adjust existing guy wires, Bekaert can help.

We're the leading supplier and manufacturer of commercial guy wires and wire products. Our quality product range includes various guy wire design capabilities for the power and communication industries.

Request a quote today to see how we can supply you with guy wires for all your utility applications!