The WaveTimer by Vulcan Line Tools: Measuring Overhead Conductor Sag & Tension

A studio shot of the WaveTimer with the power on.

A New Standard for Overhead Conductor Measurement

When Zac Young, CEO and Founder of Vulcan Line Tools, first designed the WaveTimer, he had one goal: build a tool that makes power poles more resilient. The WaveTimer was the first tool Zac built and it kickstarted our entire company. When Co-Founder, Hayden Patteson, joined VLT shortly after, he and Zac refined the tool into the sleek, one-of-a-kind hardware that it is today. So what exactly is the WaveTimer? The following article will provide a detailed overview of the WaveTimer’s technical specifications, how it works, why it is important, and its various use cases.

What is the WaveTimer? The Most Accurate Tool for Measuring Sag and Tension in Overhead Conductors

In simple terms, The WaveTimer is a field tool that measures sag and tension in overhead conductors. For readers who are unfamiliar with electric power terminology, this means it measures how much a power line, aka a conductor, sags towards the ground. The tool features rubberized housing, waterproof internals and it is powered by a standard 9V battery. It is also Bluetooth capable, allowing users to connect to the Vulcan Line Tools App, which is free on the App Store. We offer WaveTimers for both transmission and distribution systems.

How the WaveTimer Uses the Return Wave Method to Measure Conductor Sag and Tension

Utilizing the “return wave method” for measuring sag, the WaveTimer records the time it takes for a physical wave to bounce from one pole to another when a conductor is physically jerked. It also measures conductor temperature with an infrared sensor–a marked improvement from the ambient temperature readings that are common in the field today. To use the WaveTimer, users simply attach the tool to a conductor, jerk the line with their hand or a rope, and then read the recorded sag values on the VLT app. 

We did not invent the return wave method; it is a standard practice in the industry. However, performing a return wave test without the WaveTimer usually requires a stopwatch, which is subject to user error. In contrast, the WaveTimer leaves no room for error and it allows users to load their sag charts–a table which specifies the sag that should exist in each wire–into the app. This allows users to know what their sag values should be for the wire type they select in the app. Once the wave is recorded, the VLT app makes it easy to export results as a detailed PDF report.

A demonstration of the WaveTimer during the return wave method of testing sag.

Why Accurate Sag and Tension Measurement Matters for Power Line Safety and Resilience

Spans of overhead conductors are engineered with specific amounts of sag and tension so that they do not overload the poles they are attached to. Certain factors like wire size, temperature and span length influence these calculations, and failure to construct spans accurately leave them vulnerable to extreme weather events, clearance violations or unintended faults. 

For example, if the tension in a span is engineered to withstand wind speeds of 130 mph but the conductors are pulled too tight, the poles could fail at significantly lower wind speeds. Consider the opposite: a span with too little tension could sag dangerously low, increasing the risk of a vehicle clipping the low hanging wire or of conductors slapping together, causing faults. In each example, proactive construction and targeted audits can mitigate these risks.

Field Applications: How Linemen Use the WaveTimer for Power Line Construction and Audits

A linemen holds the WaveTimer, showcasing its durable design.

Linemen can use the WaveTimer and one of our Dynamometers to accurately measure conductor tension during construction. If a Dynamometer is not handy, linemen can use the WaveTimer to determine the sag values in a span and its tangents. The VLT app makes converting these values into corresponding tension values easy. Although we advocate for these practices in distribution construction, measuring sag is most commonly executed when pulling spans between transmission towers. Usually, linemen perform this task with a return wave test and a stopwatch, or by visually measuring sag with scopes or total stations. Although these methods work, the WaveTimer’s objectivity and streamlined use make it more efficient and effective than any other method in the field.

Unfortunately, the millions of line miles that exist in electric grids across the globe were not all constructed with an emphasis on matching precise sag measurements. Using the WaveTimer to check existing spans is an exceptionally effective way to determine which conductors have dangerous sag values and which do not. Linemen can perform these targeted audits with the WaveTimer, ensuring each span is constructed properly and mitigating the pole owner’s liability. We built the WaveTimer to perform this very task, and it remains unmatched in achieving the intended results.

Conclusion: A New Benchmark for Monitoring Overhead Conductors

The WaveTimer represents the future of sag measurement in transmission and distribution systems. By combining accuracy, ease of use, and modern connectivity, it solves one of the most persistent challenges in electric utility work: ensuring spans are built and maintained to withstand the forces they encounter. Whether used during construction or for targeted audits of existing lines, the WaveTimer equips linemen and engineers with the confidence that their spans meet design standards, improving grid resilience and safety. At Vulcan Line Tools, we are proud to offer the WaveTimer as a testament to innovation, precision, and our commitment to strengthening critical infrastructure.

To learn more, you can visit the WaveTimer page on our website or check out our WaveTimer video on Youtube!