Underground Cabling
Underground Cabling
Underground Cabling
Underground Installation of
Optic Fiber Cable Placing
Issued
November 2013
Abstract
Underground placement is necessary and unavoidable in certain areas for various reasons
such as nature and heritage conservation, natural obstacles, aesthetics, space and safety.
Placing cables underground has the added benefits of reducing transmission losses, aiding
planning consent and reduced risk of service supply loss through extreme weather. This
practice covers the basic guidelines for installation of fiber-optic cable in underground cable.
Keywords
Manholes, winches, Sheaves, Jetting
Method
Contents
2. Introduction 2
3. General 3
4. Precautions 3
4.1 Cable Handling 3
4.2 LED and Laser Precaution 3
4.3 Optical Fiber Handling Precautions 4
4.4 Material Safety 4
4.5 Safety During Installation 5
4.6 Personal Protective Equipment 5
4.7 Traffic Safety 5
4.8 Placing Equipment 5
4.9 Cable Protection and Handling 6
5. Preparation for Cable Placing 6
5.1 Pre-Construction Survey 6
5.2 Cable Staging Area 9
6. Tools and Materials 10
6.1 Innerduct and Micro-Ducts 13
6.2 Lubricant 14
6.3 Sheaves, Quadrant Block, and Manhole Frame 15
6.4 Winches 15
6.5 Cable Blowing and Pushing Engine 15
7. Cable Placing Methods 15
7.1 Normal Cable Pulling Method 16
7.2 Bidirectional Figure-Eight Procedure 19
7.3 Placing Assistance 20
7.4 Back-Feeding Assist to Cable Pulling 21
8. Manhole Housekeeping 21
8.1 Cable Coiling 21
8.2 Racking Cable and Innerduct 22
9. Addition Information 22
Introduction
Underground cable is placed into ducts which are being built below the ground surface. In
urban areas where space for telecommunications cable is limited, it needs to be used more
efficiently. In underground installation, the conduit provides protection from both physical and
environmental abuse. The conduit protects cable from shifting rocks, aggressive rodents, and/
or damage from hand shovels. Underground cable that is in conduit is easy to replace or
upgrade. The old cable can be pulled out of the conduit and the new pulled in without extensive
and expensive digging. Underground cable and ducts are part of the underground conduit
system. Telecommunication conduits are made from various materials and buried directly into
the soil or encased in concrete. Fiber optic cables have provided a more optimal use of
available underground conduit space because of its small cable diameter and the much higher
communications traffic capacity of each cable.
Optical cable is usually placed in a 25 to 40 mm inside diameter (ID) sub-duct which is placed
into an existing larger diameter communications conduit. Most communications conduits can be
fitted with three or four sub-ducts. Sub-ducts are often referred to as innerducts. An innerduct
provides a more efficient use of the conduit system space, with a clean low coefficient-of-friction
pathway and an extra measure of mechanical protection for an optical cable.
If micro-duct cables are used, they are usually placed into small diameter ducts that are placed
inside of the innerducts, nested two levels within a communications conduit system. These
small diameter ducts are usually from approx 5 mm to 14 mm inside diameter and called micro-
ducts.
Micro-duct cable is blown (jetted) into the micro-duct. Normally, standard size fiber optic cables
are pulled into innerduct (sub-ducts).
1
Micro-ducts can also be placed directly into larger telecommunications conduits or can be factory
assembled into a composite unit of multiple micro-ducts.
3. General
The underground placing methods described in this document are intended as guidelines.
National, state, local, and corporate specifications, regulations, and industry recommendations
normally take precedence over these. It is impossible to cover all the conditions that may arise
during a placing operation. Individual company practices for placing fiber optic cable should
supersede any conflicting instructions in this document whenever they do not exceed the
cable's optical and mechanical performance specifications.
The methods used to place fiber optic cables in ducts are similar to those used to place copper
cable. Optical cable is a high capacity transport medium that is sensitive to excessive pulling
force, tight bends, and crushing forces, therefore, proper care must be taken during the
installation procedure.
Fiber optic cables are ordered in specific lengths as calculated by an OSP (Outside Plant)
Engineer. Their lengths are determined by measuring the distance between splice manholes
plus the excess cable length required for racking the cable at all manhole locations and slack
storage for maintenance. Additional cable length is required at each splice manhole to reach to
the actual splice location (often in a trailer or tent adjacent to the manhole). In addition, extra
length should be included in the ordered length to be available if errors are made during the
splicing operation. If the excess splice length is not known, the splicing foreman should be
consulted. Never cut a fiber cable without first consulting the OSP Engineer responsible for the
job.
4. Precautions
4.1 Cable Handling
All optical fiber cables are sensitive to damage during shipping, handling, and installation.
Some of the important parameters that need special attention during cable installation are:
Cable bending radius: Optical fiber cables are designed with a minimum bending radius
and maximum tensile strength. The cable should never be bent below its minimum bending
radius. Doing so can result in bending losses and/or breaks in the cable's fibers. Generally
the minimum bending radius of a fiber cable under load is 20 × D, where D is the diameter of
cable; the minimum bending radius of a fiber cable under no load is 15 × D.
Cable Placing Tension: Optical fiber cables are designed with a maximum tensile strength.
The cable should never be loaded beyond its maximum tensile strength. Exceeding the
cable's placing tension provided by Sterlite in the Cable Data Sheet/Specification, can alter
cable and fiber performance and shorten its service lifetime.
LED and Laser beams used in fiber optic testing and transmission systems are invisible to the
human eye and can seriously damage the eye. Viewing these beams directly may not cause
any pain and the iris of the eye does not close automatically as it does while viewing a bright
light. As a result the eye may not react to protect itself causing serious damage to result to the
retina.
Therefore,
Never look directly into a fiber end that has a laser or LED coupled to it.
Never look directly into a fiber end using any magnifying lense.
If an eye is accidentally exposed to an LED or laser beam, immediately seek medical attention.
4.3 Optical Fiber Handling Precautions
Broken fiber ends created during termination and splicing can be dangerous. These
ends are extremely sharp and can easily penetrate the skin. They invariably break off
and are very hard to find and remove. Often tweezers and a magnifying glass are
needed to remove them from the skin. Any delay in their removal could lead to an
infection, which is dangerous. Hence,
Be careful while handling the fibers.
Dispose of all scraps safely and properly.
Do not eat or drink near the installation area.
Primary treatments for exposure to Isopropyl alcohol or Hexane used to clean fibers or cables
are presented in Table 2.
Hexane Isopropyl
Type of
Exposure Effect of Emergency Treatment 2 Effect of
Exposure Exposure Emergency Treatment2
Ingestion Nausea,Vomiting Do not induce vomiting, immediately Drunkenness Have victim drink water and
, Headache. seek medical assistance. and vomiting. milk. Seek medical assistance.
Contact Wipe off affected area of skin and Harmless to Wipe off affected area of skin and
Irritation. wash with soap and water. wash with soap and water.
with Skin skin.
2
Seek Emergency treatment for inhalation, ingestion, severe contact with skin, and contact with eyes.
4.5 Safety During Installation
Manhole/Underground Vault Safety:
Explosive gases or vapors might be present in manholes or handholes due to gas leaking
from nearby pipelines, tanks, or the soil. Before entering any manhole test its atmosphere
with an approved test kit for flammable, explosive, and poisonous gases.
Avoid usage of any device that produces a spark or flame in or near a manhole.
Working Safely:
To minimize the risks of an accident in the work area, follow the existing rules for setting up
warning signs, barricades, manhole guards, and cones.
Before pulling cable directly from a figure-8 configuration, make sure that the area inside the
loop of the cable (figure-8) is clear of personnel and equipment. Failure to do so may result
in injury to the personnel or damage to the cable.
Ensure that the tools and equipment used for the cable installation are in proper
working order. Improperly functioning equipment may damage cables or cause injury to
personnel.
Be careful when working near electrical hazards, if electric lines are passing through or near
the right-of-way where installation is being performed.
Bond all metallic components in the underground system together. At all points where
anyone may come in contact with the metallic components of the underground cable
system, ground the bonded metallic components to a proper earth ground to avoid electric
hazards produced by power lines or any other means.
While loading or unloading cable reels, care must be taken to prevent collision with
other reels, or damage to the reel or cable.
The reel should not be rolled over a long distance. If it is necessary to roll the reel, it should
be rolled on both flanges in the direction indicated by the arrow on the flange.
The reel should never be stored on its side (do not store a reel flat on one flange).
Cable reels should always be stored on a flat surface with blocks placed under the
flanges to prevent rolling in either direction.
The cable on the reel should be covered at the factory with a UV/thermal wrap until
just prior to installation to protect it from exposure to the sun and high temperatures.
General Issues
If possible, select a route that follows existing telecommunications infrastructure.
Before any visit is made to a prospective construction site, an up-to-date plot plan showing
the location of existing utilities shall be obtained from each of the utilities that will affect the
construction operation. The plot plan shall be noted with details characterizing each utility
and phone numbers to call if there are problems.
Select a route that provides easy access for workers, equipment, and materials.
The placing route shall have a spacious and safe staging area convenient to the job site.
The staging area shall be a location in which cable reels can be unloaded and stored prior
to use with an all-weather surface. It shall also be a location at which fiber measurements
can be made. It shall be secure from vandalism and theft.
The job site and staging area shall be protected from both pedestrian and vehicular traffic.
Splice locations shall be selected on the basis of their ability to serve as a good cable feed
and/or cable pulling location or as the location where fiber branching occurs.
Placing operations in all types of cable (aerial, buried, and underground) is normally easier
when done downhill. Try to configure the placing operation downhill.
As optical cable is placed, care must be taken not to kink, distort, or crush the cable. The
cable manufacturer's recommended minimum diameter shall be maintained. If no diameter
is recommended, use the following limits for the minimum bend diameter of the cable.
The pre-construction survey of feed, pull, intermediate assist, and backfeed manholes must
include an inspection of the respective manhole to be assured that the appropriate
equipment is chosen and the appropriate tie down hardware is available to enable these
manholes to function as required. In addition, there must be sufficient space on the ground
surface adjacent to the manhole to support the proposed operation at the manhole.
Intermediate manholes are those manholes where cable is expressed through without being
spliced. They often require considerable “rigging” to setup sheaves, quadrant blocks, or
pulling frames to accommodate any conduit misalignments in the route of cable placement.
All of the hardware used to assist in safely making these directional changes need to be
securely chained or tied in place.
Backfeed manholes are located within the cable run from which cable is fed in both
directions. Normally, backfeed manholes are located at major changes in direction of the
cable run, often closer to one end of the cable run than the other. The longer segment is
pulled first. The remaining cable is manually pulled off the cable reel and stored temporarily
on the ground in a figure-8 pattern. Cable from the figure-8 is re-fed into the backfeed
manhole in the direction of segment 2. Each end manhole in the cable run serves as a pull
manhole for the respective pulling operations.
Cable on all reels need to be inspected for damage as they are received. As a precaution and
to avoid costly extra cable removal operations, all fibers should be measured on the reel using
an OTDR. Measurements on single-mode fiber cables should be made at 1550 nm and 1300
nm on multimode fiber cables. If discrepancies are found with respect to the factory “as
shipped” test results on the cabled fiber, contact Sterlite Technologies.
Cable Placing Truck (Canada) Side take-off winch with slip clutch (Condux)
Associated Materials and Equipment
Table 4- Typical Placing Equipment Used to Place Micro-Ducts and Micro-Duct Cables
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Associated Materials and Equipment
Size OD Wall Safe working Wall Safe working Wall Safe working
Pull Strength Pull Strength Pull Strength
1.00” 1.315” 0.120” 1078 lbs 0.097” 894 lbs 0.085” 792 lbs
1.25” 1.660” 0.151” 1717 lbs 0.123” 1425 lbs 0.107” 1234 lbs
1.50” 1.900” 0.173” 2279 lbs 0.141” 1867 lbs 0.123” 1607 lbs
2.00” 2.375” 0.216” 3515 lbs 0.176” 2917 lbs 0.153” 2466 lbs
Table 5- Typical Placing Equipment Used to Place Micro-Ducts and Micro-Duct Cables
7 mm 5.5 mm
10 mm 8 mm
12 mm 10 mm
14 mm 10 mm
16 mm 13 mm
Polywater offers the micro-duct cable placing lubrication estimate shown in Table 8 to jet micro-
duct cable into various size micro-ducts. Pour approximately 75 percent of the lubricant
indicated in Table 8 directly into the micro-duct ahead of the missile with the remainder of the
lubricant being placed on the cable during the placing operation. Note, the actual quantity of
lubrication used in any placing operation varies and is dependent upon the size, condition,
length, wall type of the micro-duct, and the material in the duct and cable jacket.
Micro-Duct Size (MM) Amount of Lubrication
(OD/ID) Required Per 100 ft
6.4 Winches
Since optical cables are lighter in weight and smaller in diameter than their copper counter
parts, smaller winches are generally used to place optical cables. Most standard size optical
cables have a maximum cable placing force of 600 pounds or greater (some optical cables do
have higher loads and some lower, consult the cable specification provided by Sterlite to
determine the maximum placing load for each cable). Fiber optic cable winches tend to be
smaller than the line truck bed winches used for copper cables. Capstan winches are popular.
Some of these winches are stand alone, using portable power packs (electric or hydraulic) and
some are truck or trailer mounted using the hydraulic power take-off from the support truck.
Fiber winches should all have or be coupled to cable tension monitoring systems to ensure that
the maximum cable tension is not violated. Slip clutches are often used for side take-off
winches on line trucks.
6.5 Cable Blowing and Pushing Engine
The micro-duct system is based on the use of a combination of smaller diameter sub-ducts
and more compact optical cables using more efficient placing methods and equipment
specifically tuned to micro- duct and micro-cables. It is possible to use equipment similar to that
used to place micro-duct cable to place standard size optical cables; it is specially tuned to the
standard diameter optical cables and innerduct.
Jetting (blowing) – A system used in longer lengths of underground cable and in previously
installed micro-ducts using air pressure. Standard optical cables, micro-duct cables, and
micro-ducts can be placed using jetting. Jetting is most effective in smaller ducts of 50 mm
diameter or less (micro-ducts). It is possible to place micro-duct cable using jetting in
continuous lengths of 4,000 to 6,000 feet, depending upon the geometry of the right-of-way.
The following effects contribute to the pulling force build-up in the cable:
Cable weight (gravity)- This results in a pulling force that is proportional to the installed weight
of the cable which is directly related to the cable size, design, and the length of the cable.
Coefficient of friction- The material property that relates the normal force to frictional force
between cable and duct (or adjacent cable when several cables are present in the same
duct). The coefficient of friction affects the cable tension linearly in straight runs. In bends
and undulations of the duct, the tensile pulling force increases exponentially with respect to
the undulation's curvature and the coefficient of friction. This effect is known as the capstan
effect. It can dominate most cable pulls.
Cable tensile force- The resulting pulling load on a cable is the combination of cable weight,
curvature of the bends, location of the bends, coefficient of friction, and weight of cable (unit
weight and length). The total cable tensile force required to place the cable must not exceed
the rated cable tensile strength.
Cable compressive force- The cable can buckle under the compressive forces of a cable
pusher and become crushed from additional sidewall forces that build up on the inside of a
bend. This can also lead to a pulling force built-up that limits the distance it can be pushed.
If a cable pusher is used to assist cable placing as it enters the sub-duct and if it continues
to work if a cable jam occurs, the compressive force could cause the cable to buckle, unless
the placing engine is adjusted to stop pushing when cable compressive load reaches a set
safe level.
Cable stiffness in bends and undulations in the duct trajectory- The greater the cable
stiffness, the larger the frictional force from cable stiffness in bends and undulations in the
duct.
Table 9– Maximum Fiber Count of conventional Sterlite Fiber Optic Cable that can be
placed into various sized Innerducts
Before the cable placing operation begins, the innerduct or micro-duct system should be
checked to be assured that the cable's minimum bend radius is not violated during handling,
feeding, placing, and final positioning. The placing equipment and all pressure fittings should
be checked. The winch shall be adjusted to stop placing the cable if the placing load reaches a
level close to the maximum rated cable placing tension. If a placing engine is used, it should be
checked to confirm that the compression limits safely match the limits of the cable being placed
and have been properly and accurately set. Radios should be checked to confirm that all
manned positions along the right-of-way are in communications and prepared to start the
placement. Figure 6 shows a typical unassisted standard optical cable pulling operation.
The leading end of the cable shall be connected to the pulling line using a basket grip sized for
the cable that slips over the cable end. A wrap of vinyl tape shall be wrapped around the grip
which has been pulled tight over the cable. The pulling line shall be connected to the basket
grip with a ball-bearing swivel.
Individual conduit segments in both the intermediate assist and bidirectional placement
methods need to be kept shorter in length than the unassisted placement route. As a rule of
thumb, placing cable using either procedure should be limited to 1.5 km or shorter for each pull
segment.
Since each intermediate assist method uses a sub-duct system that is discontinuous at each
assist manhole, each discontinuous duct segment needs to be lubricated independently, i.e.,
they need to have lubrication applied ahead of the cable, and then on the cable as it passes
through the intermediate assist manhole or figure-eight manhole that leads into the next duct
segment. Each placing winch or engine used in an intermediate assist procedure needs to be
adjusted with the mechanical limitations determined for the cable being placed, i.e., maximum
compression and tensile force.
7.2 Bidirectional Figure-Eight Procedure
If necessary, a placing plan listing the pulling locations, intermediate assist, and figure-8
locations should be developed during the pre-survey of the placing project. The placing plan
will indicate the length of cable to be coiled at the “figure-8" location.
For bidirectional placing, a convenient intermediate manhole is selected for the figure-8
location. It should be near mid-span and, if possible the duct section in both directions out from
the figure-8 manhole should be placeable in a single operation.
Figure 9- Cable Pulling Showing Cable Placement with Intermediate Figure-8 Feed
Segment 1 of the cable placing operation requires pulling cable from the cable feed manhole to
the figure-eight manhole. The placing winch must be positioned at the figure-eight manhole for this
operation.
Cable is pulled or jetted to the intermediate figure-eight manhole following the procedures
outlined in Figure 9. All cable is pulled off the reel with the excess cable figure eighted in a coil
about 10 meters long at the intermediate figure-eight manhole. Care is required to avoid
damaging the cable as the excess cable is pulled out of and, in the next step, back into the
intermediate manhole. During this operation, a significant length of cable is being pulled around
a capstan winch, so care must be taken to avoid over bending the cable. In addition, the
manhole must be rigged to provide a gentile passage for the cable out, then back into the
manhole and duct system. The figure-eighting of the cable shall be done carefully, in a safe
location free from access by the public.
Sufficient cable shall be left in the initial cable feed manhole to complete the splice to its
neighboring cable and to provide cable slack for future maintenance and racking operations.
After all cable has been pulled off the reel and the excess cable figure eighted, the pulling
equipment shall be moved from the figure-eight manhole to the end manhole to complete the
cable placing operation from the figure-eight coil at the intermediate figure-eight manhole as
segment 2.
Before the segment 2 placing operation can begin, the figure eight coil must be carefully turned
over (“flipped”) so that the cable that was on the bottom is now on top. This cable coil “flip” will
enable cable to be fed off the top of the coil to the far manhole to complete the placing
operation.
The final segment of micro-duct will be placed from the figure-eight manhole to the far end
manhole. The operation shall be conducted as described above. As always, the encasing
conduit, sub-duct, innerduct, or micro-duct must be lubricated prior to the start of any placing
operation following the lubrication schedule in Table7 or Table8. Once the placing operation
begins, lubrication must continue to be applied to the cable as it is placed.
7.3 Placing Assistance
A placing plan determining pulling locations, including the intermediate assist location should
be developed during the pre-survey of the placing project. Figure 10 and Figure 11, show a
cable jetting operation with intermediate assist, both manual and automatic.
Figure 10- Cable Placement Showing Placement with Manual Intermediate Assist
Figure 11- Cable Placement Showing Placement Using Intermediate Assist Engine
An intermediate manhole can be selected as an intermediate assist location. It should be near
mid-span and, if possible, the duct section in both directions out from the intermediate assist
manhole should be place able in a single operation. The area around the intermediate assist
location should be sufficient to stage the ground support equipment (air compressor and
hydraulic pump) for the placing operation.
For an automated intermediate assist procedure to be successful, the placing engines (primary
and assist engine) need to be coordinated, so compressive forces do not build up causing the
cable to buckle or kink. This is a procedure that is difficult to perform safely and should only be
attempted by an experience placing crew. If used, the assist equipment manufacturer's
instructions must be carefully followed.
Once the cable has been placed, sufficient slack cable should be provided on each end of the
cable to enable the splice to be made to the adjoining cable, to rack cable in all manholes to
the assist manhole, and to store the standard amount of slack at each splice required by the
cable's end-user for maintenance operations. Sufficient slack must be provided in intermediate
manholes to rack the cable and sub-duct (either innerduct or micro-duct) along the sides of the
manhole, out of the way from harm and still have sufficient slack stored to accommodate the
end-users requirements.
All ducts should be plugged at the conclusion of the placing operation. If a cable has been
pulled into the duct, the duct plug should be sized for both the ID of the duct and the OD of the
cable.
Micro-duct shall be left intact through intermediate manholes during placing and racking,
whenever possible unless the micro-duct was removed to enable intermediate assistance or a
portion of the cable is branched off the cable route being placed.
Typically, a cable coil will be placed in a manhole or hand-hole to provide extra cable in the
event of network damage or extra cable for splicing fibers. In certain environments, it may be
determined that cable protection for the coiled slack is required due to the threat of rodent
damage.
If possible, protect any slack coils with split flexible conduit and store the coil in a safe
position in the manhole or hand hole.
Figure 12- Cable Pulling Showing Cable Placement using Backfeed Placement
8. Manhole Housekeeping
8.1 Cable Coiling
Spare cable from the cable placing operation should be stored in intermediate and splice
manholes (end manholes during placing) in a neat coil wrapped with a radius greater than the
minimum bend radius of the cable. Forms for the cable coiling operation can be commercially
purchased.
Cable coils should be stored in a safe location, away from the normal work operations in the
manhole. If possible the cable coil can be stored behind the racked cable. The cable coils should
be cable tied in place.
8.2 Racking Cable and Innerduct
Once the cable has been placed, sufficient slack cable should be provided in each end
manhole to enable the splice to be made, to rack cable in each manhole, and to store the
standard amount of slack at each splice required by the cable's owner to perform maintenance
operations. Also, sufficient slack must be provided in intermediate manholes to rack the cable
inside sub-duct (either innerduct or micro-duct) along the sides of the manhole, away from harm
and still have sufficient slack stored to accommodate the end-user's requirements.
The cable must be properly terminated in a splice closure. The proper clamping of the cable's
central strength member is necessary to prevent CSM pistoning. In addition, the jacket must be
properly secured to prevent jacket retraction or cable slippage.
Cable racking normally begins in an intermediate manhole or backfeed manhole and proceeds
one manhole at a time toward each end manhole (or location where cable slack is being
stored). Normally slack for cable racking is pulled by hand or if that becomes too difficult, using
a split basket grip and a hand operated cable hoist. Care must be taken to avoid over
tensioning the cable during slack pulling, or over bending the cable when forming it to the side
wall of the manhole.
When racking cables, the innerduct should be continuous through intermediate manholes. The
innerduct will provide the cable with an extra layer of protection during future work activities and
from rodents. Form the innerduct and enclosed cable to the sides of the manhole, being careful
to maintain the cable's minimum bend radius. Once the cable and innerduct is formed along the
manhole walls in a safe location, secure them to the manhole racks using plastic cable ties. If
the innerduct is insufficient in length to be formed to a safe pathway along the sides of the
manhole, it can be ring cut to allow the racking to be completed. Pulling slack innerduct from
adjacent manholes is not recommended. Cut the innerduct just beyond the first manhole rack
on both sides of the manhole. The racked, cut innerduct can be cable tied to the first manhole
rack to keep it secured. The opening in the innerduct should be covered with a split duct.
Expressing micro-duct cable buffer tubes through a splice closure is not permitted. The buffer
tubes should be opened in the splice closure and the express fibers stored in the closure's
splice trays or routed in furcation tubing through the closure. If the buffer tubes are expressed
through the splice closure, an increase in attenuation may occur at colder temperatures.
9. Additional Information
If there are additional questions on this topic or other fiber optic issues, please contact Sterlite
Technologies at:
Contact Information
telecom.sales@sterlite.com
www.sterlitetechnologies.com
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