How It’s Made: Fiber Optic Cables

We invite you on a tour of our manufacturing facilities in Carrollton, Georgia, USA. View the highly automated OFS manufacturing process that produces a wide variety of fiber optic products for telecommunications applications. Loose tube, microcables, flat ribbon, ADSS, ultra high density rollable ribbon cables and premise cables are all made here.

OFS Fiber

The Carrollton facility is vertically integrated, with fiber delivered on a daily basis from the OFS Norcross facility, approximately one hour away.

Quality

The facility is registered in compliance with the ISO 9001, ISO 14000, and TL 9000 standards. Traceability is maintained through every step of the process and ultimately back to the incoming fiber. The facility also has a fully functional product qualification lab and cable installation test track.

OFS Uses Both 200 and 250 Micron Fibers

OFS makes several different fiber structures in the Carrollton facility, including loose tube, flat ribbon and rollable ribbon structures. These structures are used in different cable types and applications.

Statistical Process Control Techniques

Each stage in the manufacturing process is highly controlled with appropriate dimensional targets and tolerances.

Colored ink is applied to Fiber

The industry standard color code is used to provide clear identification of the fibers over their lifetimes. Colored ink is applied to specified thicknesses, cured, and respooled for the next step in the process.

Buffer Tube Manufacturing Process

To make loose tubes, fibers or ribbons are paid off of their spools and a buffer tube is extruded around them. The Carrollton plant makes gel-free and gel-filled buffer tubes of different materials, including polypropylene and PBT. Different sized buffer tubes are used for different product types. Buffer tubes used in outside plant applications include either water blocking materials impregnated with super absorbent polymer or gel.

Ribbon Manufacturing Process

A matrix material is applied to the fibers to bind them together so they can be spliced as a group. 12 and 24 fiber flat ribbons are most common. Fiber color code alignment and geometric specifications are very important so ribbons can be spliced and connected in the field.

Rollable Ribbon

Rollable ribbons are only partially bonded together, enabling them to be rolled into a cylindrical package. Rollable ribbons are only partially bonded together, enabling them to be rolled into a cylindrical package. Since circles are more space efficient than rectangles, rollable ribbons cables can hold twice the fibers as comparable sized flat ribbon cables. Since these fibers are partially bonded, they can be easily spliced either as single fibers or as a ribbon, giving more deployment flexibility to the network operator.

Cabling

OFS makes two main types of cables – stranded cables and central tube cables.

Stranded Cable

Stranded cables are made by stranding tubes of fibers, flat ribbons, or rollable ribbons around a central member. Stranded cables are often used in applications requiring frequent access to fibers.

Central Tube Cables

Central tube cables are made by extruding a central tube around a fiber structure. Central tube cables can provide higher fiber density. ​  

Strength

Strength members, including fiberglass and aramid yarns are used to limit the strain on cables and fiber when tension is applied to cables.

Water Blocking Materials​

Yarns and tapes are added to provide water blocking outside the core of the cable.

Armor

For direct-buried cables, one or more steel armor layers may be added to provide rodent resistance and toning capability.

Outer Jacket

Different versions of polyethylene are used for the majority of outside plant cables. For inside plant or indoor/outdoor cables, materials are chosen to include appropriate flame and smoke resistance.

Information Printing

Type of cable, date of manufacture, length and a unique serial number that can enable traceability through the manufacturing process is printed.

Final Testing

Once manufacturing is complete, the finished cable undergoes final testing for length and optical properties.

Shipping

Cables are then packaged for shipment and loaded on trucks to their final destination. ​

HOW TO SPEAK “FIBER GEEK” | ARTICLE 5: CUT-OFF WAVELENGTH (COW)

WELCOME BACK, FIBER GEEKS! 

The first Article in this series focused on growth in bandwidth demand and attenuation in optical fibers. Article 2 concentrated on the several types of dispersion that exist in fiber today, closely followed by Article 3 – Fiber strength and reliability. Article 4 featured single-mode fiber geometries and now the latest release from OFS – Article 5, deals with “Cut-off Wavelength” (COW). This latest article will help the user to understand what “cut-off wavelength” is, why does it matter and how is it measured. 

CUT-OFF WAVELENGTH MAKES A COMEBACK IN IMPORTANCE 

Take an intro to fiber course, and you’ll learn about attenuation, dispersion, fiber geometry, maybe fiber strength. However, buried in the fine print of fiber specs is a parameter called cutoff wavelength. Although fiber manufacturers and some fiber users are aware of cutoff wavelength, it’s not as famous a parameter. Users still focus primarily on attenuation, maybe dispersion, as critical propagation properties. 

Due to relatively new operating wavelength requirements below 1310 nm, some astute end users are taking a renewed look at cutoff wavelength specifications. Relatively new Passive Optical Network (PON) protocols are looking at wavelengths as low as 1270 nm, which, optical spectrum-speaking, is a hop and a jump away from the historical cable cutoff wavelength specification λcc, 1260 nm. 

Different fibers do different jobs in today’s networks. Some fibers are bend insensitive. Some fibers enable more power to increase signal-to-noise ratios at ultra-high speeds. Cutoff wavelength is important for the performance of these fibers, but these fibers may require differences in measurement methods versus “standard” G.652-type fibers. We’ll talk about measurement methods later in this paper.

 WHAT IS CUT-OFF WAVELENGTH?

 In an optical fiber a number of different light-“modes” may exist. Modes are different types of light waves which may each carry different portions of light from the input to the output of the fiber. 

A multimode fiber, by definition, may carry several modes of light (several hundred), but in a single-mode fiber, only one mode is carried. 

The wavelength at which the fiber is at the cusp of changing from single-mode to multi-mode is called the Cut-off Wavelength. Typically, a fiber is considered to be single mode for wavelengths longer than the Cut-off Wavelength (COW) – and multimode at shorter wavelengths. In real life, the transition from single mode to multi-mode transmission does not occur abruptly at an isolated wavelength – but rather relatively smoothly over a range of wavelengths. The single-wavelength number on a specification is a simplification. 

The most common way to make a fiber single-mode is to reduce its core-size (diameter), but the contrast between the refractive index of the fiber core and the fiber cladding is also important. These two properties determine the “effective core size” which determines if the fiber is single mode or not at a given wavelength.

WHY IS IT IMPORTANT? 

The whole idea of a single-mode fiber is to keep the other modes out of the optical transmission. The reason is why Multi-Mode fibers are used for short distance transmission only: different modes traveling through a fiber take different paths. 

An optical pulse injected into a multi-mode fiber will be transmitted via different modes reaching the end of the fiber after slightly different travel times. Once the modes are recombined at the output of the fiber, the shape of the input pulse will have been distorted (blurred). This distorting effect on the pulse is known as modal dispersion and affects the bandwidth (MHz-km) of a multimode fiber. Single-mode fiber does not have modal dispersion, and consequently has much higher bandwidth over dramatically longer distances. 

The concept of cutoff wavelength is receiving renewed attention as next generation PON systems begin operating at wavelengths shorter than 1310 nm. This will be discussed in more depth later in the paper. 

“ONLY ONE LIGHT MODE IN MY SINGLE MODE FIBER, PLEASE!” 

The light mode intended for transmission in a single mode fiber is called the Fundamental Mode (also called LP01). All other modes are called Higher Order Modes, the most important of those is the Secondary Mode (LP11). 

And one might ask: “Where do those higher order modes come from?” 

These modes may be generated at splices and connections between fibers. The higher the splice/connection loss, the more powerful the Higher Order Modes (HOM) tend to be generated. 

HOMs are also called “leaky modes” because they are bound only loosely to the fiber core and tend to leak out of the fiber after traveling a relatively short distance – for wavelengths longer than the Cut-off Wavelength. The longer the distance, the more of those modes will have leaked out. 

The Cut-off Wavelength is defined as the wavelength at which the power level of the Higher Order Modes has been reduced by 19.3 dB relative to the level of the Fundamental Mode (strictly speaking this is true only for the Second Order Mode). 

MODAL NOISE PROBLEMS 

Do we need to worry about modal noise in today’s systems? Without wanting to raise unwarranted concerns, we want to highlight possible situations where modal noise may arise and be problematic. 

As briefly mentioned, splices or connectors will cause some of the light in the Fundamental Mode to be coupled into higher order modes. And likewise, light from Higher Order light modes may be coupled down into the fundamental mode by similar splices or connectors. 

Situations may arise where two splices or connectors are situated closely to each other. If they are too close, or if the Cut-off Wavelength is too high, parts of the HOMs generated at the first splice/connector may be coupled back down into the Fundamental Mode at the second splice/connector and mixed with light from the initial Fundamental Mode.

This may cause a problem because the travelling time for the light signal may typically be different in the Higher Order Modes than in the Fundamental Mode – and so the two signals may be somewhat out of phase when mixed together. Because of polarization and other effects, such phase difference may change as a result of temperature variation and stress, and this can result in a type of noise called Modal Noise. 

To create significant levels of modal noise two joints with large connection losses must exist (one is not enough). Furthermore, the two joints must be so closely spaced that Higher Order Modes have not leaked out of the fiber before reaching the second joint. And finally, the laser used must exhibit some level of mode partitioning. 

WHY ARE THERE DIFFERENT TYPES OF CUT-OFF WAVELENGTH? 

The Cut-off Wavelength of a fiber depends on the length of the fiber, the longer the fiber the lower the Cut-off Wavelength tends to be. For that reason, there are 3 types of Cut-off Wavelengths defined to match different applications: 

  • CABLE CUT-OFF WAVELENGTH (λcc): It is very easy to mistake this term for “Cabled COW” – but in principle it does not really matter whether the fiber is cabled or not. The initial intention with this parameter was to simulate a situation with two closely spaced cable splices, for example in a repair situation. 20 meters splicing distance was considered a relevant minimum – and to simulate fiber being deployed in splice cassettes, a 1-meter fiber length including one 80 mm loop was added in each end for the measurement set up. Effectively the full length of the fiber measured is 22 meters. 
  • JUMPER CUT-OFF WAVELENGTH (λcj): As the name suggests it simulates a jumper cable. It is measured on a 2-meter length of fiber with one winding which diameter may be freely defined – which in the US is typically 152 mm. 
  • FIBER CUT-OFF WAVELENGTH (λcf): As the name suggests it simulates a fiber being bent in only large diameters. In principle it is measured on a 2-meter length of fiber with one 280 mm diameter, but as explained later special care must be taken during measuring – especially for bend-insensitive fibers. 

Because Cable COW is measured on a 22 m fiber sample whereas Fiber COW is measured on 2 m fiber, Fiber COW is typically higher than Cable COW. 

Normally it is possible to find a good statistical correlation between the Cable COW and the Fiber COW. Since only 2-meter fiber is needed when measuring Fiber COW, it is easier to measure Fiber COW than Cable COW where 22 meters are needed. And because of the correlation Fiber COW measurements are often sufficient to ensure that the Cable COW is within limits. 

Also, cabling fibers often has an effect of stripping out higher order modes, due to either macro or micro-bending of the fibers inside the cable sheath. In situations where this effect is significant, Cable COW measured on a cabled fiber may be lower than Cable COW measured on a non-cabled fiber (and of course lower than Fiber COW). 

It depends on the fiber type and design, but a realistic example for a step-index fiber is a fiber cutoff of 1350 nm could have a corresponding cable COW of 1260 nm.

WHY IS CABLE CUT-OFF WAVELENGTH SPECIFIED AS 1260 nm IN IEC AND ITU-T RECOMMENDATIONS? 

Initially Single Mode fibers were intended for 1310 nm operation, and manufacturing variability of lasers were rather large, so lasers sold as “1310 nm lasers” could in fact emit light at rather different wavelengths than 1310 nm. So, to create a certain “guard band”, the maximum Cable COW was defined to be 1260 nm. 

Today, laser wavelengths may be more tightly controlled and extremely accurate, but those lasers may also be more costly than less accurate lasers. Furthermore, some FTTH/PON transmission formats (especially newer ones such as XGS-PON) use wavelengths close to 1260 nm. So, the 1260 nm COW today has renewed relevance. 

BEND-INSENSITIVE FIBERS – AND PROBLEMS MEASURING THEIR ATTENUATION 

This may seem like a subject entirely different from Cut-off Wavelength – but measurement problems are quite similar and may not be obvious at all. 

To determine the Cut-off Wavelength, two measurements of the power on the output of the fiber are compared: 

A. Power in the Fundamental Mode (LP01) only 

B. Power in the Fundamental Mode (LP01) and the Higher Order Modes (which in practical terms means the Second Order Mode: LP11

“B” is just a simple measurement of output of the fiber – including all modes. But in order to measure “A” we need a filter to get rid of the Higher Order Modes. They are loosely bound modes, and in a standard G.652 fiber they will tend to leak out of the fiber relatively quickly – especially when the fiber is bent in small diameter loops. Two 80 mm loops – perhaps with an added 25 mm loop – in a 2-meter G.652 fiber will do the trick, so this is often used as a HOM filter. 

MEASURING ATTENUATION USING THE CUT-BACK METHOD 

When measuring the attenuation of a Bend Insensitive fiber – including some advanced Large Area G.654 fibers – different methods may be used. The Cut Back measurement method is often considered the reference method. Light is injected into the Fiber Under Test (FUT) and the aim is to measure the power injected into the fiber (at the beginning of the fiber) and compare that to the measured power at the end of the fiber. Subtract the two and the fiber attenuation is found – divide this by the fiber length, and the attenuation in dB/km is found. 

To determine the exact input power level, the fiber is often cut a short distance from the actual input end of the FUT, and the input power level is measured. 

It is always important to avoid Higher Order Modes at the input of the measured fiber, since they will leak out of the FUT over a relatively short distance and be missing at the output of the FUT. HOMs are like ghosts – appearing at the input of the FUT and then disappearing along the fiber length. With these around, one would tend to measure a “too high” power level at the input of the fiber – and the resulting calculated fiber attenuation will then be too high. Such increased attenuation will tend to be more pronounced at shorter wavelengths. 

Previously, such attenuation measurements were predominantly made on standard G.652 fiber and that was easy. You could grab the first 2 meters of the G.652 FUT, make the desired 2 or 3 loops directly on the fiber itself within those first 2 meters of fiber and that would give you your HOM filter and get rid of the Higher Order Modes. Your cut-back point for attenuation measurement could then be situated right after the first 2 meters of the FUT – so you would only waste 2 – 3 meters of fiber for each measurement. 

But on bend insensitive fibers it is not quite as easy to get rid of the higher order modes. These fibers tend to better restrict the light from leaking out during fiber bends. Unfortunately, that is true for the higher order light modes as well – those modes which we would want to get rid of when measuring the fiber. 

However, the 2-meter G.652 standard fiber with two 80 mm and one 25 mm loop may still be used. It may be spliced to the Fiber Under Test and if a good splice is obtained only an insignificant level of Higher Order Modes may be generated at that splice point – ensuring a good measurement if the splice point is also used as the Cut Back Point. 

Another possibility is to use the first 22 meters of the FUT including the two loops of 80 mm recommended for measuring Cut-off Wavelength. Since that is the recommended test set up for COW measurement, you know that after 22 meters the HOM level is very low at the FUT’s COW or longer wavelengths. The Cut Back Point may be chosen to be just after the first 22 meters of the FUT but if very high precision measurement is required, or if FUT is relatively short, more than 22 meters may be needed. 

On OTDR measurements problems caused by HOMs are often hidden. The reason for this is that an OTDR will typically have a “Dead-Zone” during which the light detector of the OTDR is recovering and as such unable to detect the incoming light signal. This may cover some 500 meters during which length the HOMs have since long leaked out of the fiber.

Future Proof Your RDOF Investment


Transcript:

Hi, I’m Mark Boxer Technical Manager for Solutions and Applications Engineering for OFS and this is what’s new in my world.

We are seeing a tremendous amount of recognition around the country that fiber is the answer for connectivity now and into the future. We’ve seen just unprecedented interest in fiber networks around the country and the benefits that bandwidth brings to an area and specifically with a focus in rural areas. I live in a rural area this is an old, restored farmhouse and we are seeing a lot of interest in broadband even in very remote and rural areas. The Fiber Broadband Association is in the process of publishing some projections showing that demand for a household will exceed a gigabit per second.

If you’ve been using OFS fiber for years you know this is something you’ve probably heard about for a long period of time. It’s something your network is well prepared for. There has been lots of innovation especially over the last few years with fiber. There have been some groundbreaking technologies introduced and one of those is the concept of rollable ribbon. We see rollable ribbon making its way really into all parts of the network and we think that’s going to bring a tremendous amount of benefits to network operators including higher density. Once you have higher fiber density you can put more fibers into a smaller space. That frees up a lot of benefits with underground networks because you can pack more fibers into a smaller duct. For aerial networks now you can go longer distances with less sag or less weight on your poles so a lot of different benefits there. Also, since it’s a ribbon then you get the benefit of ribbon splicing.

We’re seeing a lot of interest in rollable ribbon being applied throughout the network and on top of that we’re seeing a lot of interest in builds to the home, builds to the MDU. These networks have a lot of bends and so they require that their fibers have a lot of bend insensitivity and so we’ve seen a lot of builds of those kinds over the last six months to year.

At OFS we bring a lot of different solutions. If you’re a network operator don’t get overwhelmed that you have to use this technology or that technology. A lot of these are just different tools in the toolbox and you can mix and match to make your network the most sustainable and viable for the for the future and OFS can really help with that.

So, one of the things that we are happy to do is spend some time with you looking at the choices that go into the network. So if you’re interested in learning more about some of the choices and the trade-offs in their network and how we could potentially help with that please feel free to contact me or your OFS representative and we’d be happy to help.

And that’s what’s new in my world.

HOW TO SPEAK “FIBER GEEK” | ARTICLE 4: SINGLE-MODE FIBER GEOMETRIES

 WELCOME BACK, FIBER GEEKS! 

The first Article in this series focused on growth in bandwidth demand and attenuation in optical fibers. Article 2 focused on several types of dispersion that exist in fiber, followed by Article 3 – Fiber strength and reliability. 

This article, the fourth in the series, will focus on single-mode fiber geometries. 

When speaking about fiber geometries, we typically consider diameters of core, MFD (Mode Field Diameter), cladding and coating. Also, the concentricities of those and the ovalities – and then the actual curl of the fiber. More on that later however. 

The primary impact of fiber geometry occurs in the splicing and connectorization processes. Fibers with good and consistent geometry tend to splice and connect better with lower connectorization losses than do others. However, as highlighted previously in Article 2, fiber concentricity could also play an important role for polarization mode dispersion (PMD) performance and is an important parameter. For high quality fibers geometry has been good for a long time, and we may have been so accustomed to it that we sometimes take it for granted. However, this may not always be the case. 

We’ll work our way through a typical fiber specification, highlighting the importance of various single-mode fiber geometry specifications. In the first figure we present the basic properties of the geometry of a fiber. 

CLADDING DIAMETER (OUTER GLASS DIAMETER) 

Cladding diameter is the outer diameter of the glass portion of the fiber. For telecommunications fibers, this diameter has been 125 microns (μm) for a very long time. On the other hand, the diameter tolerance has not always been 0.7 μm. 

During the 1980s, optical fibers had outer diameter tolerances as high as +/- 3.0 μm. As illustrated in Figure 2, trying to match up 8 micron fiber cores when cladding diameters varied between 122 and 128 μm in diameter could result in very high losses, since the two cores may be significantly misaligned even though the claddings of the two fibers are perfectly aligned. This situation is why fusion splicing machines required additional technology to help align the actual fiber cores. This extra technology, however, increased the price of the splicing units. 

As the industry matured, single-mode fiber diameters remained the same at 125 μm. However, over the same time period, the specification tolerance declined to 0.7 μm with typical variation along the length of the fiber becoming even tighter. 

From a manufacturing perspective, such tolerances were not easy to achieve. When fiber was first invented, the developers had to create manufacturing methods along with ways to measure fiber diameter. When manufacturing to tolerances of tenths of a micron, inputs such as stray air currents, vibrations or particulate in the glass can cause significant diameter variability. These factors require top- tier fiber manufacturers to have very tight control over their processes and procedures. 

As diameter variability has decreased, splicing machines have reduced the alignment technologies needed. While there has been a significant decrease in the price of these machines, there has been no corresponding substantial increase in splice loss. Core alignment splicing machines still provide the best performance, however smaller “fixed V-groove” machines with lower prices and limited alignment capability have significantly reduced the performance gap. The typical splice loss for OFS AllWave®+ Zero Water Peak (ZWP) Optical Fiber, spliced using a core alignment splicing machine, is roughly 0.03 dB, whereas the same fibers spliced with a fixed V-groove machine have an average loss of approximately 0.05 dB. In a comparison of the absolute values, that is a significant difference. However, in the context of use in most fiber optic network applications, the difference is actually rather insignificant. 

Enabled by tighter fiber geometry, the reduced cost of splicing machines is one of the factors that have contributed to the overall decrease in the cost of building fiber networks. In fact, this change has ultimately enabled fiber to the home to become a reality. 

MODE FIELD DIAMETER (MFD) 

Mode field diameter (MFD) is another specification related to fiber geometry. In a typical G.652.D- compliant single-mode fiber, not all of the light travels in the core; in fact, a small amount of light travels in the fiber cladding. The term MFD is a measure of the diameter of the optical power density distribution, which is the diameter in which 95% of the power resides. 

MFD is important for two main reasons. 

The first reason is that fiber bending loss is typically correlated with MFD. Unless special fiber designs are used, as the MFD increases, bend loss also increases, and vice versa. Historically, fibers with smaller mode field diameters are less bend sensitive. That being said, modern fiber designs has enabled fiber manufacturers to make bend insensitive, single-mode fibers with a nominal mode field diameter of 9.2 μm – which is the same as the vast majority of classical standard G.652.D fibers. However, there are also fibers with MFD as high as 8.6 micron offering superior bending performance, with very low bending losses even for bending diameters as low as 5 mm – which is half of the smallest bending diameter specified by ITU-T for G.657.B3 fibers. 

Second, because of the ease of use, OTDR measuring instruments are often used to measure attenuation. However, OTDRs only give correct results if the measurement conditions are perfect. A sudden jump in MFD is definitely not a perfect measurement condition. So in the case where two fibers of different mode field diameters are spliced together, the OTDR will errantly show either a power gain, known as a “gainer”, or elevated loss, depending on in which direction the measurement is taken. When measured from the larger MFD into the smaller, a gainer is produced. When measured from the smaller MFD into the larger, an elevated loss is seen, as shown below. This is an artifact of the OTDR measurement method and does not affect transmission properties. Breaking and re-splicing the fibers will typically not change the result, unless there’s a bad cleave or some other anomaly at the splice interface. The correct way to measure splices overall is bi-directional OTDR, which is even more important for fibers with MFD mismatches. 

This fact shows why it may be advantageous to use bend-insensitive fiber with MFDs of 9.2 micron. Since experience with installation and measurements of fibers is almost always gained working with standard G.652.D fibers with MFDs of 9.2 micron, such bend insensitive G.657 fibers will behave in a very familiar way in terms of splicing and control measurements. Especially when splicing to the installed base of 9.2 μm MFD single-mode fiber. 

CORE-CLAD CONCENTRICITY ERROR 

Core/clad concentricity error (CCCE or CCE) is also called Core-Clad Eccentricity and measures how well the core is centered in the fiber. CCCE is measured in microns and, of course, the closer the core is placed to perfect center, the lower the CCCE value and the better it is. Again, core aligning splicers tend to give the lowest splice losses. 

CLADDING NON-CIRCULARITY 

Clad non-circularity is also called Cladding Ovality and measures a fiber’s deviation from being perfectly circular – becoming an oval rather than a circle. It is measured as a percentage difference between the “long” and the “short” diameter of an oval. If the Cladding Non-Circularity is zero the cladding forms a perfectly round circle. Similar to other fiber properties, better cladding non-circularity can result in improved splicing and connectorization performance. 

FIBER COATING 

While coating specifications are not as stringent as glass specifications, they are also important – especially when fibers are used in ribbons. The two main parameters are Coating Diameter (Uncolored) 237 – 247 μm and Coating-Clad Concentricity Error of max. 0.5 micron. 

For roughly the first 30 years of single-mode fiber manufacturing, a coating nominal diameter of approximately 245-250 μm was standard in the industry. However, in 2014, OFS launched a 200 μm fiber in response to the need for higher fiber density in fiber optic cable designs. 

Although the difference between 200 and 250 μm is not tremendously large, smaller diameter fibers can enable twice the fiber count in the same size buffer tube in a cable, while also still preserving long-term reliability. This fact has led to many new compact cable designs, including extremely small micro-cables, loose tube duct cables and all-dielectric, self-supporting (ADSS) aerial cables. As the demand for higher fiber density continues to increase, we can expect to see even more cable designs taking advantage of smaller diameter coatings. Important though, is that the coating will still be able to sufficiently shield the fibers from micro-bending, which may otherwise cause increased losses in the fiber when the fiber is inadvertently being “squeezed” in the cable – especially with low temperature. 

Another possibility is to make the glass fiber itself less sensitive to such potential problems – so it’s not just a simple task of reducing the thickness of the fiber coating, but obtaining a sufficiently good fiber performance too. 

Besides inherent size, coating diameter control is extremely important. Coating diameter can affect the size of the overall bundle in fibers. If the coating is too thick, the overall bundle may incur strain sooner than expected. If, on the other hand, coating concentricity is not good, there can be additional concerns particularly when splicing ribbons. 

FIBER CURL 

The final parameter we will discuss is fiber curl. 

Fiber curl assesses the non-linearity of bare glass. In other words, fiber curl measures how straight the glass fiber is when no external stressors are present. If imbalanced stresses are frozen into a fiber during the draw process, curl can result. This curl can show up during the splicing of fiber optic ribbons or when fixed V-groove splicing machines are used. 

If curl occurs, the two ends of the fiber will not be straight or match up during the splicing process. This situation leads to both high losses and difficulty splicing. Curl is measured in meters of curl, with a typical specification being > 4m. When optical fiber comes out of the fiber draw, it is annealed during the manufacturing process to reduce the effects of curl. As a result of this process, for users of top-quality fiber, fiber curl poses no concern for typical telecom applications. 

Fiber geometry is often taken for granted by end users, primarily because it has been very good for so long. However, it has taken hard work and the contributions of innumerable people over many years for fiber geometry quality to reach its current level. 

HOW TO SPEAK “FIBER GEEK” | ARTICLE 3: FIBER RELIABILITY

WELCOME BACK, FIBER GEEKS! 

Article 1 in this series focused on growth in bandwidth demand and attenuation in optical fibers caused by bending, and the built-in mechanisms scattering and absorption. Article 2 focused on several types of dispersion that exist in fiber. 

This article, the third in the series, will focus on fiber strength and reliability. 

FIBER RELIABILITY

 Except for products specifically intended for short time use only, lifetime and durability are normally of rather high importance for the user. As for optical fibers, the installation of the cabled fibers is typically both time consuming and very costly, and so reliability and lifetime may be even more important. 

Historically this has resulted in a lot of focus on fiber lifetime, and although materials for optical fiber manufacture have been under constant improvement over the last 30 – 40 years, the longevity of even some of the first fiber optic cables is impressive. 

Unlike most other fiber properties, we are here dealing with statistical properties which are difficult and time consuming to measure, and the exact lifetime of an individual fiber cannot be predicted. 

As such this is not different from lifetime considerations for other products, but failure consequences may typically be more severe. 

Fiber has a reputation for excellent reliability, and that hasn’t been acquired by luck. For most end users, fiber just works, and they don’t give the topic much thought. However, this performance is based on a deep understanding of the mechanical performance of the glass to the molecular level. Researchers have spent entire careers acquiring this understanding and translating this knowledge to product design, manufacturing, and installation recommendations. 

WHY DO FIBERS BREAK?

For starters, pristine glass optical fiber is stronger than steel, when measured diameter to diameter. Although the actual intrinsic strength of glass can vary according with sample preparation, it is often greater than 700,000 pounds/square inch (PSI), compared to 70,000- 85,000 PSI for cold rolled steel. 

 Although glass is very strong, it is brittle so it cannot be stretched for large amounts without breaking. Imperfections and mechanical flaws may weaken the glass significantly as may impurities even as small as fractions of a micron. 

In order to limit the number of impurities to an absolute minimum, OFS use synthetic silica to make our glass. Synthetic silica (SiO2) is hence made from ultra-pure chemicals which are pure to the parts per billion level, and the actual core of the fiber is pure to the 10 parts per trillion level. It would resemble allowing only one bad rice-grain in a 20 ft standard shipping container filled with good rice. By keeping such an extremely high glass purity, the risk of fiber weakening because of impurities is minimized. Other manufacturing methods may not provide similar high purity of the finished glass fiber. 

 

But impurities are not the only reasons that may cause a fiber to break. A glass surface typically contains a number of cracks of different sizes. This is true for fiber glass surfaces as well, and when stress is applied to the fiber, the cracks will grow larger. As might be expected, a large stress on the fiber will cause fiber cracks and other flaws to grow more rapidly than if only a small stress is applied to that fiber. 

There may be a huge difference in the speed by which the cracks grow, and this may not always seem obvious. More on that later. 

Another issue which may not seem obvious is that stress is also applied to a fiber simply by bending that fiber. As shown in Figure 3 the outermost surface of a fiber bend will be stretched and result in tension – whereas the innermost surface will be compressed. Compression does not cause cracks in the fiber surface to grow larger – but tension does. 

It probably seems more obvious that tension applied along the length of the fiber (typically by pulling the fiber) will also cause cracks and flaws to grow. 

 

 

When cracks or flaws grow larger the strength of the fiber is reduced because a smaller cross section of the fiber is now holding the fiber together. So, a fiber with large cracks or flaws will break at a lower strain than a pristine fiber containing only small (or no) cracks. 

To ensure that no large cracks or flaws are present in the fiber, a manufacturing step called “proof testing” is added after the actual making of the fiber. During proof testing, every 1 – 2 meter section of the fiber is subjected to a relatively large strain. So large that it makes the fiber 1% longer. Under such large strain cracks and flaws in the fiber will grow quickly, and if the cracks are large enough the fiber will simply break. This ensures that after proof testing no large cracks or flaws exist in the fiber anymore. However, small cracks and flaws will still be present and that is why the glass production method is so important. The purer the glass, the less likely problems will occur long term. 

 

The proof test itself is simple. Fiber is typically guided around a pulley with a 1 kg weight attached to it for 100 kpsi proof test (Figure 6). 

Fibers for use in submarine cables are normally proof tested even more stringently (2% elongation) to ensure even better lifetime performance. 

An undamaged fiber which is proof tested 1% (100 kpsi) and used in standard applications and cable constructions will have a very long lifetime – typically 40 years or more. But fibers may get damaged. If that happens before proof testing, the fiber will break and the problem is eliminated.

However, damage to the fiber after proof testing may happen on rare occasions. Fibers are wound on spools for easy and safe handling and transportation and if the wound fiber “package” is somehow affected by a mechanical impact – as for example if the fiber spool is accidently dropped and hits the corner of a table – this may create large cracks in the fiber surface, and the fiber may suddenly not possess the expected strength anymore. 

Likewise, the actual glass surface of the fiber may be “scratched” – potentially leaving large cracks in the fiber surface. Such scratches may have different causes but probably the most obvious of those causes is that the tool used to strip the coating of the glass fiber may inadvertently inflict scratches on the fiber surface. Also, sharp small objects may penetrate the fiber coating if the fiber is being forced against them – again possibly scratching the fiber glass surface. 

In “loose tube” cable constructions fibers are placed in plastic tubes, which are helically wound around the cable-core. Such a helical construction ensures that cables may be pulled – and thereby elongated – quite a bit during installation before strain is transmitted to the actual fibers. The effect is the same as seen in a classical “spiral” telephone handset cord which can be extended quite a long way without putting additional strain on the copper wires within the cord. 

Most cable constructions are similarly able to “absorb” significant strain on the cable before transmitting any additional strain to the fibers themselves, and in general such a “maximum pulling force” is always specified for cables – although different names may be used for it. 

Nevertheless, a small risk does exist if for example heavy machinery stretched sections of a cable so much that the actual fibers were unintentionally subjected to excess tension, leading to fast growth of cracks in the fiber surface. As a result, the fiber lifetime may have been reduced – possibly without leaving traces on the cable or the fiber themselves. With modern equipment, training and knowledge, fiber damage problems are, however, highly uncommon. 

In some situations, thermal variances may result in the movement of cables relative to the closures, and that may put the fibers under additional tension from time to time. 

Because of helical structures present in many cable constructions the fiber is effectively situated in large diameter bends along the full cable length. Furthermore, it is common practice to coil a small amount of excess fiber in 50 mm or 60 mm coils in splice cassettes. So, in reality, the fiber is almost always under constant – but small – stress during its operational lifetime. Since the bending diameters are typically large the resulting lifetime for an un-damaged fiber is still very long. The breaking risk of a high-quality fiber under such conditions is therefore negligible. A very important feature for cables carrying signals to thousands of users.

For a damaged fiber, however, a rather puzzling situation may arise. The fiber may be fully installed, control measured, and all parameters may appear to be fine. However, because of damage the fiber may contain rather large cracks, which may propagate and hence weaken the fiber. Even with commonly used cable constructions and splice cassettes, damaged fibers may break rather quickly. It’s possible that fiber breaks can start appearing months after installation when everything appeared to be in order at the time of installation and even when nobody has actually touched the fibers since. 

Some fiber cables are specifically intended for applications where small bending diameters are required. This could be drop cables to cell towers or 5G small cells – and in particular cables intended for installation in homes and apartments where it is important to be able to route the cable closely around door frames, windows and ceilings in order to make the cable as invisible as possible. Cables as thin as 0.6 mm are available, which may be bent with a radius as tight as 2.5 mm, while maintaining a failure risk which is still much smaller than that of typical electronic consumer equipment. 

In figure 8) the results of a typical lifetime test are shown. The test registers the lifetime of a high-quality fiber when that fiber is bent at different diameters. What is important to notice is that lifetime is hugely dependent on the bending radius. For the fiber in the test, the lifetime changes from 1 minute to 40 years by changing the bending radius from 1.0 mm to 1.8 mm. Although very long lifetime predictions tend to be somewhat questionable, it is obvious that a bending radius of 2.5 mm – like the one recommended for some ultra-bend insensitive fibers – will still give a very long lifetime. 

However, rather than focusing on lifetime it may be much more interesting for the user to have a prediction of the number of expected failures over a reasonable period of time. For example, computer hard disk drives are often characterized by the Annualized Failure Rate (AFR) representing the expected average number of failures over one year. Some investigations have shown approximately 1% of such failures expected over a year. 

To compare fibers with that, and using internationally recognized lifetime models, a fiber cable used inside an apartment with for example 12 quarter-circle bends of 2.5 mm radius will have an expected failure rate of 45 ppm over 30 years. That is 0.0045% failure risk over 30 years (not in just 1 year). 

So, fiber optic cables in typical indoor home installations with bend radii as low as 2.5 mm still have exceptionally less failure risks than the typical electronic household equipment which we know and use in our daily life. And since a – very rare – fiber break will affect only a few users, the possibility of having almost invisible cable installations using thin cables and 2.5 mm radius bending outweighs the small risk of failure for many users.

HOW TO SPEAK “FIBER GEEK” | ARTICLE 2: DISPERSION

WELCOME BACK, FIBER GEEKS! 

As a quick refresher, article 1 in this series focused on growth in bandwidth demand. We also looked at attenuation in optical fibers caused by factors external to the fiber e.g. bending, and built in attenuation mechanisms i.e. scattering and absorption. 

In this second article, we will focus on the several types of dispersion that exist in fiber. 

DISPERSION – WHAT IS IT? 

Much, but not all, of the traffic traveling through fiber networks takes the form of pulses of laser light. Such a pulse is created by turning a laser on and off, creating light pulses where “no light” represents a digital “0” – and “full light” represents a digital “1”. Digital information is consequently a series of “no light” and “full light” transmitted in a code which a receiver at the other end of the fiber understands and can convert to a digital electrical signal. 

Illustrating such a signal would be a series of square pulses as shown in Figure 1. 

Whenever such a signal is affected by dispersion, the edges of the square pulses will be rounded, and the pulse will be spread out over time. So dispersion broadens the pulses. 

If the dispersion is small, the detector at the other end of the fiber will still be able to detect the signal correctly. Once the dispersion grows too large, the broadened pulses will overlap each other and the detector will start misreading the signal, creating errors that will effectively hamper the transmission quality. A measure of that quality is the BER (Bit Error Rate) which states the number of transmission errors relative to the total number of transmitted bits. 

Since a faster transmission rate requires pulses to be of a shorter duration, this also means that a given level of dispersion will be more harmful to faster transmission rate signals. Furthermore, dispersion is almost always dependent on the fiber length – the longer the fiber, the greater the dispersion. 

Hence transmission is limited by: A) The dispersion of the fiber B) The transmission rate, and C) The length of the fiber. Dispersion can be described as a “speed limiter”- and the 3 main types are: 

Modal Dispersion, Chromatic Dispersion and Polarization Mode Dispersion.

Modal Dispersion is the most serious of the dispersion types, and hence the most severe “speed limiter”. 

Light “modes” are different types of waves carrying the light through the fiber. In a “Multi Mode” fiber, the core is rather large and may typically allow up to 17 different modes to propagate. In a “Single Mode” fiber, the core is so small that it will allow only one mode to propagate. 

The problem is that the different modes follow different paths through the fiber – and these paths are of different lengths. Some modes travel close to the center of the core – others bounce against the outer edges of the core, and these modes travel a longer way than the ones close to the center. So the different modes travel different distances – and hence some tend to travel faster than others. Parts of the light being injected into the fiber will travel via one mode – other parts via another mode – and so on. If nothing is done to mitigate this, parts of the input signal will arrive at the output later than other parts – and this will cause the output signal to be “dispersed” relative to the input signal as illustrated in Figure 1. 

To try to minimize the dispersion of the signal to the output of the fiber, the fiber core of a multimode fiber is designed to delay the Light Modes travelling close to the core (which is the shortest distance) and to speed up the modes travelling the longest distance. In a perfect world this would result in all modes bringing light simultaneously to the output of the fiber. Alas the world is less than perfect, and as such a bit of Modal Dispersion cannot be avoided in real life. 

This means that, even though Multimode fibers are able to use very price efficient light sources (like LEDs or VCSELs) they are still limited to transmission distances of typically less than 2 km, actually often less than a few hundred meters. 

The way to avoid Modal Dispersion is to shrink the size of the fiber core. In a small fiber core there is only room for one light mode to exist, called the Fundamental Mode. In such single-mode fibers, higher order modes may indeed be generated at splices or connectors, but they will leak out of the fiber after traveling a short distance through the fiber. 

Having now found a way to avoid the most important speed limiter we can turn our attention to the next in line. 

Chromatic Dispersion means that light of different wavelengths travel with different speeds along the fiber. Again, such a difference results in the “blurring” of the signal on the output side of the fiber and effectively acts as a speed limiter. 

One might wonder why this should be such a problem, since lasers used to inject light into the fiber have very precisely defined and stable wavelengths. However, quickly turning a laser light on and off actually by itself generates a number of new wavelengths close to the original laser wavelength. Most of these new wavelengths are luckily quite weak and will not cause problems – but unfortunately as the laser light is turned on and off ever more quickly, the range of generated wavelengths broadens (Figure 5). 

In such transmission systems the problems caused by Chromatic Dispersion worsen with increasing transmission speed and with longer fiber lengths (scaling linearly with fiber length). 

Trying to minimize problems with Chromatic Dispersion the “Dispersion Shifted” (ITU-T G.653) fiber type was initially developed. In classical standard single-mode (ITU-T G.652) fibers the Chromatic Dispersion is zero around 1310 nm. The Dispersion Shifted fibers were targeted for the Chromatic Dispersion to be zero around 1550 nm, because the attenuation of the fiber is lower at 1550 nm and so this combination seemed ideal. 

Basically, this worked fine right up until DWDM arrived. In DWDM systems a number of individual channels are transmitted over the same fiber. Each channel is assigned a unique wavelength, but unfortunately the fiber non-linearity called Four Wave Mixing (FWM) tends to cause unwanted noise problems in DWDM systems if the Chromatic Dispersion in the fiber is very low. 

So realizing that some level of Chromatic Dispersion is preferable in order to limit fiber non-linearity problems in DWDM systems, Non-Zero Dispersion Shifted fiber (ITU-T G.655) was developed. This fiber type has a small amount of Chromatic Dispersion around 1550 nm (significantly smaller than standard G.652 fibers) so the “speed limitation” is smaller – but still the Chromatic Dispersion is high enough to reduce non-linearity problems very significantly. Later the G.656 Non- Zero Dispersion Shifted fibers were developed as a response to the demand for an increasing number of channels in DWDM systems. When the number of channels go up, the individual channels need to be packed more closely together – and that in turn requires more Chromatic Dispersion in the fiber to reduce the effect of the Four Wave Mixing. 

In parallel with the development of new fiber types with different Chromatic Dispersion characteristics, special devices with negative Chromatic Dispersion were developed. Since transmission fibers normally have positive Chromatic Dispersion, a combination of those two can be used to reduce total Chromatic Dispersion for a full fiber link to almost zero. 

With the ability to reduce the total chromatic dispersion of a transmission link, the higher Chromatic Dispersion of the G.656 fibers was consequently an acceptable technical compromise – leaving only cost issues still to be considered. 

In many of the recent high-capacity transmission systems, the Chromatic Dispersion of the transmission fiber is compensated electronically with high efficiency, and for such systems fibers with high Chromatic Dispersion may actually be advantageous because it helps to limit fiber non-linearities.

Just to make confusion complete, a single-mode fiber will actually be able to carry TWO versions of the fundamental light mode. The reason for this is that light may exist in two different polarizations, the modes of which are perpendicular to one another. The phenomenon is known from some sunglasses which cut away one of those polarization modes. Reflected sunlight from the sea surface or a wet road will predominantly consist of light in one of these polarization modes – whereas light reflected by other objects will consist of a mixture of the two polarization modes. Cutting away the polarization mode of the reflected light will “kill” the reflections, but let the other polarization mode pass through the glasses, leaving other objects visible. 

In an optical fiber, the two polarization modes will both exist, but may travel at different speeds through the fiber. Such speed-differences will arise if the fiber core is not perfectly circular and if stress is present in the fiber. Stress can be “frozen” into the fiber during manufacturing if the fiber geometry is not absolutely perfect, for example, if the cladding or coating is not circular, or if the center of the core is different from the center of the cladding or coating. 

Even using state of the art, high-quality manufacturing process, the fiber will not be geometrically 100% perfect, hence there will be a speed-difference between the two polarization modes, dispersion will result, and it may limit high speed transmission through the fiber. Even if the fiber were 100% perfect, the slight bending of the fiber in a cable would introduce stress in the fiber – creating PMD. So this is our third speed limiter. 

Looking at a fiber from a “PMD-perspective” it may be thought of as having a “fast” and a “slow” lane. An effective way of reducing PMD is by twisting the fiber back and forth during manufacturing so that a high number of shifts between the “fast” and “slow” lanes are effectively seen by the light travelling through the fiber. 

Because stress is an important cause of PMD, externally applied stress will also affect fiber PMD. In reality just holding a fiber between two fingers may change PMD. As a result, the PMD of a fiber may be affected both by the cabling of the fiber and by external stresses, for example vibrations from a nearby railroad. 

As with other dispersion types the effect of PMD increases with increased transmission distance (PMD scales with the square root of the distance) and increased transmission speed. For transmission rates of 2.5 Gbps and smaller, PMD is normally not a problem. For very high transmission rate systems, the compensation of PMD is today made electronically and built into the transmission system. 

HOW TO SPEAK “FIBER GEEK” | ARTICLE 1: CRITICAL OPTICAL PARAMETERS – ATTENUATION

 The fiber optic cable world has come a long way over the past 30 years. Products have become more rugged and user friendly, making it easier for people to enter the industry and work handling optical fiber and cable. While this is great for the industry, many people may understand the “how to” but not necessarily the “why” of fiber optics. To understand the “why” behind fiber and cable products, the next step is to become a full-fledged “fiber geek.” Because the industry changes so quickly, this is an ongoing process. The purpose behind this series of articles is to enable the reader to understand some secondary fiber specifications and their importance to the network. 

Once fiber is deployed, it’s very expensive to replace. For this reason, the fiber that’s installed should be capable of withstanding multiple generations of hardware while also having plenty of room for additional wavelength growth. 

FIGURE 1: Already Defined ITU-T Wavelength Band
FIGURE 1: Already Defined ITU-T Wavelength Band

The graphic on the right highlights how wavelength usage has grown over the past three decades. For the first 30 years, applications were focused in the 1310 nm and 1550 nm regions. Given the explosive demand for bandwidth (even more so since COVID-19), it’s reasonable to assume that the next 30 years will require many more wavelengths, with potential applications across the entire optical spectrum. 

The demand for bandwidth is expected to continue far into the future, driven in part by requirements for breakthrough applications such as higher resolution video, virtual reality and other applications. We expect this demand to continue to drive the need for optical spectrum provided by fiber. Fiber recommendations such as ITU-T G.652 and ITU-T G.657, are very important for network designers in setting minimum performance levels, but can ultimately be insufficient to meet the requirements for future networks. For this reason, performance beyond the standards can be very important. 

This article will focus on critical optical parameters starting with attenuation, or loss in the fiber. Attenuation is a very important optical parameter, and there are many aspects to it. Additional articles in this series will focus on other optical parameters, including chromatic and polarization mode dispersion, splice loss, and an introduction to non-linear effects. 

Keeping a low fiber attenuation has always been a focal point in fiber development – and today even more so with the widespread use of Coherent Transmission systems. These require large core and ultra-low loss attenuation fibers (typically ITU-T G.654 fiber types) for optimal performance of 100G and faster transmission systems. 

Attenuation is typically measured in terms of optical dB. It is a logarithmic measurement where the Loss of a fiber equals 10*log (“Power at the- input side of the fiber” / “Power at the output side of the fiber”). Basically every 3 dB of loss corresponds to the optical power being cut in half. It is fair to assume, that the attenuation of a fiber is almost constant over the length of the fiber. So if a fiber loss is 0.25 dB/km, a total loss of 3 dB will be reached after 12 km of fiber has been passed by the optical signal in the fiber. 

Looking at the different loss mechanisms in fibers, it may be helpful to distinguish between: 

A): Attenuation caused by factors external to the fiber (as for example bending), and 

B): Built in attenuation mechanisms. 

Looking at B) first, there are two main loss mechanisms in optical fibers: Scattering and Absorption. 

SCATTERING 

FIGURE 2: Scattering of Light in All Directions

Also called “Rayleigh scattering”, even the best and purest, synthetic quartz glass (of which OFS fibers are made) is not 100% homogeneous. They consequently contain small fluctuations of glass density, which are frozen into the glass during manufacturing and may scatter the light when hit by a light ray (this is the same mechanism responsible for the blue color of the sky, when sunlight scatters off molecules in the atmosphere). Much of the light will continue traveling in the original direction, but a small part of the light will be scattered in all directions. Some light will propagate sideways out of the fiber, where – for transmission purposes – it will be lost. Some of it will actually be scattered backwards towards the sender. This is the phenomenon used by OTDR measurement devices to measure fiber attenuation, so the device only needs to be connected to one end of the fiber. 

In optical fibers scattering is dominant at shorter wavelengths whereas the opposite is true for the other built in attenuation mechanism: Absorption (Figure 4). 

ABSORPTION

FIGURE 3: Absorption, Light Converted to Heat

Basically absorption happens when a light ray hits something – and gets converted into heat. So for practical purposes the light simply “disappears”. 

Even extremely small impurities – down to a fraction of a micron – may absorb light, causing unwanted attenuation. It may be small particles – but it may also be impurities in the raw materials used for fiber manufacturing. This is why such extremely close attention is paid to the quality and purity of the raw materials used. 

Due to the inherent material structure of glass, Absorption increases rather drastically at wavelengths longer than approximately 1550 nm (Figure 4) 

Of particular interest over the years has been the hydroxyl (OH-) ion, which absorbs light around 1383 nm, giving rise to the so-called “water-peak” in the attenuation curve for the fiber (figure 5 – black curve). Being a by-product of the actual manufacturing process, it is difficult to fully avoid the presence of hydroxyl ions in the fiber, but it is possible to pacify the attenuation increase at the wavelengths close to 1383 nm. This is done by adding deuterium gas which interacts with the free bond of the hydroxyl ion thereby acting as a barrier securing excellent long-term Water Peak attenuation performance. 

FIGURE 4: Scattering and Absorption  Wavelength Dependency

Conventional single-mode fibers meeting the G.652 recommendation may have a high Water Peak loss. This could limit the use of the fiber in some applications and may also make the fiber less useful in transmission systems using modern Raman amplification, where amplifier laser-pumps would typically operate 110 nm below the transmission signal wavelength. 

OFS have fibers classified as Zero Water Peak (ZWP) with even better specified Water Peak performance than the so-called Low Water Peak (LWP) fibers. The long-term stability of ZWP fibers is excellent whereas for some types of ITU-T G.652 fibers the water peak attenuation might actually increase over their lifetime, slowly reducing the quality of the network. 

Because of the optimized Water Peak performance, ZWP fibers serve the widest ranges of wavelengths and support the highest number of applications, as illustrated in Figure 1. 

Figure 5 shows three different grades of ITU-T G.652 fiber, and how they may be performing in the water peak region around 1383 nm. 

FIGURE 5: Water Peak Loss of  Three Fiber Grades

For the most part, scattering and absorption properties are locked into the fiber during manufacturing. 

Bending, however, is another story… 

BENDING

Bending is a very important mechanism. As briefly mentioned, it is caused by factors external to the fiber and so both the cabling process and installation in the field can affect attenuation caused by bending. 

FIGURE 6: Macrobending Light  will leak out of tight bends.

To put it simply, what makes an optical fiber work is the use of different types of glass for the fiber core and for the glass surrounding the core (also known as the cladding). In this way, a sort of a tubular mirror surrounding the core is created. This is what keeps the light inside the fiber, using the concept of “total internal reflection” to guide the light. However, this mirror is not a perfect one. It only works if the light rays in the fiber run almost parallel to the core, and so if the fiber is bent (too) tightly (i.e. past the “critical angle” when reflection turns to refraction), light will leak out of the fiber causing loss – or attenuation. 

This is called macro bending, where the diameter of the bending is larger than a few millimeters, which is what one would intuitively understand as “bending” the fiber. 

FIGURE 7: Microbending Loss  caused by lateral stress.

Another type of bending is called micro bending. It concerns bending diameters smaller than 1 mm and could happen – as an example – if a fiber is squeezed between two sheets of sandpaper. Much more relevantly it may also happen if the fiber is being squeezed inside the cable construction (for example by the tubes containing the fibers) creating stress on the fiber. As loads/stresses increase, so does the loss. 

Both types of bending loss cause attenuation increase, but it is possible to tell the two types of bending apart by considering the added loss at different wavelengths as illustrated in Figure 8. 

Macrobending losses tend to be small at short wavelengths, but may increase rather dramatically at longer wavelengths. 

FIGURE 8: Difference between Micro-and  Macro-Bending Loss vs. Wavelength

Microbending losses are also typically present at short wavelengths, but the loss increase tends to be smaller than for macrobending at the longer wavelengths. 

All of the trends in fiber deployment point to the increased importance of fiber bending performance. 

Service providers constantly want to put more fibers into a smaller space which means that while buffer tube diameters keep shrinking, the fiber counts used in these buffer tubes keep increasing. This leads to a situation where there is less room for fibers to move before touching a buffer tube wall, thereby increasing the risk of microbends. 

In addition, service providers primarily installed cables in either the outside plant, the inside of central offices, or into remote cabinets. Everywhere great care was taken to avoid small diameter bending. However, today’s fiber is going to places where it hasn’t gone before. It’s going inside our homes and businesses and also up poles and onto rooftops to feed cellular and Wi-Fi sites. 

Tolerance to bending will be even more important in the future. 

Micro and macro bends affect the network in ways that are not always obvious. 

Bend-related losses are sometimes experienced in cold temperature environments. For this reason, fibers and cables should always be tested under low temperature conditions. As a network designer, it’s always a good idea to account for at least some optical margin for small potential attenuation increases in cold temperatures. 

FIGURE 9: Next Generation Fiber Networks  may use longer wavelengths than today –  increasing requirements for low bending
loss fibers already now.

Especially very high-density designs may benefit from using bend insensitive fibers due to the unavoidable bends and lack of free space for fiber movement in the cable design itself. 

While these issues are already important today, they will become even more important tomorrow. The reason is that next generation optical transmission protocols may typically use longer wavelengths than the existing protocols. 

As highlighted earlier, longer wavelengths will often result in higher bending loss. Theoretically, a GPON network operating flawlessly today at 1490 nm – containing inadvertent bends – could have its reach reduced by almost half when it is upgraded to NG-PON2, operating at 1603 nm. 

So a FTTH network installed today and working fine may not be suited for operation with future generation transmission equipment. 

HELP IS ON THE WAY 

In order to enable more compact cable constructions and allow for easier installation and perhaps even allow for the use of less experienced craftspeople for cable installation, quite a bit of attention has recently been focused on developing fibers with reduced sensitivity to bending i.e. those defined by the ITU-T Recommendation G.657. 

G.657 specifies 4 different classes of fibers: “A1”, “A2”, “B2” and “B3”. 

The “A” fibers are required to also fulfill (or to comply with) the specifications of the ITU-T G.652.D recommendation, whereas the “B” fibers may deviate from G.652.D on some parameters. The numbers (1, 2 or 3) signifies the fibers tolerance to bending – B3 fibers being most bending tolerant. Many “B3” fibers do today comply with G.652.D and should rightfully be labelled: “A3”, but such a class is not specified by ITU-T. 

ITU-T G.657.A1 fibers are the closest to standard G.652.D fibers and may soon be the primary choice for the vast majority of fiber networks. OFS has combined G.657. A1 and G.652.D performance with a 9.2-micron mode field diameter. 

FIGURE 10: Fiber Distribution Hub

G.657.A1 fibers with 9.2-micron mode field diameter perform the same way as standard G.652 fibers in terms of splicing – and can consequently be said to splice “seamlessly” to the huge base of already installed fibers. By offering the same splice performance as standard G.652 fibers, installation crews and quality inspectors will notice no change in performance and hence be given no cause for concern – even 

though the advantages of better tolerance to bending will still be there. 

These fibers are ideal for most of today’s typical short-distance (<1000 km) and low data rate (<400Gbps) applications, including standard outside plant (OSP) loose tube, ribbon, rollable ribbon, microduct cables, and drop cables. 

ITU-T G.657.A2 fibers can be bent more tightly with lower loss. They are most commonly used in central office and cabinet environments, such as Fiber Distribution Hubs (FDH). These fibers are also commonly used in building backbone networks and as tails for various pre-terminated panels and other devices. In these environments, the fibers may need to be bent more tightly than in typical OSP cable applications. 

The application spaces just mentioned for A1 and A2 fibers would typically involve one fiber to carry traffic for thousands of customers, meaning that a fiber break would affect the service to thousands of users. Here reliability is consequently paramount. In such situations A2 fibers (and A1 as well) offer the advantage of providing an “early warning” signal of increased attenuation whenever they are bent tightly enough to potentially cause reliability concerns. This is especially important for central office applications where one fiber could provide the feed for millions of customers. 

ITU-T G.657.B3 fibers are the third main category of bend insensitive fibers. These fibers are designed and recommended for use in the drop portion of a Fiber-to-the- Home (FTTH) network serving a few customers per fiber. Homes and buildings with lots of tight spaces are very demanding places to deploy fiber. For optimized performance in such applications OFS has fiber which is designed and specified for use with bending radii as low as 2.5 mm which is significantly less than the minimum bending radius of 5 mm specified in the G.657.B3 recommendation. 

OFS has fibers used in cables with a diameter of only 0.6 mm, enabling almost invisible in-house cable routing with a minimum of bending management. This avoids bulky and distasteful installation in private homes. For more demanding deployments, ruggedized cable designs with a diameter of 4.8 or 3mm may even be routed around corners and stapled using fast and easy installation practices, with negligible signal loss. 

G.657 fibers which are not compliant with G.652.D are often assumed to have very small cores giving rise to significant additional splice losses when spliced to standard G.652.D fibers. However, that is not necessarily so. It is possible to get G.657.B3 fibers specified with an ultra-low bending radii of 2.5 mm and – whereas these fibers are not “seamless” fibers – they do in fact comply with the G.652.D recommendation in terms of core size. The only thing preventing such fibers from complying with G.652.D is the Chromatic Dispersion, and since they are primarily intended for in-building applications, the length will typically be much less than the 10 – 40 km fiber length in which the higher Chromatic Dispersion may typically start presenting problems. 

Regarding bending loss however, the performance of such a fiber is significantly better. The loss for a single turn of 2.5 mm radius at 1550 nm for such a fiber is max. 0.2 dB – whereas the similar loss for a standard G.652.D fiber exceeds 30 dB. 

 

LC Crimp & Cleave Termination Instructions

for 50 and 62.5 µm GiHCS®, 200 µm HCS® LC Connectors

Important Safety and Warranty Information

Please Read First!
Please make sure to READ and understand the termination instructions completely. Improper assembly will cause poor termination results and cause damage to termination kit components.

Download the pdf document for the full instructions

Make sure you WEAR eye protection during the termination process. Bare optical fiber is sharp and may splinter; handle very carefully and make use of the provided fiber optic shard disposal container.

For more information please CONTACT the sales representative in your region or call the factory for technical support:
Mon-Friday, 8:00 am-5:00 pm EST.
860-678-6636
770-798-5555 [Outside the USA and Canada]

Content
LC Termination Kit Contents
Related Products and Accessories (Sold Separately)
LC and LC Duplex Connectors
Insertion Loss Test Kit

Termination Instructions
Step 1: Slide Strain Relief Boot
Step 2: Remove Outer Cable Jacket
Step 3: Remove ETFE Buffer
Step 4: Install Connector Body
Step 5: Cleave Optical Fiber
Step 6: Install Anti-snag Latch or Duplexing Clip

Maintenance & Trouble Shooting Guide
Importance of Cleave Tool Cleaning
Cleave Tool Cleaning Kit
Troubleshooting


LC Termination Kit Contents

Kit Contents
Part Numbers/Description
DT03732-LC1 . . . . . . . . . . . GiHCS LC Termination Kit
DT03732-LC2 . . . . . . . . . . GiHCS LC Cleave Tool Only
P76859 . . . . . . . . . . . . . . GiHCS LC Instruction Manual
AP01224 . . . . . . . . . . . . . . . . . . . . . . . Cable Strip Tool
BT03865-07 . . . . . . . . . Crimp Tool LC (Black Handles)
CP01229-22 . . . . . . . . . ETFE Buffer Stripper w/ prong tool and brush
AP01225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scissors
K60791 . . . . . . . . . . . Optical Fiber Shard Disposal Unit
K60792 . . . . . . . . . . . . . Alcohol Prep Pad (Box of 100)
Other Items Required (not included in kit): Safety Glasses, Marker
Order an OFS LC Termination Kit Number DT03732-LC1 Now


LC and LC Duplex Connectors

Related Products and Accessories (Sold Separately)
Part Numbers/Description
P26763-01 . . . . . . . . LC Simplex Connector (Beige Boot)
P26763-02 . . . . . . . . . LC Simplex Connector (Black Boot)
P26764-01 . . . . . . . LC Duplex Connector (2 Beige Boots)
P26764-02 . . . . . . . LC Duplex Connector (2 Black Boots)
P26764-03 . . . . . . . . . . . . LC Duplex Connector (1 Beige + 1 Black Boots)
P10188-15 . . . . . . . . . . . . . . . . . . Insertion Loss Test Kit for 50 and 62.5 µm GiHCS LC Connectors
P16247 . . . . . . . . . . . . . . . . . . . . Cleave Tool Cleaning Kit (Includes cleaning fluid and safe cleaning swabs)


STEP 1:  Install Strain Relief Boot

Slide STRAIN RELIEF BOOT (tapered end first) onto cable end and slide approximately 3 inches [76 mm] out of way.


STEP 2: Remove Outer Cable Jacket

  • Mark cable outer jacket 2.5 inches [63.5 mm] from cable end with a marker
  • Using 2nd hole (marked 1.6) from the open side of the cable jacket strip tool, remove the 2.5 inches [63.5 mm] of outer jacket.

STEP 3: Remove ETFE Buffer

  • Insert the buffered fiber through the guide tube of the ETFE Buffer Strip Tool, all the way in until the cable jacket bottoms out inside it.
  • Holding cable securely, squeeze the tool’s handles to cut ETFE buffer then PULL STRAIGHT to remove the ETFE buffer.

  • With alcohol prep pad folded in two, wipe the surface of fiber where the ETFE buffer was just removed.

 

 

 

STEP 4: Install Connector Body

  • Locate the CONNECTOR BODY subassembly into the CRIMP TOOL nest as shown. Close the crimp tool handles lightly to secure connector in nest, but do not yet apply crimp
  • Insert stripped fiber into CONNECTOR BODY subassembly until the cable jacket bottoms out inside the connector
  • Squeeze handles of CRIMP TOOL to apply crimp. CRIMP TOOL will not release until fully crimped.
  • Remove CONNECTOR from CRIMP TOOL nest. Slide up and
  • install BOOT onto CONNECTOR.

  • Locate the CONNECTOR BODY subassembly into the CRIMP TOOL nest as shown. Close the crimp tool handles lightly to secure connector in nest, but do not yet apply crimp
  • Insert stripped fiber into CONNECTOR BODY subassembly until the cable jacket bottoms out inside the connector
  • Squeeze handles of CRIMP TOOL to apply crimp. CRIMP TOOL will not release until fully crimped.
  • Remove CONNECTOR from CRIMP TOOL nest. Slide up and
  • install BOOT onto CONNECTOR.

STEP 5: Cleave Optical Fiber

  • Holding the CLEAVE TOOL in a horizontal position, grip the handle while leaving your index finger free to actuate trigger
  • Gently insert CONNECTOR BODY into cleave tool as shown. Be sure to have it fully inserted and release the CONNECTOR BODY
  • Using index finger, slowly depress trigger to perform the cleave operation. The cleave process is complete when the optical fiber snaps away
  • from the connector. Do not release the trigger just yet!
  • Before releasing the trigger, remove CONNECTOR BODY from the
  • cleave tool and grasp the optical fiber scrap while releasing the trigger.
  • Gently remove the scrap fiber from the cleave tool while keeping it away from the tool’s diamond blade. Place the scrap optical fiber into the fiber optic shard container for safe disposal.

STEP 6: Install Anti-snag Latch or Duplexing Clip

Simplex Connector:
• Spread the clip slightly as shown.
• Install the clip around the connector, aligning as shown.
• Wrap around and snap on to secure.


Duplex Connector:
• Spread the clip slightly as shown.
• Install the clip around the connectors, aligning as shown.
• Wrap around and snap on to secure.


The PDF document also includes a Cleave Tool Cleaning Guide:
For cleaning your cleave tool, please order the OFS Cleave
Tool Cleaning Kit (part #P16247) which includes recommended cleaning fluid, swabs, and complete instructions.

The PDF document also includes a fiber optic troubleshooting guide for:

  • Dim-light termination and no light termination
  • Poor cleave quality or high insertion loss
  • If the fiber does not cleave
  • If the fiber protrudes or recesses after cleave


Download our LC Connector Family Spec Sheet

Visit our Knowledgebase and filter by Installation Resource to find a list of all our fiber optic instructions.

Learn more about our fiber optic building solutions

A Focus on the Critical Optical Parameter Attenuation

Our first article in this series highlighted some bandwidth demand drivers and introductory standards information. This article will focus on critical optical parameters starting with optical attenuation. Additional articles in this series focus on other optical parameters, including chromatic and polarization mode dispersion, splice loss, and an introduction to non-linear effects.

Fiber Wavelength Bands

> Download the Full Article

There are three main loss mechanisms in fibers, and we’ll briefly discuss each. Those Attenuation mechanisms are:

  • Scattering
  • Absorption
  • Bending

Scattering

The first mechanism is “Rayleigh scattering” of light in fiber. This mechanism contributes most to the baseline attenuation of fiber. A certain amount of light is scattered in the glass. In the simplest of terms, scattered light is simply light that is no longer guided through the optical fiber, but instead propagates in some other random direction (an interesting side note is that OTDRs measure loss by using the light that is scattered backwards in a fiber so the device only needs to be connected to one end of the optical fiber). Since some light doesn’t transmit forward through the glass, loss occurs. The classic attenuation curve has a relationship of attenuation proportional to 1/λ4 and is driven by the properties of Rayleigh scattering. Rayleigh scattering is the result of small fluctuations of glass density in an optical fiber and is the same mechanism responsible for the blue color of the sky, when sunlight scatters off molecules in the atmosphere.

The scattering-related attenuation properties of the glass are determined by the materials used in the glass, and are frozen in during fiber manufacturing.

Absorption Attenuation

Impurities may absorb or reflect light. This is why fiber manufacturers pay such close attention to the quality of materials used in the glass and to cleanliness during manufacturing. Particles as small as a fraction of a micron can be large enough to absorb enough light to increase loss.

Besides particles, impurities in the raw materials used in the fiber manufacturing process itself can increase loss. That’s because the hydroxyl (OH) ion is a by-product of the manufacturing process. It absorbs light in the wavelength range around 1383 nm.

The graph to the right shows the loss performance across the wavelength range with three different grades of fiber.

> Download the Full Article

Bending

Bending is a very important mechanism. The cabling process and installation in the field can affect attenuation caused by bending.

Let’s go back to Fiber 101. Fibers use the concept of total internal reflection to guide light. The refractive index profile of the core and the cladding determine how light is guided, and the term “critical angle” is used to describe when reflection turns to refraction and light is lost from the fiber. In short, when fiber is bent tightly, light can be lost.

There are two main modes of bending – macrobending and microbending.

While the end result of both types of bending is attenuation, the mechanisms and how they manifest differ.

> For more details, Download the Full Article

Other Ways Microbends and Macrobends Show Up in the Network

The concepts of micro and macro bends affect the network in ways that are not always obvious.

Bend-related loss is also sometimes experienced in cold temperature environments. For this reason, fiber and cable qualifications should always include tests to see how products perform in cold temperatures. As a network designer, it’s always a good idea to account for at least some optical margin for small potential attenuation increases in cold temperatures.

Help is On the Way

The good news is that fiber manufacturers have developed fibers that can withstand different amounts of bending while also reducing loss compared with traditional fibers meeting the ITU G.652.D Recommendation. These fibers are called bend insensitive or bend optimized fibers, and are defined by ITU Recommendation G.657.

For the network designer and installer, a thorough understanding of various attenuation mechanisms can assist with the network planning and installation processes, enabling proper loss budgeting and the use of appropriate products for the application.

In most situations, attenuation is the most important network parameter, and this article has provided enough background for you to be well on your way to fiber geekdom on this topic. However, fiber geekdom is a journey, not a destination, and there’s always more to learn. OFS has multiple decades of experience with fiber optic networks. Please contact your local OFS representative if you would like additional information regarding any of the items in this article.

> Download the Article for full details.

About the Author:

Mark Boxer - Technical Manager, Solutions and Applications Engineering for OFS

Mark Boxer is Technical Manager, Solutions and Applications Engineering for OFS. In this role, he assists customers deploying fiber in a wide variety of network design scenarios around the world and analyzes trends in telecommunications markets that drive new product innovation. Mark has a BME degree from Georgia Tech, and has spent his 30+ year career in the fiber industry. His experience includes varied roles in manufacturing and applications engineering for fiber-based products and markets. Other activities include inventor of six US Patents, member and past Secretary of the IEEE Power Engineering Society Fiber Optic Working Group, contributing member to the Fiber Broadband Association (FBA) (formerly FTTH Council) Technology Committee and Board of Directors member of the FBA.

Placing Fiber Optic Cable in Underground Plant

Placing Fiber Optic Cable in Underground Plant

1. Overview

This document covers cable placing in conduit, innerduct, handholes, and manhole structures. The innerduct may be direct buried or placed in larger diameter conduits. In some applications, the innerduct may be lashed to an aerial strand.

This document covers conventional cable placing techniques that are used to pull or blow (cable jetting) the cable into the conduit or innerduct.

> Download full Article for more details

2. General Rules

2.1 Route Survey and Inspection

It is recommended that an outside plant engineer conduct a route survey and inspection prior to cable installation. Manholes and ducts should be inspected to determine the optimum splice locations and duct assignments. A detailed installation plan, including cable pulling or blowing locations, intermediate assist points, and cable feed locations should be developed based on the route survey.

2.2 Maximum Rated Cable Load

The maximum rated cable load (MRCL) for most OFS outside plant fiber optic cables is 600 lb; however, the cable documentation should always be checked because lower values of MRCL may apply for some cables. When using pulling equipment to install cable, measures should be taken to ensure that the MRCL is not exceeded. This includes the use of breakaway swivels, hydraulic pressure relief valves, and electronic tension control systems.

2.3 Minimum Bend Diameter

Fiber Optic Diameter Bending During Installation

The minimum bend diameters for OFS cables are defined for both dynamic and static conditions. The dynamic condition applies during installation when a cable may be exposed to the MRCL, e.g., while pulling the cable around a sheave or capstan.

 

2.4 Temperature Limits

Storage and installation of OFS fiber optic cable is limited to the temperature ranges. Be aware that solar heating due to sunlight exposure can increase the cable temperature well above the ambient temperature.

3. Underground Optical Cable Precautions

Before starting any underground cable placing operations, all personnel must be thoroughly familiar with local company safety practices. Practices covering the following procedures should be given special emphasis:

> Download full Article for more details

4. Innerduct

Fiber optic cable is most often placed in a small-diameter innerduct rather than a large-diameter conduit. For existing conduit structures, multiple innerducts can be placed in a single conduit to provide multiple cable paths in the duct. Innerduct is also recommended because it provides a clean continuous path for the installation of the fiber optic cable.

4.1 Diameter Ratio and Area Ratio

Diameter and Innerduct area ratios.

Diameter ratio and/or area ratio are used to determine the optimal cable OD that should be installed in an innerduct. Either ratio can be used, but consistently using one or the other is important to avoid confusion.

4.2 Direct Buried Applications

Studies have shown that vertical undulations in direct buried innerduct can greatly increase the required cable installation forces.

5. Cable Lubricant

Cable lubricant should be used when placing fiber optic cables. Recommended cable lubricants include Polywater4, Hydralube5, and similar cable lubricants that are compatible with polyethylene cable jackets. Both the winch line (or pulling rope) and the cable should be lubricated.

> Download full Article for more details

6. Cable Placing Methods

6.1 Backfeed Technique

The backfeed technique is a common installation method that is used to divide the cable installation into two separate pulls. The backfeed technique may also be used near equipment offices when one end of the cable must be pulled by hand into the building, or at manhole locations where the cable route changes direction.

6.2 Forward-Feed Technique

In the forward-feed technique, the leading end of the cable and excess cable length are pulled out of the innerduct at an intermediate manhole and stored on the ground in a figure-eight. This technique can be used multiple times during a cable installation to greatly increase the distance between cable splices.

6.3 Figure-Eight Installation Techniques

If figure-eight techniques are used during cable installation, the cable should be handled manually and stored on the ground. Place the cable on tarps to prevent damage from gravel, rocks, or other abrasive surfaces.

Fiber Optic Cable Underground Installation

When figure-eighting heavy cables (264 fibers or more), the cable stack should be offset to prevent sheath dents and cable damage. Although sheath dents do not typically damage fibers, this type of cosmetic damage is undesirable. When utilizing the offset method, each crossover point of the cable stack should be offset about 2 inches instead of being stacked directly on top of each other.

Standard vs Offset Figure Eight

6.4 Handholes

Handholes are frequently used to provide access to cable splices and slack storage coils. On long cable pulls, handholes may be used to facilitate intermediate-assist placing operations. The intermediate-assist handholes are typically installed near obstacles or at a predetermined spacing that coincides with the maximum expected cable installation length.

7. Pulling Fiber Optic Cable

The following instructions assume general familiarity with outside plant cable placing procedures. They also assume that the innerduct is in place and a lubricated pulling tape or rope has been installed in the innerduct.

7.1 Feed Manhole

Breakaway Swivel Connector

Mount the cable reel on the reel carrier so that the cable feeds off the top of the reel. Position the cable reel adjacent to the manhole and in-line with the innerduct. The cable reel should be positioned close enough to the manhole so that excessive cable length is not dragging on the ground, but far enough away to maintain slack cable in the event of a sudden start or stop during the pulling operation. A distance of 10 – 15 feet is generally sufficient. Attach the pull line to the fiber optic cable using a cable grip and swivel connector. Caution: A breakaway swivel connector is required if a tension limited winch is not used to pull the cable.

7.2 Intermediate Manholes

The innerduct in intermediate manholes may be continuous through the manhole or it may be interrupted. In either case, the innerduct should be positioned in a straight path from entry duct to exit duct. If the innerduct is continuous and has been racked, remove the innerduct ties and straighten the innerduct through the manhole. If necessary, slack innerduct can be cut out using an innerduct cutter. Secure the innerduct in the manhole to prevent it from creeping into the main duct during cable placing operations.

> Download full Article for more details

7.3 Pull Manhole

OFS recommends the use of tension-limited winches for pulling fiber optic cable. The tension control may be accomplished by electrical, mechanical, or hydraulic methods. In any case, the tension-limiting device must be routinely calibrated as recommended by the equipment manufacturer. Cable winches that display cable tension but do not have automatic cutoff are not sufficient to protect the cable. If a tension-limited winch is not used, a breakaway swivel must be used to connect the fiber optic cable to the pulling line.

7.4 Capstan Winches

7.4.1 General

Breakaway swivels do not protect the fiber-optic cable after the cable pulling-eye passes the intermediate capstan winch; therefore, intermediate-assist capstan winches must be tension-limited. The capstan must also meet the minimum cable bend-diameters.

7.4.2 Set-up

The capstan winches should be positioned along the cable route where the expected pulling tension will be 600 pounds or less. Proper positioning of the capstans prior to the start of the pull will eliminate construction delays caused when an unplanned intermediate capstan assist must be added to the placing operation.

7.4.3 Slack Cable Loop

During the pulling operation, a slack loop of cable must be maintained on the pull-off side of the capstan as shown in Figure.

Intermediate Manhole Set-up

7.4.4 Adding Intermediate Capstans

 If an intermediate capstan is added during the cable pull and the cable pulling eye has already passed through the manhole, a loop of slack cable must be pulled to the intermediate manhole before cable is wrapped on the capstan.

Adding an Intermediate Assist Capstan

7.4.5 Removing Cable from Intermediate Capstan Assist Winch

At the conclusion of the pull, the cable on the capstan is twist free. However, one twist per wrap will be generated in the cable if it is removed from the capstan and straightened.

8. Blown Optical Cable Installation

Cable blowing systems use high-pressure, high-velocity airflow combined with a pushing force to install the cable. A hydraulic or pneumatic powered drive wheel or drive belt is used to push the cable into the innerduct at the feed manhole. Controls and gauges on the cable blowing system allow the operator to monitor and adjust the air flow and push force that is exerted on the cable. Some cable jetting systems use a plug at the cable end to capture the compressed air and generate a small pulling force on the end of the cable.

9. Optical Cable Coiling

9.1 Coils Stored at Intermediate Holes

Many end users require that coils of slack cable be stored in intermediate manholes along the cable route. These slack storage coils are used for future branch splices or route rearrangements. It is important that the coiling method accommodates the proper coil diameter and does not introduce kinking or excessive twist into the cable.

9.2 Fold-Over Method

The Fold-Over Method is recommended for storing moderate lengths of slack cable. Form a cable bight and then twist the bight to form the first cable coil. Fold the coil over to form the second cable coil.

> Download full Article for more details

9.3 Teardrop Method

The teardrop coiling method is recommended for storing longer lengths of cable since it is easier to roll the cable than perform repetitive folding operations. The cable is stored twist free by rolling the cable bight in a manner similar to that used on the cable end.

9.4 Garden Hose Method

The garden hose method is recommended for large diameter cables because only one turn of cable is handled at a time. The storage coil can be formed directly on the manhole racking as each additional loop is added. Each loop can be taped in place as it is added to the storage coil. This method can be used to store any length of slack cable.

9.5 Coils Stored at Splice Locations

Slack cable must be stored at splice locations to allow for splicing. Typically, a cable length of 50 to 100 feet is required for splicing purposes; however, the actual cable length may vary depending on the accessibility of the manhole.

10. Racking Fiber Optic Cable and Innerduct

Cable racking normally begins in intermediate manholes and proceeds manhole by manhole toward each end of the cable. Slack for racking the fiber optic cable may come from either the feed or the pull manhole depending on which end is closer and the amount of excess cable that is available. The preferred method of obtaining racking slack is pulling by hand. If the cable cannot be moved by hand, a split cable grip can be attached to the cable and the cable can be pulled using a cable winch or a chain hoist. Do not exceed the maximum tension rating or violate the minimum bending diameter of the cable while pulling the slack.

Cable coils should be racked in a location where they will not be damaged, preferably on the manhole wall behind in-place cables. Do not decrease the diameter of the cable coils. If slack cable must be removed from the coil for racking purposes, remove one or more loops from the coil and then enlarge the coil to absorb excess slack. Tie the coil securely in place with plastic ties.

> Download full Article for more details