Outside Plant Construction Guide

Introduction
Review Of Fiber Optic Technology. 
Project Preparation And Guidelines.
Underground Cable Construction.
Underground Cable Installation.
Aerial Cable Installation.
Completing Outside Cable Plant Installation.
  
 

Underground Cable Plant Construction

 
Underground cables are pulled in conduit that is buried underground, usually
1-1.2 meters (3-4 feet) deep to reduce the likelihood of accidentally being dug
up. In extreme cold climates, cables may need to be buried at greater depths
where there temperatures are colder and frost penetrates to greater depths.
The process usually begins with digging a trench to bury the conduit which is
generally PVC plastic pipe, sometimes with pre-installed innerduct (also called
duct liner) with a pulling tape to facilitate the actual cable pulling process.
Directional boring can also be used to avoid digging up the surface, for
example in crossing streets or sidewalks.
 
If the conduit and cables are all dielectric, as they usually are, a conductive
marker tape should be buried above the conduit to assist in future cable
location and as a warning to anyone digging in the vicinity of the cable.
Conductive tape to be detectable should be no more than 300mm (12 inches)
below the surface.
 
This chapter covers many topics of relevance to OSP construction that should
be considered as part of the overall project planning. For additional detail on
the design, refer to the FOA online Guide material or the textbook on fiber
optic network design.
 
 
Dig Once
 
Due to the disruptive nature of burying conduit, especially under roadways,
many governments which grant permits for burying cable require the
contractor to install extra conduits along the route to prevent having to dig
again for any future cable installations. Since many cities have extensive
conduits already buried for other services or may have required extra conduit
to be buried during prior installations, conduit may be available for pulling new
fiber optic cables.

 
Call Before You Dig
The old story about the most likely fiber optic communications system failure
being caused by "backhoe fade" is not a joke – it happens every day. But it
reminds us that digging safely is vitally important. The risk is not just
interrupting communications, but the life-threatening risk of digging up high
voltage cables or gas lines. There are several services that maintain
databases of the location of underground services that must be contacted
before any digging occurs, but mapping these should be done during the
design phase and double-checked before digging to ensure having the latest
data.
At the same time as the cable is installed, markers like these indicating its
location and ownership can also be installed.

 
Trenching
 
It’s immensely important for trenches to be excavated to such a depth that the
crown of the duct has at least 800mm (32 inches) of backfill cover, in all soil
conditions, except for where hard rock conditions are encountered. Where it is
not possible to obtain the specified minimum trench depth, the client must be
consulted.

 
The trench depth in hard rock conditions can be relaxed (i.e. apply for a
concession) to a minimum depth of 300mm (12 inches) backfill cover over the
uppermost duct. But it then requires protection in the form of a concrete slab
(either pre-cast, or cast in situ) placed on top of the padding material before
backfilling. This concrete slab shall have a strength of 20 Mpa reinforced with
high tensile wires and measure; 75mm (3 inches) thick by 300mm (12 inches)
wide, and 900mm (36 inches) in length.          
 
      
 
Concrete encasing is not endorsed enthusiastically by everyone; some argue
that it turns a previously flexible duct into a long unreinforced concrete beam
of little strength, prone to fracture with ground movement. And, this in turn
could potentially damage an encased duct. A view not shared by everyone.
 
Before pouring concrete, a slump test must be performed (take photos of this
procedure). How do we measure the ideal slump? A  slump of 10 cm or less is
typically deemed acceptable (must not shear-off or collapse) - or as per client
spec. Concrete that is poured too wet will be weak, regardless of how it is
cured

                                                                            
                                    
 
 
Trench Width
 
One other obvious consideration is the width of the trench, which of course, is
dependent on the duct diameter.
 
Trenches that are too narrow will not allow for proper duct installation,
whereas trenches that are overly wide are unnecessarily costly. On top of this,
a too wide a trench will allow for too much duct snaking from the reel memory.
Below are typical examples of proper trench sizing:
 
 
Areas where work is to be performed shall be cleared of all trees, shrubs,
rubbish, and other objectionable material of any kind, which, if left in place,
would interfere with the proper performance or completion of the
contemplated work.
 
 
Pilot Holes
 
When the trench has been set out, pilot holes needs to be dug at 25 – 30 m
(80-100 feet) intervals, particularly at points where the new trench crosses
existing services. The pilot holes should be at least 150mm deeper and wider
than the proposed trench.
 
Pilot holes are one of the most effective methods utilized not only for the
location of services, but also to determine the position of a trench, relative to
other services.
 

 
Location of Services
 
The Contractor will generally be liable for any damages to existing services. It
is the responsibility of the Contractor to locate all existing services. No
excavation work should begin without having a copy of the approved
wayleave/s on site. A utility representative can be asked to point out the
position of a service and sometimes even oversee the work.
 
Cable Locators can find the exact path and even estimate the depth of the
utility service. Investing in a ground penetration radar (GPR) is the best
investment for fail-safe trenching. They are used to identify underground
services and formations although readings can be affected by the presence of
high voltage power cables.

 
Ground Penetrating Radar Diagram
 
Any trenching done in the vicinity of existing services should be done very
carefully to prevent accidental damage to a service. Hand excavating is
necessary to uncover known services prior to commencing with mechanical
excavation.
 
Any damage to existing services must be reported immediately to the project
manager.
 
 
Trenches Deeper than 1.2 meters
 
Where the depth of a trench exceeds 1.2m and workers need to enter the
trench, adequate measures must be taken by the contractor to provide
support for this trench. No person must work alone in an excavation or trench
that is greater than 1.2m deep.

 
 
3 basic methods used for protecting workers against trench cave-ins are:

   sloping
   trench boxes
   shoring

A ladder provides a safe means of access to the trench.

                                                                                                                             
  
Barricades and signs are to be used at safe distances from edges to protect
unattended
excavations.                                                                                                        
 
Machinery must never be placed in or near excavations and trenches where
exhaust fumes may contaminate below ground atmospheres that workers are
required to occupy.
 
Care shall be exercised in the moving or removal of shoring to prevent the
caving or collapse of the trench faces being supported.
 
 
Suggested Trenching Practices (possibly not mentioned elsewhere)
 

   All excavation work must be performed under the supervision of a

responsible person who must be competent to exercise such
supervision.
   Proper excavation and preparation of the trench will inhibit
unanticipated longitudinal and cross-sectional strains and stresses on
the duct.
   Trench walls shall be vertical for at least the height of the bedding and
then as vertical as possible.
   Exercise care when trimming trench floors to ensure that they are
level.
   If any street furniture (street names, traffic signs, bus shelters, etc.)
have to be moved, arrangements must be made with the relevant
authority for the removal, storage and re-erection.
   Mark-out the proposed trench with lime.
  

 
 
Barricading Construction
 

   Provide adequate warning, guidance and protection for motorists,

pedestrians, cyclists and workers from all foreseeable hazards.
   In high traffic areas, erect fencing or place barriers measuring at least
1,2m in height as close as possible to the excavation. All barricading
shall be well supported.
   An additional precaution is to provide clearly visible boundary
indicators at night or when visibility is poor.
   Wear high-visibility vests (at all times), safety boots and hard hats
when working at or near a public street or highway or when working at
night.
   When excavations are in progress next to the road, ensure proper and
sufficient warning road signs placed at distances well before and after
the work in progress. To warn approaching traffic, a flag person must be
placed at least 40m before a “men at work” sign. Approved road cones
must be placed at regular intervals along the whole route where
trenching is in progress.
   Backfill as soon as possible.

 
Trenching Near Curbs, Guttering, Paving and Driveway Crossings     
 

   Where excavations pass beneath kerbs, guttering or driveways, etc.,

proper support shall be provided for these structures until tunnelling and
backfilling is
completed.                                                                                 
   Where tunneling is not an option, the existing concrete paving shall be
neatly cut with an angle grinder to deliver smooth, uniform edges.
   Where ducts are to be laid beneath existing paving blocks, the pavers
shall be carefully removed to be reused. Paving blocks must be re-laid
on a bedding of sand and reinstated to its original state or better.    

 
 
Road Crossings
 

   The contractor shall inform the relevant road authority 48-hours prior to
the commencement of the work or as required by local ordinances. It is
the responsibility of the Contractor to ensure that every law regarding
traffic, safety, traffic signs and barricading is complied with.
    Directional drilling is the preferred method for crossing roads as it
causes minimum disruption.
   The angle of the crossing should be as near a right angle to the road
centerline as possible.
   The edge of the trench must be cut using asphalt/concrete cutters to
deliver smooth, uniform edges.
   The minimum depth that any service may be placed under a road is
800 mm.
   The duct/s shall extend a distance of at least 0.5m beyond the edge of
the road.
   All excavated material and equipment must be placed and demarcated
in such a way to not inconvenience vehicles and pedestrians.
   No person may off-load on a public road, any materials that are likely
to cause damage to a road surface.

 
Stream and River Crossings    
 

 
Before any serious thought is given to the installation of a high-density
polyethylene (HDPE) duct at a river crossing, the network designer will consult
with a geotechnical expert to conduct a comprehensive study. 
                                                                                
This investigation will reveal the most efficient way to accomplish the crossing
in question. Horizontal directional drilling (HDD) (discussed later), has become
a popular river crossing option, and as explained later, rightfully so.      
                                                         
The duct must be sealed at both ends to prevent water or dirt ingress.   
 
 
 
Bridge Crossings 
 
 
This work is typically undertaken by experts in this field. First and foremost,
the use of existing ducts or service culverts within bridges must be fully
explored. Not all bridge structures will have the exact same installation
configuration and procedures may vary to accommodate your specific
requirements. Ducts attached to the underside of bridges must not affect its
load bearing capacity, reduce the clearance or cause other
issues.                                     
 
The contractor shall inform the bridge owner 48-hours prior to the
commencement of the work.
 
The most common method to be used will involve the use of a hydraulically
operated crane fitted with a safety basket be positioned adjacent to the bridge
balustrade. From this position, workers wearing safety harnesses can be
hoisted over the balustrade and lowered into a working position as required.
                                                                                                                      
Bracket mounting positions can now marked out on the side or underside of
the bridge as directed by the design drawings and instructions. Next, drill the
holes, fit the concrete anchors and mounting brackets and firmly secure them.
 
The steel or ultra-high-density polyvinyl chloride (UPVC) base carrier duct can
now be positioned and firmly secured. The microducts can then be pulled
through the newly mounted base carrier. Use a continuous length of duct (no
joints permitted).
 
Where required and as stipulated in the design instructions, both the approach
and departure ends may have to be encased in concrete where they traverse
the bridge abutments and enter the ground. It is desirable of course, for the
end-product to be both safe and visually appeasing.
 
 
Trenching Near Power Cables
 
Where no physical barrier exists, no duct or cable shall be laid within a
distance of 600mm (24 inches) measured horizontally, nor cross within a
distance of 300mm (12 inches) measured vertically from any high voltage
power cable. Where this separation is compromised, the duct or cable must
be separated by concrete slabs.
 

 
The standard protection slab is 900mm x 300mm x 75mm (36 x 12 x 3 inches)
thick. This slab will be reinforced with 3.55 mm (1/8 inch) high tensile wires.
 

 
 
 
Rock Blasting
 
Blasting for excavation shall not be performed without written permission
obtained in advance, from the agency having jurisdiction. Procedures and
methods of blasting shall conform to all local laws and ordinances. It is the
responsibility of the Contractor to establish appropriate safety and health
practices and determine the applicability of regulatory limitations prior to
blasting.
 
 
 
Duct
Deviation                                                                                                             
     
 

Handholes and manholes typically facilitate changes in direction. However,

ducts may deviate from a straight line provided that individual lengths may be
offset by no more than 35mm (1.4 inches), the offset is in the same direction,
this to avoid creating S-bends and the maximum overall deviation between
MHs / HHs does not exceed 15˚.
                                                                                                                             
        
Spacers should be used when placing multiple ducts in a trench. They prevent
ducts from twisting over and around each other. By keeping the ducts in
straight alignment, cable jetting and/or pulling tensions will be reduced.
 
                                                                                                                             
        
 
Steep Gradient Trenching

 
Where excavations needs to be done on inclines, a layer of sand bags should
be placed at regular intervals (5m apart), to prevent the possible wash away
of backfill material. Always consider the risks of land stability or earth
movement, when trenching on embankments (specialist technical
investigation may be required).                                                                          
 
 
Tree Roots
 

                                                                                                           
Prior to undertaking tree/bush/shrub clearing/cutting as may be necessary for
trenching, approval in writing from the relevant authority and/or property
owner needs to be obtained. Tree roots exposed while trenching must not be
cut unless absolutely unavoidable. Never cut roots over 25mm in diameter,
unless advice has been sought from the local authority. Ducts are to be
sleeved in a HDPE pipe, if not 100mm away from existing tree roots.
 
 
Surface Material
 
Surface material (paving slabs, soil, grass, etc.) removed for construction
must be kept apart by placing them on opposite sides of a trench, where they
are least likely to interfere with traffic, pedestrians and drainage
systems.Mow-able lawn shall be cut in square blocks and put aside and be
kept moist until reinstated. Where trenches pass through gardens, the
contractor shall seek direction from the owner.
 

 
 
Duct Un‐Coiling and Installation Process
 
Duct un-coiling can be accomplished by pulling the conduit straight into a
trench from a stationary rotating de-coiler or by laying the conduit into the
trench from a forward moving de-coiler positioned on a trailer. Ducts shall not
be un-coiled without the use of a Vertical or Horizontal De-Coiler. De-coilers
will prevent twisting, bending or kinking from occurring during the installation
process.
 

 
Once the duct coils are secured inside the de-coiler, only then can the
containment straps on the duct coil be cut. Next, rotate the de-coiler slowly to
unwind the duct out in one plane.
 
Generally, the ducts are placed in the trench, one length at a time and joined
on the floor of the trench using couplers. As the ducts are laid and jointed,
install end caps on ducts at all MH/HHs to prevent water and dust from
entering. Care shall be taken to ensure that no dirt collects between the duct
and coupler to deliver an airtight seal.
 
Ducts shall be laid in a straight line between MH/HHs. It is never ideal to have
directional changes, but if unavoidable - keep the bending radius as big as
possible and offset is in the same direction. At MHs or HHs where the duct
goes straight-through, allow for sufficient slack for the duct to be secured
against MH or HH walls.
 
 
Duct Installation - Moving Trailer Method
 
This method is most efficiently used where the path to be followed does not
contain any obstructions that require the duct to be placed under. Move the
trailer slowly along the trench route while unwinding and placing the duct in
the trench. Take care not to over spin the reel.
 
 
Duct Installation - Pulling Method
 
The duct can also be pulled and placed by hand or by a mechanical pulling
machine with the help of a pulling device that is fitted in‐between duct and
mechanical pulling machine. the two types of pulling attachment devices most
commonly used are a pulling grip or basket grip.
 
 
 
Filling The Trench
 
A typical trench will be filled with the materials shown in the diagram below.
 

Bedding and Padding

 
Bedding is the material constituting the even floor of an excavated trench onto
which ducts are laid. The bedding should be raked if necessary to ensure it is
level. Padding the the layer of material covering the ducts. The material used
for bedding and padding must be of a granular, non-cohesive nature, graded
between 0.6 mm and 13 mm, or as per client spec. It is desirable to pass both
bedding and padding through a sieve before putting it back in the trench.
 

          

 
Care shall be taken to place padding material simultaneously on both sides of
the duct to prevent lateral movement. The compaction of padding shall be
executed manually using a hand tamper. Duct buckling is much more
probable when the padding material does not provide adequate side support.
 
 
Backfill and Warning Tape
 
After the padding is tamped, backfilling of the trench can be done. Material
excavated from trenches may be used as backfill, provided that it contains
stones no greater than 150mm ( 6 inches) in diameter, trash, or organic
matter that could potentially damage ducts.
 
Backfill material is to be installed in layers not exceeding 300 mm (12 inches),
with each layer compacted before the next is added. After compacting the first
layer of backfill, the warning or marking tape is placed. Take photos of this
procedure as proof of existence. Hopefully, the warning tape will be
encountered before damaging any ducts or cable.
 
   
 
 
 
Backfilling (Concrete)    
 

 
Before filling the trench with concrete, check the consistency of the concrete
(slump test). Tamper the concrete using special care not to damage the ducts.
Check for cavities in the concrete. Allow for the concrete to cure (harden).
                                                                                                                             
       
As mentioned earlier, some contractors believe a concrete backfill turns a
once flexible duct into a long unreinforced concrete beam of negligible
strength, very likely to fracture with ground movement. This in turn could
potentially damage the duct. This view is not shared by
everyone.                                                                                                             
                     
 
 
Trench Compacting         
 
 
Once a poorly compacted layer is in place, it is difficult if not impossible to
achieve good compaction in the layers above. This is a key point; a
consequence of poor backfill compaction is high percentage of air voids.
Manual compaction is performed until the ducts are covered by both a 150mm
layer of padding and 300mm of backfill, at which point a vibratory plate
compactor can be used.
                                                                                                                             
        
The compaction of the final backfill layer shall be by means of a compaction
machine and shall be compacted to a density higher than or at least equal to
that of the virgin soil parallel to the trench. After completion of the backfill, a
DCP test must be done. This test must be documented.
 
 
Optimum Moisture Content (OMC)
          

 
Moisture conditioning of the backfill material shall be carried out by the
contractor. If not specified by the client, the following 2 Field Tests for
Optimum Moisture Content (OMC) can be used:    
A handful of backfill tightly squeezed in the hand, shall be wet enough so that
it binds together with no more than slight crumbling when the hand is
opened.                               
 
 
Dynamic Cone Penetrometer (DCP) Testing
 

 All excavations are subject to compaction tests - which must be

documented.
 8 tests per km, is recommended.
 Uses a free-falling 8-kg hammer which strikes a cone, causing the cone
to penetrate the soil and, then measuring the penetration per blow,
called the penetration rate (PR), in mm/blow.
 Always keep the DCP vertical and watch where you place your fingers.
 The trench density must be better or at least equal to that of the virgin
soil parallel to the trench.
 A 25mm PR is typically deemed acceptable.

 
        
 
Micro-trenching
 
 
The time-honored method of burying ducts involves digging trenches with a
backhoe or a pick and shovel brigade. Alternative methods of deploying
underground fiber cables includes using storm water drains and sewers, while
another is micro-trenching, which involves using a machine cut a narrow slot
in the road surface. The benefits of micro-trenching are less disruption to
roads and sidewalks, faster deployment and more cost effective trenching.
 
Microtrenching is also highly effective with microducts and blown microcables.
A single groove can hold a 6-duct microduct that can allow installation of 144
or 288 fiber cables. If only one cable is needed at the time of construction,
adding cables in the future can be done without additional construction.
 
Depending on the type of road and the depth of existing services, the micro-
trench can be anything from 20 mm to 60 mm (0.8 to 2.5 inches) wide and,
300 mm to 500 mm (12 to 20 inches) deep, usually near the edge of the
roadway.  The machine has a blade in front (much like a giant angle grinder)
which cuts into the road surface.
 
 
Horizontal Directional Drilling (HDD)                                                         
 
HDD is a drilling process where a drill head is steered underground. This
method is adopted by all companies but generally sub-contracted to
specialists. HDD is the preferred method to cross roads, highways, railway
lines, rivers and all other services that may prove to be too dangerous or
costly to cross using conventional methods like trenching and/or ploughing.
Rigs capable of drilling up to 300 metres (1000 feet) in one drill are available
and various sizes of ducts can be installed with this equipment.
 

 
The depth of any hole drilled for the installation of a new service, must be at
least 800 mm (32 inches) below surface of the road, or as per client spec. At
river crossings the distance between the bottom of the water and the drilling
hole should be 10-times the diameter of the pipe and not less than 3 m (10
feet). If the accuracy of the drilling is not specified in the wayleave, the area in
which the drilling may wander should not exceed a 40mm (1.6 inches)
diameter around the predetermined axis.
                                                                                                                             
 
The HDD process involves 3 installation stages: pilot drilling, reaming the pilot
hole and pulling the duct into the reamed hole. The course of the drill is
monitored and can be controlled as rods progress following an upward sloping
path, before emerging at an intended point. The drill head is then removed
and replaced with a back reamer, ± 20% larger than the duct or cable to be
pulled into the hole. The duct is attached to a swivel connection on the back
reamer. The drill-rods and reamer are rotated and pulled through the hole,
enlarging it and pulling-in the duct at the same time. The whole operation is
carried out with pressurized drilling mud, which both carries away the spoil
and supports the hole.
 
The covering must not be less than three times the final diameter of the
drilling hole and at a minimum of 1.5m (6 feet). Soil removal during the drilling
process is the responsibility of the contractor.
As always, the location and depth of underground services must be pre-
determined before drilling can commence - as sudden deviations are not
possible to bypass obstacles.
 
 
Direct-Buried Installations
 
On paper, direct-bury is fairly simple and very cost-effective - you dig a trench,
install the cable and re-instate. However, once in the ground, it is perhaps
more susceptible to damage from unrelated digging activities than cable in a
duct, and much more importantly, it is difficult to access and repair.
 
 
In general, plowing-in the direct burial cable is the most desirable and
economical method of cable placement in open or rural areas where there
likely to be fewer obstacles to impede the progress of the plowing equipment.
In urban or sub-urban areas where there can be many obstacles such as
underground utilities, sidewalks, road crossings etc., trenching has
advantages.
 
On all direct-buried installations, armored cable must be deployed -which
provides for both crush protection and prevention of rodent penetration.
 

     
 
If only an armored cable is to be placed, a trench no wider than 375 mm (15
inches) will do. The trench should be 1.2 m deep (4 feet) or as stipulated in
the wayleave. Grade off abrupt changes in terrain ahead of the plough.
Excavate at least 5 m at the starting point, to allow for the plough to
immediately lay the cable at the correct depth.
 
Always start the plough tractor’s movement slowly and increase speed
gradually only after the cable slack is taken up from the cable delivery system.
 
Ploughing operations must be observed continuously for obstructions, proper
feeding of the cable, specified depth, following of the marked route, and the
safety of the crew. Stoppages in the plough-in process should only be for the
loading of cable or marker tape and when the terrain demands for this.
 
Warning Tape must be placed approximately 300 mm below the ground
surface, directly above the cable.
 
It is critically important for manholes and hand holes to be built only after the
plowing-in of the cable. Pre-fabricated man holes and hand holes are often
utilized.
 
Each section, after plowing-in, the cable must be checked with an OTDR for
possible damage.
 
After the plough in process is completed, the trench must be levelled by back
blading with the plough-in machine or using a TLB to level the disturbed
areas.
 
 
Armored Cable Grounding (Earthing), Bonding and Surge Protection
 
The National Electrical Code (NEC) recommends that non-current carrying
armour shields and metallic strength members be bonded and grounded.
 
Proper grounding and bonding is required for the safe and effective
dissipation of unwanted electrical current, and it promotes personal and site
safety. Typically, optical fiber cables do not carry electrical power, but the
metallic components of a conductive cable are capable of transmitting current.
When the armoured cable is correctly bonded and grounded, it minimizes the
risk of unwanted electrical current that could potentially harm personnel,
property or equipment. Required…By electrical codes and equipment
manufactures | To protect personnel and equipment
 
The armoring of optical fiber cables shall be lugged and bonded to an earth
bar using a soft multi-stranded 6 mm² green / yellow insulated bonding cables.
Bonding cables shall be kept as short as practically possible and must contain
no sharp bends.
 
Note: The difference between the terms bonding and grounding:
·       Bonding is the multiple connections to metallic parts (at every joint),
required to form a continuous electrical path.
·       Grounding is the act of connecting that path to an earth.

 
The Procedure
 
Use a cable knife to score the outer sheath of the armoured cable
approximately 25 mm (1 inch) long. Take care not to damage the inner
sheath.
 

Slide the base plate under the armour.

 

Place the top plate over the base plate and tighten down the lock nut.
 

Cover the grounding clamp and split portion of the sheath with vinyl tape and
connect to the ground system or bond thru.
 

 
 
 
 Underground Cable Markers  
 
   
In 'non-built-up areas' underground routes must be marked with identifiable
markers.    
GPS coordinates of all MHs /HHs must be taken and documented to form part
of the as-built documents. These markers shall have a length of not less than
1.8 m and a diameter of not less than 100 mm. Markers shall be planted 600
mm deep, opposite a MH or HH and be well compacted. Passive markers can
also be buried at key points during construction or used to mark existing
facilities.
 
 
 
Manholes and Handholes
 
Manholes (MH) and handholes (HH) shall be positioned as far away as
possible from road junctions. MHs and HHs must to be built according to
prescribed dimensions and specifications.
 

 
   
 
Before any concrete is placed the Contractor shall examine the shuttering for
firmness and correctness of position and remove all dirt and other foreign
matter.
 
Hand mixing of concrete is permitted in exceptional cases but only with written
permission of the client. Concrete mix shall be such that a strength of 20MPa
(2.5:2.5:1) is obtained 28 days after pouring.
 
Duct entry points into HHs / MHs must be drilled, without cracking or
damaging the surrounding structure. Ducts shall enter and exit HHs / MHs in
line with the direction of the route, for them to be coupled thru without any
obvious effort, as a continuous duct.
 
HH / MH external labeling should be done on the coping and NOT the lid, as
lids can get damaged and be replaced. GPS coordinates for the location must
be recorded. On completion of a HH / MH, the Contractor shall re-instate the
area around the HH / MH to its original state or better.
HH / MH covers shall be finished flush with the surface area.
 
Where bricks are used to construct HHs the following must apply:

   Written permission obtained from the client.

   Use only baked quality clay bricks sourced from an approved
manufacturer.
   The wall thickness must be double brick or better.
   Re-enforce every third layer of bricks.
   The outer wall must be waterproofed.
   Use an approved footway-type or roadway-type frame and cover.
 
HH Installation

   All duct entries and exits at the HHs must be a watertight seal.
   All ducts in HHs shall be coupled through.
   Incoming ducts must have a watertight seal.
   Ducts must be sealed with a watertight coupling cast or inserted into
the wall of the HH
   HH covers must be watertight or must have at least a double seal.
   HH covers should be 150 mm (6 inches) above natural ground level
with the fill shaped back to natural ground level in a 2 m (6.5 feet) radius
around the HH cover.
   On paved sidewalks or verges, next to roads or streets, a cast in-situ
concrete or asphalt backfilling shall be sloped to not impede pedestrian
traffic. In these instances the HH installation shall be such that it is not
more than 50 mm higher than the surrounding paved sidewalk.
   The inside surface of the HH shall be sealed using an approved
bituminous product.

HH / MH Inspection

   Splice closures are secured.

   Cable slack neatly stored and secured with no compromise to the
bending radius.
   Left tidy and clean.
   Ducts sealed in-between wall.
   End Caps fitted to empty ducts.
   Used ducts sealed in-between cable and duct.
   Cables and ducts are clearly labelled.
   HH/MH clearly marked on the coping.
   Locating disk in position.

 
Safe HH / MH Working Procedures
 

   Obtain a HH / MH entry ref for the work to be undertaken.

   At least 2-persons must be present before entering a MH.
   Ensure that the vehicles are parked in such a manner that they do not
create an obstruction or hazard to traffic and/or pedestrians.
   Use barricades and cones that are clearly visible around the HH / MH.
   Pour water around the lid of the HH / MH, to prevent creating a spark
when opening it.
   Lift HH / MH covers using your legs and place the cover at least 2 m
(6.5 feet) away from the opening.
   Before entering  the confined space, test at 3-levels (bottom, middle,
and top) for:
   Oxygen content
   Flammable or explosive gases
   Hydrogen sulphide
   Each level must be tested for a minimum of 60 seconds.
   Use only an approved calibrated gas detector.
   Ensure that the gas detector is in operation the entire time spent in the
MH.
   An aluminium ladder in good operating condition must be used to enter
the MH.
   Raise or lower tools and/or equipment into a MH using a rope or
bucket.
   Never place equipment or tools near the edge of a HH / MH.
   Constant ventilation is required when performing work within a MH.
   Water in a MH (not containing object-able content) shall be pumped-
out into the storm water system. If not possible, or onto area, a suitable
distance away, with positive drainage.
   Never fusion splice in a HH or MH.

 
Installation Underground In Other Services
 
There are methods using robots to install fiber optic cable in storm sewers or
other underground pipes. They have been used in center cities where
construction is difficult but not widely.
Aerial Cable Installation

 
Aerial Cable Installation
 
Deploying fiber above ground on poles or towers removes the need for
underground digging and is particularly useful when the ground is uneven,
rocky or both. Aerial installation is generally much less costly than
underground construction also.
 
Fiber in a duct solutions have a major aesthetic advantage; once installed,
they are invisible, leaving no mark on the landscape. Unlike aerial
installations, they are less affected by most adverse weather like high winds
or freezing rain. But underground installations can be vulnerable to flooding
damage.
 
However, there are a number of reasons for choosing an aerial solution, such
as:

 Aerial fibers are typically much faster and cheaper to deploy than buried
networks.
 The planned route may be undulating, rocky or both, making digging
less appealing.
 All-Dielectric Self Supporting (ADSS) cables can be erected in close
proximity to power transmission lines. This of course, allows for pole
sharing, which of course, reduces installation costs and speeds-up
deployment.

Before beginning aerial installations, the design of the cable plant must be
properly done and checked. Routes must be surveyed, ground conditions
tested, all components procured and received. Permits from local authorities
must be obtained and coordination with local agencies such as traffic and
police must be properly planned.
 
If poles exist already, it is required to have proper permits for adding
communications cables and the poles must be “made ready” by the owner of
the poles are authorized parties. This may take considerable time which must
be factored in the planning of the project. Sometimes lightweight fiber cable
may be lashed to previously installed cables such as older copper phone
cables or CATV hardline coax, but proper permissions must be obtained.
 
Prior to installation, the location of splice points and storage of slack cables
must be determined and noted in the design. Splice locations should be
chosen with the need for parking a splice truck, van or trainer nearby.
 
 
Cable Jackets
 
Polyethylene (PE) is the material of choice for use as an aerial OSP cable
jacket. The performance of raw PE can degrade rapidly through exposure to
sunlight but the addition of carbon black to the cable jacket absorbs the UV
light to protect the plastic jacket of the cable. Jacket colors other than black
are rarely used for aerial installations and then only for enhancing
identification.
 

 
 
Safety
 
Aerial cable installation can be hazardous as personnel may working at
considerable height above the ground on ladders, bucket trucks or even
climbing poles and near electrical transmission wires. All workers should have
proper training and personal protective equipment before being allowed to
work on aerial installations.
 
 
 
 
Pole Handling Personal Protection Equipment (PPE)

 Safety boots with steel caps.

 Protective clothing with long sleeves.
  Shoulder pads.
 Gloves.
 Hardhat.

 
Climbing Ladders

 Keep hands free of tools or materials when climbing or descending a

pole or ladder.
 Workers climbing up or down ladders must always face the ladder and
maintain a 3-point contact. This effectively means that 2-hands and 1-
foot or 2-feet and 1-hand must be on the ladder at all times.
 Ladder must be positioned correctly (1-4 ratio).
 Ladder must be properly secured (lashed and held).
 Ladder must be in a good condition.
 The ladder must suit the application.
 A worker must be correctly positioned on the ladder.
 A safety harness must be worn and secured to the pole once the
working position is reached.
 Never climb intermediate poles if the span they support is being placed
under tension.

 
 
Transportation of Poles
 
Poles must never exceed the 0.5m vehicle overhang and must have a red flag
secured on the overhanging end. Poles that are loaded onto a pole carrier
must be secured to ensure that the cargo does not move while it is in transit.
 
Pole Off-Loading Procedure
Ensure that the removal of any one pole will not cause shifting or rolling of any
of the remaining poles.

Step 1: Unfasten the poles.

Step 2: Slide one pole at a time towards the rear end of the vehicle.
Step 3: When the pole reaches its equilibrium point, the persons on the
vehicle must raise their end slowly.
Step 4: The persons on the ground slowly pull the pole until 1m of it is left on
the back of the vehicle bed.
Step 5: The persons on the ground receive the pole and gently place it on the
ground.
A pole must never be dropped on the ground, as this could damage the pole
and/or cause injury to team members.
 
Pole Handling Ratios
 
Smaller poles may be handled manually with sufficient personnel available but
larger poles require proper mechanical aids.

7m pole =4 people
8m pole =6 people
9m pole = 8 people or a mechanical aid
10m pole = mechanical aid.
11m + pole = mechanical aid
 
 
Survey          
 

 Survey rods must be planted in line at selected pole positions so that,

when erected, the poles will be in a straight line.                                    
 A spirit level must be used to verify that there is no lean to the
rods.         
  As the survey advances, the rear rods used for lining up - will be
withdrawn and survey pegs driven into the ground in the exact position
previously occupied by the survey
rod.                                                              
 The location of the poles to be erected along roads shall be in
accordance with the way leave drawings and conditions stipulated by
the authorities
concerned.                                                                                          
 Square wooden pegs shall be used to mark the position of every pole,
stay or
strut.                                                                                                      
 The numbering (or other details) and marking of the wooden pegs shall
be done as agreed upon by both the client and contractor.             
 The tops of pegs that show the positions of angle poles must be marked
with blue lumber crayon crosses.                                                            
 A survey peg for a strut position must show the approximate spread of
the strut.

 
 
Survey Equipment and Tools

 Digital camera spare batteries.

 GPS with tracking function and spare batteries.
 DCP tester.
 Tape measure.
 Measuring wheel.
 Survey pegs and hammer
 Road cones.
 Clip board, survey sheet/note book and stationary.
 Construction vehicle – with signage and an orange light mounted on the
rooftop.
 Road map and/or proposed route detail drawing/s from the client.
 Reflector jacket.
 Personal Identification.

 
 
Survey - Gather Route Information

 The information on this route must accurately indicate distances.

 Take photos of all obstacles on the route (existing services, bridge
crossings, rocky areas, buildings, built-up areas, paved/tarred areas,
wetlands, overhead obstacles, etc.).
 Identify all obvious landmarks where the route changes direction (take
photos).
 Note down any road repair work necessary - record distances and GPS
coordinates.
 Provide for a series of DCP test readings along the route and document
the exact positions.
 Description of the topography along the route (sloping, edge of cliff,
adjacent to lake, forest surroundings, rivers, swampy areas, etc.) -
record distances and GPS coordinates.
 Description of the ground condition along the route and distances
(rocky, sandy, grassy, clay, etc.) - record distances and GPS
coordinates.
 Indicate the distance to the nearest town, where the civil works material
(sand, cement, stone, water, tools, etc.) can be sourced from.
 Locate possible warehouse/camp sites where material can safely be
stored.
 Indicate the availability of hospitals / clinics / police stations along the
route - in case required during operational activities.
 Plan the route to allow for projected road or rail deviations.
 Double-check recorded details on the return journey.

 
 
Pre-Install Meeting
 
A pre-install meeting or meetings must be held to discuss the survey results,
the optimum pulling sites, span lengths, installation equipment and hardware
requirements, logistics, splice locations, terrain and other vital installation
topics.
 
Checks to be undertaken prior to commencing with the planned aerial work
  Does the contractor have approved aerial route drawings, signed by the
client?
 Do the drawings show the alignment of the aerial route within the
wayleave specification?
 Are the wayleaves in place? (must be kept on site at all times).
 Have the locations of existing services been marked and shown on
drawings?
 Are the aerial route drawings being marked indicated on which side of
existing road/pathway to stay?
 Has the accessibility of poles to splicing vehicles been considered?
 Does the cable have a UV resistant cable jacket?

 
 
Wooden pole inspection (prior to installation)

 Correct type of pole supplied? (length and thickness)

 Excessively bent or cracked poles should never be used. Horizontal
cracks perpendicular to the grain of the wood may weaken the pole.
One large knot or several smaller ones at the same height on the pole
may be evidence of a weak point on the pole.
 Inspect the pole for evidence of termites or ants.
 Ensure that all poles are fitted with ‘end plates’ and strapping at both
ends.
 The poles should never be off loaded and stacked on the ground for
long periods as this could cause damage to the poles as well as the
environment.
 Hammer Test (existing poles): Rap the pole sharply with a hammer
weighing about 1kg, starting near the ground line – then continue
upwards around the pole to a height of approximately 1.5m. The
hammer will produce a clear sound and rebound sharply when striking
sound wood. Decayed areas will be indicated by a dull sound or a less
pronounced hammer rebound.

 
Hole-digging Tools
          
 
The tools provided for hole-digging include picks, shovels, earth augers,
crowbars, drills and sledge hammers. The tools to be used for any particular
work are determined predominantly by soil conditions. On large projects and
wherever ground conditions permit, hydraulically powered Earth Augers can
be used. It looks much like a corkscrew and produces extremely clean
holes.                                                                                               
 

Pole Holes   
 
Poles must be buried sufficiently deep for stability. The depth depends on the
height of the pole. Check with local authorities to confirm these dimensions.
 

 
All excavations for pole holes will be such that the survey peg indicates the
center of the hole. If the holes are too large, the soil will be unnecessarily
disturbed and the poles will not be supported by solid earth. (A diameter of
approximately 400mm (16 inches) is recommended). Where a hole is dug on
sloping ground, the depth of the hole shall be measured from the lowest point
on the ground surface. In extreme rocky conditions where holes cannot be
excavated to the specified depth, an arrangement between contractor and
client can be reached for poles to be set in concrete.
 
 
Poles set in Concrete
                                                                                                                             
                 

 
Where poles are planted in soil that is difficult to compact, such as sand and
swampy areas and in extreme rocky conditions, the poles can be cast in
concrete. Only new wooden poles can be set in concrete. The hole must be
circular in shape. The hole diameter must be kept to a minimum, but be
sufficiently wide to accommodate at least 85mm of concrete between the
sides of the pole and the undisturbed ground.
 
The concrete to be used must be made from a mixture of 1 part cement, three
parts sand and three parts crushed stone (1:3:3 mix - 15MPa). Concrete must
not be compacted around the poles, but thoroughly tamped around the pole
with a suitable wooden stick, until the hole is filled. The bottom of the pole
must be allowed to “breathe” – therefore, backfill with 10cm of soil before
pouring concrete.                                                                                    
 
 
 
Pole Spacing
 
It is advisable to maintain a uniform span length and depart from this only
when it is rendered necessary by conditions such as: (1) uneven ground (2)
sharp bends (3) or to avoid dangerous positions. This may necessitate the
planting of additional poles or omitting of poles. Steel measuring wires for
standard span lengths should be made up locally. When the length of span
has been chosen the appropriate wire should be used to determine the
distance between successive poles. A steel tape measure should be used for
checking the length of the measuring wire daily during the survey.
 
 
Local ADSS Span Lengths
 
All dielectric self-supporting fiber optic cable can be installed without a
messenger over relatively long spans. ADSS installation will be covered later.
 

 
 
 
Pole Planting Process

 Ensure that all holes necessary for pole dressing are drilled prior to
erection.
 A pole should be erected by laying it on the ground in such a position
that by raising the top section, the base should slide into the hole.
 Backfilling and ramming must take place in 150 mm ( 6 inches)
intervals.
 Where stones are available they should be used to stiffen the holding.
 During the backfill and ramming process, always ensure that pole
plumbness is maintained.

 
Suggested Pole Planting Work Practices

 Avoid dongas, culverts, drains or water channels.

 Avoid obstructing private roads and entrances.
 Restrict road crossings to a bare minimum, and if possible, stick to the
same side of the road throughout.
 Avoid trees and where not possible, select a position which will
minimise interference from trees – even at the expense of construction
costs being increased slightly by this action.
 Along national and other proclaimed roads the poles and stays should
be located in the position agreed to by the Road Authority and as
indicated on the wayleave.
  Keep the route as far away as practically possible from power lines.
 Where the ground is very soft, poles may be planted 300 mm ( 12 in)
deeper than specified, but only if the necessary vertical clearance is
maintained.
 Ensure that all holes necessary for pole dressing are drilled prior to
erection.
 Maintain a distance of at least 1m from trig beacons and stations.
 The principle to be followed in all cases is that neither stays nor poles
are to be planted where they are likely to cause obstruction or to be
dangerous to users of the road, or where they are likely to interfere with
ordinary road maintenance such as the clearing and trimming of the
edges of the road or the cutting of drains, gutters, etc.
 In railway reserves, the poles should be located as close as possible to
the boundary fence.

 
 
Types of Stays
 
Terminal Stays
 
Terminal stays are provided where the route starts and ends. This stay must
be on the side of the pole opposite to the direction of the cable route.
 

 
Line Stays
Line stays should be installed at every 13th pole along the route or spaced
alternatively as per specification. Line stays must be installed on poles either
side of rivers and road crossings where normal span lengths are exceeded.
 
 
 
 
Wind stays & Angle stays
 
Wind stays are used to stabilize a cable route against wind. Fitted at 90˚
against the direction of the cable route and on either side of a pole. Angle
stays are used to counter-act a change in direction of the cable route by more
than 15˚or as per client specs.
 

 
Stay Guards
 

Stay guards must be fitted on all stays exposed to pedestrians, cyclists or

vehicles, to make them more visible.
 
 
 
Struts
 

Struts can be used as an alternative to where stays create traffic hazards,

block roads or where a property owner objects to the fitting of a stay. Struts
must be installed on the opposite side of the pole to where the angle stay
would have been fitted, to counteract cable strain.           
 
Stay Holes
 
The cross-section of the hole shall be confined to the smallest size necessary
to accommodate a stay plate.
 

 
The depth of stay holes shall be 1.5 ( 5 feet) meters or at such a depth where
the unthreaded portion of the stay rod protrudes by no more than 25mm ( 1 in)
above ground level. Stay rods without plates may be used where solid rock is
encountered. The stay rod is now inserted in a hole drilled into the rock and
secured with cement. In difficult to dig ground conditions shallower holes are
allowed subject to approval and shall then be backfilled using concrete.
 
 
Spread/Height Ratio
 
The spread is the distance from the foot of the pole to the point to where the
stay enters the ground.
 

 The height is the distance from the ground to the pole attachment.
 Wind stays shall have a spread/height ratio of 0.6:1
 Terminal and line stays has a spread/height ratio of 1:1

 
 
 
Termination of Stay Wire to Pole or Crosshead
 

 
  Wrap the top pre-formed “make-off” without overlapping around the pole
twice at the prescribed height with ends meeting.
 Twist the top of the preformed “make-off” around the stay wire.
 Cut the stay wire at the correct length to ensure that the proper
spread/height ratio is maintained.
 Place the bottom of the preformed “make-off” through the crosshead
eye.
 Then pull tight and cut the suspension wire in line with the crosshead
and twist the bottom preformed “make-off” around the stay wire (ensure
that the crosshead is threaded to the outer most of the stay rod).

 
 
Messenger Wires (Suspension Strands)
 
If the cable is to be lashed to a messenger wire, the messenger wire must be
sufficiently strong to support the cable under expected environmental
conditions, including wind and possible ice in winter. If designing an aerial
system requires installing a messenger wire, the design must include
calculations for the messenger wire size based on expected cabling loads,
span lengths and other possible uses including future cables being added to
the span on the same messenger wire.
 
Designs for the messenger wire should include the type of wire chosen, how it
is attached to the poles for both dead ends and crossovers, slack and sag,
etc. The proper design is the minimum acceptable size of messenger wire
with adequate strength, because larger wires weigh more and are more
susceptible to wind and icing. Consulting with a knowledgeable applications
engineer, often those with the fiber optic cable supplier, can provide the
knowledge needed to design and install the proper messenger wires.
 
Installing messenger wires on electrical utility poles for fiber installation.
 
 
Lashing Fiber Optic Cable To A Messenger Cable
The installation process of a lashed aerial fiber optic cable will generally
require one or more bucket trucks to allow workers to reach the location of the
lashing, guide cables around poles and through trees or other obstacles and
move the lasher across poles.
 
Two trucks lashing cable to a messenger. The lasher is just to the left of the
pole.
 
 
There are two ways to lash cable to a messenger, the moving reel method
and the stationary reel method. In the moving reel method, the reel is moved
slowly under the route while the lasher is pulled along to lash the cable to the
messenger. This method generally only works when the reel vehicle can drive
along the entire route.
 

Moving reel method

 
The stationary reel method leaves the reel in place and the cable is pulled
along the route and temporarily attached to the messenger with cable blocks.
After the cable is placed, the lasher is pulled along the route to lash the cable.
The lasher can push the blocks to the next pole for removal or be removed as
the lasher moved along the route.
 

Stationary reel method

 
 

 
Lasher being pulled for stationary reel method
 
 
Extra Fiber For Handling And Service Loops
 
At the ends of every section of cable where it is being spliced or terminated,
the cable must be long enough to reach the splicing van or trailer plus about 5
m (16 feet) to allow for entry into the splicing van or trailer and have sufficient
cable length for preparation and splicing.
 
The cable plant design should include plans for location and placement of
service loops to safely and neatly store this excess cable and a splice closure
after splicing is complete.
 
 
Installation Of All-Dielectric Self-Supporting (ADSS) Cable
 
ADSS is a special OSP cable that is designed to sustain larger tension loads
over long periods of time. ADSS cable does not need any additional support
so it is small, lightweight and easy to install. Because it is non-conductive, it
can be installed on towers or poles nearer electric wires, making it especially
popular with electrical utilities. It can also be installed on long spans (up to 6
km in some cases) so it is easier to install in rugged or rural areas where it is
difficult to install a messenger wire first.
 
ADSS cable plants require careful designs to ensure the route is accessible
by versonnel and/or vehicles for pulling cable and splicing. In particular notes
the locations of poles so proper span lengths can be chosen. The cable plant
design should include plans for location and placement of service loops to
safely and neatly store this excess cable and a splice closure after splicing is
complete.
 
As with any specialized cable, it is recommended that the designer work with
the manufacturer to ensure the span lengths are chosen appropriately for the
cable and the proper mounting hardware is chosen. Every manufacturer of
ADSS cable has recommendations for hardware and special handling
instructions for installation. Hardware for the secured ends of the cable (called
dead-ends) and supports at intermediate poles must be chosen to be
appropriate for the cable size and tension loads. Special attention must be
paid if the cable bends at the pole; special hardware may be needed.
 
Since ADSS cable does not need a support wire, it needs to be supported by
pulleys at each pole during installation. After the cable has been pulled,
pulleys will be replaced by supports at intermediate  poles and dead-ends at
locations where it is tensioned for drops or because it is at the maximum span
length specified for the cable. Poles must be prepared for the installation of
the pulleys and the final cable hardware before cable pulling begins.
 

Installing ADSS Cable with the stationary reel method

 
A pulling rope is attached to the cable with a swivel pulling eye and a wire
grip. The cable reel should be placed well away from the first pole to prevent
bending the cable excessively at the first pulley. The reel should have a brake
to maintain significant tension as the cable is being pulled to prevent excess
sagging between poles. 
 
The cable is positioned on the first pulley by a worker in a bucket truck or if
the cable is low enough, by a worker on a ladder or using a special support
pole. The cable is pulled by the pull rope while the worker in the bucket truck
places the cable on the pulleys in sequence. Care should be taken to ensure
the cable does not touch the ground and get dirty.
 
A moving reel installation method can be done if there is a clear route for
driving a vehicle with the reel of cable. A bucket truck follows to place the
cable in the pulleys. Care must be taken to maintain the proper tension while
paying off the cable from the reel.
 
Once the entire cable has been pulled into place, the support hardware for
each intermediate pole can be attached and the pulleys removed. At the ends
of the section, the dead-end hardware is attached to the cable and the entire
span is tensioned from one end.
 
Since ADSS does not have a steel messenger, wind vibration can be a
problem with the lightweight fiber optic cable. Wind vibration can cause
degradation of the support hardware. Vibration dampers of several types can
be installed to control wind vibration.
 
At the ends of a section of cable where it is being spliced, the cable must be
long enough to reach the splicing van or trailer plus about 5 m (16 feet) to
allow for entry into the splicing van or trailer and have sufficient cable length
for preparation and splicing.
 
Dual dead-ends are used to secure the two cables meeting at the pole for
splicing. All slack cable should be stored on cable storage brackets attached
to the cables or the pole. Special fittings are available for slack storage and
should be chosen for the location of the storage.
 
 
 
Figure-8 Cable
 
Figure-8 cable is an OSP cable with a messenger wire molded on the side of
the cable. It is less commonly used for aerial installations but may be useful
where no messenger is available. It is installed like a messenger wire but care
must be taken to protect the fiber cable from damage.
 

 
 
 
(C) 2018 The Fiber Optic Association Inc.

Introduction and Classification of Aerial Fiber Optic Cables

Aerial fiber optic cable refers to a kind of fiber optic cable that is designed and used for outside plant
(OSP) installation between poles by being lashed to a wire rope messenger strand with a small
gauge wire. Generally speaking, they are usually made of heavy jackets and strong metal or aramid
strength members. Adopting aerial fiber optic cables, the aerial construction will allow the installers
to reuse the existing pole infrastructure without digging up other roads to bury cables or ducts, and
will also save the capital expenditure for the network providers to some degree.
According to the installation methods, aerial fiber optic cables can be generally classified as two
types—catenary wire and self-supporting: the former is a kind of regular outdoor loose-tube cables
that can be helically lashed to a messenger or another cable (common in CATV); the latter is strong
enough to support itself between structures without using conductive metal elements, which can be
further divided into All-Dielectric Self-Supporting (ADSS) cable and Figure 8 cable. Figure 8 aerial
cables are the most commonly-used aerial fiber optic cables. And it can be divided into three main
types: GYTC8S, GYXTC8Y, and GYXTC8S.
GYTC8S GYXTC8Y GYXTC8S

Small cable diameter.

Low dispersion and attenuation. Small cable diameter. Small cable diamet

Excellent mechanical and environmental Low dispersion and attenuation. Low dispersion and atte

performances. Excellent mechanical and environmental Excellent mechanical and en

Steel-wire strength member ensures performances. performances.

Features
tensile strength. High strength loose tube that is hydrolysis Corrugated steel tape and t

Corrugated steel tape and the PE outer resistant. sheath ensure crush res

sheath ensure crush resistance. Medium Density Polyethylene (PE) Jacket, Water blocking system to im

Water blocking system to improve the low friction installation. waterproof ability

waterproof ability.
 Figure

(Internal

Structure

Figure

(Optical

Cable)

Outdoor aerial application

Long-haul and LAN communication

Applicatio
Subscriber network systems
ns
Junction communication systems

CATV & Computer networks system

Installation Guide to Aerial Fiber Optic Cables

Aerial fiber optic cable installation is complicated and time-consuming on account of considerations
on natural destruction and man-made damages before installation. No matter what type of aerial
fiber cable is, the cable installation procedure is similar. The following steps will teach you how to
install aerial fiber cables.
Pre-Construction Preparations

Before starting the installation, the following preparation items must be done to ensure the whole
installation procedures go on wheels.

 A Pre-survey—planning the cable route, which will determine the aerial cable installation

method to be used, as well as the equipment and material requirements.

 Installation Issues—investigating the conditions of the ground along the route, including

clearance problems over roadways, driveways, trees or other obstructions, etc.

 Splice Locations—selecting splice locations allows verification of the transmission design

and makes preparation for cable order lengths, making sure that the locations won't lie in

sites where access is inconvenient or hazardous.

Aerial Fiber Optic Cable Installation Procedures

Two typical methods for aerial fiber optic cable installation—moving reel method and stationary reel
method. Here are the basic steps for these two installation methods.
Deploying Aerial Fiber Optic Cable With a Moving Reel Method
The moving reel method is normally adopted when a cable reel trailer or aerial lift truck can be
moved along the pole line and there are no obstructions to prevent raising the cable. It is a one-pass
operation without requiring the use of cable blocks or pull lines, saving time for the whole
deployment. However, it is not usually used in the entire cable deployment and the stationary reel
placing is needed invariably.

The deployment follows this sequence:

Step 1: The cable reel should be mounted on a reel carrier on a cable trailer or aerial line truck. Then
the reel carrier is driven along the cable route.

Step 2: As it advances along the route, the cable ought to be paid off the reel with no back tension
on the reel, guided to the pole, and supported with appropriate hardware.

Step 3: Check whether the distance between the aerial line truck or cable truck and the position of
the first pole is suitable, ensuring that there is sufficient slack cable available for splicing and slack
storage.

Step 4: Then the installer should fit the appropriate dead-end support to the cable, raise it to the
correct support level, and mount the dead-end to the pole.

Step 5: The placing vehicle must be driven parallel and close to the pole line as possible when
maintaining constant speed and tension.

Step 6: Once the cable pay-off is an adequate distance past the next pole in the route, the cable
should be raised to the required pole height and placed into a J hook or temporary support.

Step 7: Continue to install span by span until the entire run is completed and the final dead-end pole
has been reached.

Step 8: At this point, the cable should be tensioned to the correct sag level using suitable chain hoist
equipment at the "free" end of the cable before it is dead-ended to the pole.

Step 9: Finally, the cable can be lifted out of the temporary J hooks or temporary supports and
permanently fixed using tangent assemblies.
Deploying Aerial Fiber Optic Cable With Stationary Reel Method

The stationary reel method is generally used when the cable is installed above the existing lateral
cable and other obstructions. The types of vehicles and available placing equipment will also depend
on whether to use this method or not.

The deployment procedure is as follows:

Step 1: Install a series of temporary cable supports, chutes, or tangent blocks at each pole along the
route.

Step 2: Then, a pull line is threaded through the cable supports and attached to the outside of the
cable using a breakaway swivel and a cable pulling grip. It is then used to pull the cable through the
cable blocks into position.

Step 3: If the cable is pulled with a winch, the pulling rope or winch line must be installed through the
cable supports. A non-metallic rope or winch line should then be used to pull the cable.

Step 4: When the installation tension exceeds the maximum rated cable load (MRCL), the pulling
winch should be calibrated to stop the operation. A dynamometer with an audible alarm or visual
display should be used to monitor installation tension in case this type of winch isn't available.

Step 5: After the cable has been pulled into its final position, with slack for building access or for
splicing, the cable should be tensioned until the correct sag level is reached. Then it should be
terminated at each dead-end pole along the route.
Post-Construction Inspection

Work doesn't finish completely after aerial fiber optic cable installation. Post-construction inspection
is also important for a successful cable deployment. Check the following items to examine whether
your installation is successful.

1. Before splicing, inspect the aerial cable plant thoroughly, especially pay attention to the exact
location of all splice points.

2. Presence of kinked or damaged cable.

3. Improperly installed or missing drip loops.

4. Improperly installed or missing grounds.