Telekom Handbook for Cabling Works

SPECIFICATION LINES

WE FO 001

ISSUE APRIL, 1995

FIBER OPTIC UNIT LOCAL NETWORK HEADQUARTERS 17th FLOOR, WISMA TELEKOM TELEKOM MALAYSIA BERHAD 59200 JALAN PANTAI BAHARU

KUALA LUMPUR

Specification Lines WE FO 001 Issue April, 1995

Local Network Headquarters Telekom Malaysia Berhad

SECTION I

GENERAL NO. CONTENTS PAGE

1. SCOPE 1


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GENERAL

1. SCOPE

The specification covers all aspects of optical fibre cable installation for:

a) underground b) overhead c) direct burial d) on vertical racking/in riser e) on horizontal racking/cable tray

Other aspects of optical fibre cable works procedure included are splicing of fibre ends, preparation of mechanical jointing closure, installation of Fibre Termination Box and Fibre Distribution Panel. Another associated part describes the Acceptance Test and Commissioning procedures for optical fibre cable and equipment. The Fibre-In-The-Loop (FITL) projects use single mode optical fibre cables of loose and ribbon fibres. The optical fibre cable length supplied to TM shall be within one (1) to three (3) Km for each drum. It shall also be provided with manufacturer's test report and free from physical damage.



SECTION II

DEFINITIONS NO. CONTENTS PAGE

1. DIGITAL DISTRIBUTION FRAME (DDF) 1

2. FIBRE DISTRIBUTION FRAME (FDF) 1

3. FIBRE TERMINATION BOX (FTB) 1

4. HORIZONTAL RACKING 1

5. INTERNAL CABLE 1

6. MAIN DISTRIBUTION FRAME (MDF) 1

7. RIPPING 1

8. SUBDUCT 1

9. SUBSCRIBER DISTRIBUTION FRAME (SDF) 1

10. SUPERSTRUCTURE 1

11. TUNNEL 1

12. VERTICAL RACKING 1


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DEFINITIONS

1. Digital Distribution Frame (DDF): A connection frame that provides flexibility for

interfacing the digital signal line (2/8/34/140 Mb/s digital signal) on coaxial cable. 2. Fibre Distribution Frame (FDF): A frame in the central office that provides flexibility

for interfacing between the external cable and the terminal equipment. 3. Fibre Termination Box (FTB): A box where external optical cable is spliced to the fibre

cord cable. 4. Horizontal racking: A flat metallic surface for laying and anchoring optical cables in

horizontal plane or known as cable tray. 5. Internal cable: Connecting cables between termination box and equipments up to MDF

termination blocks. 6. Main Distribution Frame (MDF): The point of interconnect between telephone

exchange equipment and local network cable pairs. 7. Ripping: Process of breaking the soil along the plough line to facilitate installation of

direct buried optical cable. 8. Subduct: A 32 mm diameter PVC or HDPE pipe provided by TM to facilitate installation

of optical fibre cable. 9. Subscriber Distribution Frame (SDF): The distribution frame in subscriber's premises

on which the local cable pairs and internal cables both terminate. 10. Superstructure: A steel frame to hold equipment rack in equipment room within the

MDF. 11. Tunnel: A cable passage large enough to permit entry by personnel. 12. Vertical racking: A flat metallic surface for laying and anchoring optical cables in

vertical plane or known as ladder racking.


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SECTION III

INSTALLATION OF PVC SUBDUCTS NO. CONTENTS PAGE

1. GENERAL 1

2. MATERIALS 1

3. INSTALLATION PROCEDURE 1

4. TESTING 3

5. TYPICAL SUBDUCT INSTALLATION 3


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INSTALLATION OF PVC SUBDUCTS

1. GENERAL

This specification describes the items required and practices for installing PVC subducts into a 4-inch ducts. Positions of ducts to be installed with subducts shall follow the normal selection for installing copper cable that is starting from the lowest layer on extreme sides and working its way up.

2. MATERIAL

2.1. Items supplied by TM

The following items shall be supplied by Pengurusan Bahan:-

i. PVC subduct ii. Flange holder (Plate B) iii. End cap

2.2. Items supplied by Contractor

I. Tape PVC 19 mm self adhesive ii. Adhesive - Solvent cement iii. Cotton waste iv. Mechanical aids and tools for laying subducts

2.3. Quality of material

All materials unless otherwise specified are to be in accordance with the British Standard Instruction or its equivalent in so far as those specifications apply.

3. INSTALLATION PROCEDURE

3.1 Preparation of worksite and manhole

Work procedure shall be as specified for normal cable laying. Refer to Specification Lines WE 303.



3.2 Preparation of Ducts

Ducts should first be cleared of obstructions. Rodding of allotted ducts (avoid blocking the entry to other ducts) should be done using rod sweep cane, PVC rods or any approved equipment. Clean the ducts by using mandrel cutting, brushes and cleaning disc and remove obstructions where encountered. The test mandrel used for testing shall be of 457mm in length and 83mm in diameter, the cylindrical brush shall be 108mm in diameter. All duct ends must be intact and straight.

3.3 Preparations of Subducts

i) Jointing of Subducts

The spigot of the subducts shall be wiped clean. The solvent cement shall be applied to the spigot as well as the end of another subduct. The end of the subduct where the solvent cement were applied shall be positioned and pressure applied for the two subducts to be jointed. In no circumstances shall dirt or grit be allowed to enter the joints.

ii) Bunching of subducts

Bunch the three (3) subducts together firmly by twining/lacing using an adhesive tape and place into position as shown in Figure 1.

iii) Cutting of subducts

Subducts shall only be cut where necessary at right angles to the bore preferably with a saw in a simple cutting motion according to the requirements of the work. Inside edges of cut subducts shall be thoroughly rounded off or so dressed before being put into position that they can be no possibility of damage to optical fibre cables from the edges.

3.4 Laying of Subducts

i) Drawing of subducts into duct

The pulling-in (3 subducts at the same time) can be done manually or with a cable-pulling trailer depending on the distance between manholes. The pulling-in of subducts is made in the same way as for the pulling-in of cables.

ii) To prevent the subducts from twisting, attach swivel to the subducts as

shown in Figure 2.

iii) Fixing of Subducts at the Manhole



Hold the subducts as shown in Figure 3 using the PVC plate B. Two PVC plates are required in each manhole. Each of the PVC plate (Flange Holder) is placed at the duct mouth with each subduct inserted and adhered with solvent cement into each of the three holes of the plate. Screw each corner of the plate to the manhole wall to secure the subducts from creepage.

iii) Make a 1 inch slit at the side of each subduct mouth and slide the end of

nylon rope to prevent it from moving into the subduct before closing with the end cap.

iv) Ensure end caps are tightly fitted to the subduct mouth. These end caps

shall be removed for cable installation.

v) Fixing of Subducts at the Cable Chamber

One PVC plate B shall be installed at the duct mouth and screwed to the cable chamber as shown in Figure 4.

4. TESTING

i) On completion of the subduct line between any two jointing chambers or sites thereof, rod each and every subduct laid using rod sweep cane, PVC rods or any approved equipment.

ii) All tests shall be carried out in the presence of the Superintendent Officer and if

any obstruction or defects is discovered, it shall be rectified forwith to his satisfaction.

5. TYPICAL SUBDUCT INSTALLATION

A typical installation of a subduct section is as illustrated in Figure 5.



SECTION IV

INSTALLATION OF CORRUGATED SUBDUCTS FOR OPTICAL FIBRE CABLE

NO. CONTENTS PAGE

1. GENERAL 1

2. MATERIALS 1

3. INSTALLATION PROCEDURE 1

4. ACCEPTANCE TESTING 3

5. END CAP SOCKET 3


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INSTALLATION OF CORRUGATED SUBDUCTS

FOR OPTICAL FIBRE CABLE 1. GENERAL

This specification describes the practice for installation of corrugated subduct into a 4 inch duct. Subducts are installed to facilitate drawing and installing of optical cable. The position of ducts to be installed with subducts shall follow the installation of PVC subduct.

2. MATERIAL

2.1 Items supplied by TM

The following items shall be supplied by Pengurusan Bahan:-

i. HDPE Corrugated Subduct for optical cable. (Completed with draw rope pre-installed).

ii. Flange holder (PVC Plate B). iii. End cap. iv. O-ring.

2.2 Items supplied by Contractor

i. Tape PVC 19mm self adhesive ii. Cotton waste iii. Adhesive iv. Mechanical aids and tools for laying of subducts.

2.3 Quality of materials

All materials unless otherwise specified are to be accordance with the British Standard Instruction or its equivalent in so far as those specifications apply.

3. INSTALLATION PROCEDURE

3.1 Preparation of worksite and manhole Work procedure shall be as described for normal cable laying. Refer to specification Lines WE 303.



3.2 Preparation of ducts

Ducts should first be cleared of obstructions. Rodding of allotted ducts (avoid blocking of entry to other ducts) should be done using rod sweep cane, PVC rods or any approved equipment. Clean the ducts by using mandrel cutting, brushes and cleaning disc and remove obstructions where encountered. The test mandrel used for testing shall be 457mm in length and 83mm in diameter, the cylindrical brush shall be 108mm in diameter. All duct ends must be intact and straight.

3.3 Preparation of subducts

i) Prior to laying, three (3) subducts shall be bunched together by wrapping

tightly with three layers of adhesive tape at every 1.5 meter along the bunch as shown in Fig. 1.

3.4 Laying of subducts into ducts

3.4.1 Drawing of subducts into duct is done by manual pulling in the direction

of main duct joints. The allowable maximum pulling tension is 80 KN.

3.4.2 Both duct and manhole entrance must have subduct protector as protection for the HDPE corrugated subducts when pulling.

3.4.3 Ensure that subducts are not twisted during pulling by attaching swivel to

the pulling end as shown in Figure 2.

3.4.4 All three subducts must be pulled at the same time.

3.4.5 Cutting subducts

i. Ensure sufficient nylon rope for pulling optic cable before cutting the subducts of the required length.

ii. Subducts shall only be cut at right angles to the bore with a sharp

blade around the subduct according to the requirements of the work and ensure no deformation during cutting.

3.5 Termination of subducts at the manhole

i. Insert an O-ring over each subduct 70 mm from its ends.

ii. Insert the three subducts into PVC plate B.

iii. Secure PVC plate by bolting two of its diagonal corners to the manhole

wall.

iv. Again insert the O-ring over the subducts at the front of the plate and ensure that the plate is closely fitted to the duct entrance.



v. Make a 1 inch slit at the side of each subduct mouth and slide the end of

nylon rope to prevent it from moving into the subduct before closing with the end cap.

vi. Ensure end caps ere tightly fitted to the subduct mouth.

Refer to Figure 3 for the arrangement of accessories at manhole.

Two PVC plates, twelve O-rings and twelve (depending on quantity of spare subducts) end caps are required in each manhole.

3.6 Termination of subducts at cable chamber

3.6.1 Follow procedure 3.4 (i) to (iii). Then, subducts must be cut in line with

the duct mouth as shown in Figure 4. 4. ACCEPTANCE TESTING

4.1. On completion of the subduct line between any jointing chambers or sites thereof, test each subduct lines by using a mandrel as shown in Figure 5. Installation can only be approved once a complete length of subducts is installed with the complete accessories and sufficient nylon rope for further cable installation is available.

4.2. All installation shall be carried out in the presence of the Superintendent Officer

and if any obstruction or defect is discovered, it shall be rectified forwith to his satisfaction.

5. END CAP SOCKET

After every subduct lines are installed and tested, fix the end caps to the subduct ends for protection. The end caps shall be removed for cable installation.

6. Figure 6 shows the installation of a subduct section.



SECTION V

INSTALLATION OF OPTICAL FIBRE CABLE INTO SUBDUCTS NO. CONTENTS PAGE

1. GENERAL 1

2. TOOLS AND MATERIALS 1

3. PRECAUTIONS 3

4. METHOD OF CABLE LAYING INTO SUBDUCTS 5

5. LABELING 12


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INSTALLATION OF OPTICAL FIBRE CABLE INTO SUBDUCTS

1. GENERAL

This specification describes the practices for optical fibre cable installation in subducts and the precautions taken during its handling. Its jointing and splicing specifications are described in Section IX and X respectively.

2. TOOLS AND MATERIALS

The following main tools and materials (with their usage) are required for installation of optical fibre cable into subduct.

2.1. Tools & devices

No. Tools & Devices Usage 1 Safety Cone. Traffic safety device or warning.

2 Barrier & Barricades. Traffic safety device or warning.

3 Flags. Traffic safety device or warning.

4 Canvas Tent & Frame G.I. For workmen working shade.

5 Flashing Light. Traffic warning device at night.

6 Manhole Key. For opening the manhole cover.

7 Gas Detector. To detect any dangerous gases present in manhole.

8 Water Pump. To pump out water in manhole.

9 Portable Generator. To supply electrical power (e.g. for a blower power supply)

10 Exhaust Fan/Blower. To send in fresh air into the manhole.

11 Cable Jack For cable drum jacking.

12 Rodding Tools (PVC Type). For rodding through a duct or subduct.

13 Cable Cutter. To cut the cable neatly and easily.

14 Cable Grip. To grip the cable pulling end.

15 Shackle. To connect the cable pulling end and the pulling


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No. Tools & Devices Usage rope.

16 Swivel To prevent cable twisting during pulling work.

17 Pulling rope. For pulling the cable.

18 Cable Roller To guide cable into duct or subduct.

19 Cable Protecting Bend (cable guide).

To prevent the cable or duct socket from damage when pulling cable into duct/subduct.

20 Tension Meter (Dynamometer).

To measure the pulling tension.

21 PVC Sheeting (6m x 3m).

For cable protection while working on Figure 8.

22 Transceiver/Walkie talkie. To communicate between positions of cable sending and pulling ends during cable laying work.

23 Pliers, cutting nippers, etc. General usage.

2.2. Materials

No Materials Usage

1. PVC Tape. For protection of cable grip and installation or

miscellaneous use.

2. Galvanized Iron Wire. For binding the cable grip and installation or miscellaneous use.

3a. Cable Bracket of Fixed Type (Cable Bearer).

For supporting the optical

b. Cable Bracket of Sliding Type (Cable Bearer Bracket).

fibre cable in the manhole.

4. Closure Supporting Plate. To support the joint closure on the Cable Bearer Bracket.

5. Anti-Floating Device To prevent the Cable Bearer Bracket from moving (floating).

6a. Cable Tie #3 For fixing optical fibre cables to the cable bearer bracket. Also used to secure both ends of marking tape wrapped around optic cable.



No Materials Usage

b. Cable Tie #6 For fixing the joint closure to the closure

supporting plate 7. Protection Tubes (Helically

Coiled) For protection of fibre cables carrying heavy traffic and important circuits.

8. Orange Marking Tape To differentiate fibre optic cables from copper cables.

9. Cotton Waste For miscellaneous use.

3. PRECAUTIONS

3.1 Handling of optical fibre cable drums

a) During loading or unloading, cable drum must not be subjected to any severe shock or damage and not to be rolled freely down a slope.

b) Drums shall never be rolled at any distance for the purpose of transportation except for short movements around a manhole or cable jointing place. For short movements, drums shall always be rolled in the direction of the arrow marked on their flanges or battens.

c) Drums shall always remain battened until just before the beginning of actual cable installation work.

3.2 Allowable tension and laying speed

Cables shall be laid not exceeding a specified pulling tension. During cable installation, do not jerk the cable or stop immediately during pulling, but it shall always be kept under uniform pulling tension.

3.2.1 Allowable tension

A maximum pulling force for the present contracts (Tomen,



Marconi/Hesfibel , Opcom and Perwira Ericsson) are stated below:

CONTRACT NO. OF CORES MAX. PULLING

FORCE

TOMEN

4, 6, 8, 12, 24, 36 & 48

1.7 KN

MARCONI/

HESFIBEL

4, 6, 8, 12, 24, 36, 48 & 96 1.1 KN

OPCOM 4, 6, 8, 12, 24, 36, 48 & 96 2 KN

PERWIRA

ERICSSON

4, 6, 8, 12, 24, 36, 48 & 96 2.5 KN

Table 1

3.2.2 Adjustment of pulling tension

Pulling force shall be handled by manual manpower or a suitable pulling equipment such as fibre cable winch. During cable pulling the tension between the head pulling end and intermediate pulling end shall be synchronised where communication among workmen in manhole sections can be done by using transceivers.

3.2.3 Laying speed

The laying speed shall be less than 15 m/min.

3.3 Permissible cable bending radius

Optical fibre cable shall be handled very carefully and keeping as large a curvature as possible. During cable laying, the minimum bending radius of cables shall be more than 20 times of the outer cable diameter. When setting the cable, the bending radius may be reduced to 10 times the outer cable diameter.



3.4 Length of cable end for jointing

Before cutting the fibre cable, sufficient overlap length of 150 cm shall be given for jointing cable ends. See Fig. 1.

4. METHOD OF CABLE LAYING INTO SUBDUCTS

4.1 Checks and investigations before cable laying

The following tasks shall be performed before starting of cable laying:-

4.1.1. Confirmation of manhole

Confirm the position, type and span of the manholes with the related subduct plans.

4.1.2. Preparation of worksite manhole.

a) Place the manhole guards, safety devices and warning sign such as fences, safety cones, flashing lights, red flags, sign posts, etc. around manhole before removing the manhole covers.

b) When working in manhole, the first warning notice should be

placed at 70 to 100 metres from hazard, but on high speed roads, it should be 100 to 200 metres ahead. Where one half of a high speed road is closed, it should be 400 to 500 metres ahead. Position the flagmen when necessary.

c) Test for the present explosive gases, asphyxiating gases, toxic

gases and stagnant water in manhole by using a gas detector or other suitable means. If required, necessary actions (before workmen enters the manhole) shall be taken for easy and safe work performance as follows:

i. Pumping water out of manhole and cleaning. ii. Ventilation to get rid of harmful gases.

4.1.3. Identification and confirmation of duct and subduct.



a) Check the position of duct and subducts where cables are to be installed.

b) Confirm the draw rope (nylon rope for corrugated subduct) is

installed.

i. Cable test-piece passing (as described below) should be done if draw rope is available. - A cable test-piece passing having the same diameter as the

outer cable diameter or more with a length of about 2 m is passed through the subduct to check the degree of scratches received by the sheath of the cable test-piece. The cable test-piece is coated with black enamel to facilitate easy inspection for scratches. Also swivels are attached to it at both ends. The inspection results gives a basis for the judgement of subduct conditions and whether the cable can be laid into the subduct smoothly or not.

ii. If the draw rope is not available, rodding process should

proceed as follows before cable test-piece passing is done.

- When the top end of the rod (e.g. rigid PVC pipes) reaches an adjacent manhole, a pulling rope is attached to their tail end. This pulling rope shall be passed through the subduct by pulling the rod out of the subduct.

- For a short section duct, rodding may be achieved with a

pulling rope directly inserted into the subduct.

Suitable remedial measures such as alteration or repair should be taken after consultation with the Superintendent Officer when it is impossible to perform rodding due to a damaged or clogged duct or subducts, having a level difference, etc.

4.1.4. Existing cable rearrangement

Due to changes in bends, fixing positions or other works in a manhole, the existing cable shall not be rearranged unless necessary. Adequate protective measures shall be taken as required for existing cables installed in the relevant manholes.

4.1.5. Cable drum confirmation



The cable drum number, cable piece length, cable size and cable pulling end (clockwise and counterclockwise) shall be confirmed by comparing with straight line diagram or other related design drawings.

4.2. Positioning of cable drum

a) The cable drum setting position is determined when considering the cable

laying direction. The cable drum shall be placed on the same side of the manhole as the cable laying direction, and in line with the duct/subduct so that the cable can be reeled-out into the sub-duct in a smooth curve without being kinked. Figure 2 shows the setting position for a cable drum.

b) The cable drum is jacked up using cable jacks. It is important to make the

drum shaft horizontal by adjusting the cable jacks.

c) The firmly fitted battens on the cable drum shall be removed carefully to prevent cable damage.

4.3. Attachment of pulling rope to cable end

The running end of a cable is called the pulling end which must endure the pulling tension. The method of attaching the pulling end is classified into the categories according to the type of cable used as follows:

a) For a pulling end not provided with pulling eye, a cable grip, shackle,

swivel and a pulling rope are attached as shown in Figure 3a. The cable grip and tension member in a cable should be embodied together to keep allowable pulling tension of fibre cores.

b) For a pulling end provided with a pulling eye at the cable factory or at

installation site, a cable grip is not used. A shackle, a swivel and a pulling rope can be attached directly to the pulling eye as described in Figure 3b.

To prevent cable twisting during cable laying, a swivel should always be used in the position between the cable grip (or pulling eye) and the pulling rope.

4.4. Cable laying

4.4.1. Liaison arrangement



During cable laying, liaison men should be placed between the lead-in and take-out manholes to maintain close communication by using transceiver or other device to cope with the cable laying work.

4.4.2. Reeling-out cable

a) When reeling-out cable, use cable roller at the lead-in manhole and

cable protecting bend (cable guide) at the subduct mouth for cable protection as illustrated in Figure 4.

b) The presence of cable damage should be carefully checked while

the cable is being reeled out.

4.4.3. Laying method.

There are three methods of laying the optical fibre cable(as described in Figure 5):

i. Unidirectional pulling. ii. Bi-directional pulling. iii. Intermediate manual pulling.

4.4.3.1. Unidirectional pulling

This method is applicable for pulling short length of cable within 1 km. It can be pulled manually or by using an automatic mechanism such as fibre cable winch.

a. Manual pulling method

To pull optic cable manually, workmen shall be placed at every manhole to assist the pulling operation under the specified pulling tension (as described in Table 1) towards the splice location. In this case, preparing cable in the form of Figure 8 is not required.

b. Automatic pulling method (using fibre cable winch)

This method is still under feasibility study. When the method is found suitable and approved, the detail work procedure and the relevant specification will be added.

4.4.3.2. Bi-directional Pulling

This method is recommended for considerably complicated cable routes having curves or level difference of subducts at



pull through manholes and installation of cable lengths greater than 1 km.

a. Bi-directional pulling method

i. Place the cable drum at the midpoint of the cable length (to

be located at the nearest manhole). ii. Pull the cable towards one of the splice locations into

subducts in continuous operation. iii. Uncoil the shorter cable length for the second pull on a

PVC sheeting placed on the ground in the form of Figure 8 on top of the other so that cable is not twisted and damaged.

A suitable space measuring about 6m x 3m is necessary for uncoiling the cable. This operation is shown in Figure 6.

iv. Pull the cable end of the uncoiled cable into the opposite

direction.

4.4.3.3. Intermediate manual pull

This method is recommended for pulling cable in straight route and distance greater than 1 km by using manual pulling method. However, the other method is by using an automatic mechanism as described in 4.4.3.1.b above.

a. Manual pulling method:

i. Place the cable drum at the end of the cable length (to be

located at the nearest manhole. Refer to Fig. 2). ii. Attach the pulling rope to the cable end. iii. Pull the cable towards one of the splice locations into

subduct in continuous operation. iv. After pulling the cable through four or five manholes

(average of 1 km distance), make Figure of 8 until all the cable is uncoiled.

v. Pull the cable towards the splice location as described in

para a(iii). For the cable length is greater than 2 km per drum, repeat the procedure as described in para a(iv).



A manual pulling method is as shown in Fig. 7.

4.4.4. Checks and treatment after cable laying:

a. Storing excess cable

After the cable length has been laid into the subduct, sufficient excess length for jointing, testing and restoration should be stored at each jointing manholes.

The formula for cable allowance calculation for each cable end is as follows:

No. Location Formula

1. Jointing manhole 3L + 2W + H

2. Pull-through manhole 2H + L

3. Pull through manhole (Potential growth areas)

3L + 2W + 2H

where, L = length of manhole/joint box

W = width of manhole/joint box H = height of manhole/joint box

b. Cable setting in manhole

The cables should be set in the manhole in conformity with the following principles:-

i. Cables entering/leaving the manhole should be avoided

from crossing and cables shall be given a well protected position (refer to Figure 8 and 9).

ii. During positioning of cables, bend when required and with

careful attention given to the permissible bending radius.

iii. When bending cable, the following cable length should be kept straight.

- minimum 6 cm from a duct inlet. - minimum 6 cm from a cable joint end.



iv. All cables passing through manholes must be tied together to the cable bearer bracket by using cable tie no. 3. Refer to Figure 9.

v. A cable joint should be kept horizontal as much as possible.

vi. At jointing manhole, four additional cable bearers (to be

installed at both end walls) must be installed to support the cable.Refer to Appendix I for its details. Lay and tie the cable on the bearer bracket by using cable tie no. 3. Refer to Figure 8.

vii. When a cable joint is partially located to one side of a

manhole, the space between the cable joint end and the duct inlet should be kept at more than 60 cm.

viii. A supporting plate shall be used to support the jointing

closure which is placed between cable bearer brackets. The jointing closure is then tied to the supporting plate using cable tie no. 6.

ix. An anti-floating device must be attached together to the

cable bearer bracket to prevent the cable bearer bracket from floating during water level rise inside the manhole.

x. In manholes constructed at both ends of a bridge, cable

slack of more than 100 cm long should be provided to absorb cable creep caused by the expansion and contraction of the cable laid over the bridge because of temperature variations.

xi. Anti-creepage devices shall be installed when necessary

(along highways and hill stations) to prevent cable creepage.

xii. The cable entries at cable chamber shall be sealed after

each cable installation with duct sealing ring or duct plug/ SVT blocks (Isolectra contract - K 46920084) .

xiii. In manholes or cable chamber which have many fibre

cables (carrying heavy traffic and important circuits), the optical fibre cable shall be protected using helically coiled protectors or its equivalents at the required lengths such as at jointing closure, from subduct to cable bearer or other parts when necessary. For easy identification of optical without protection tubing, an orange marking tape shall be



wrapped around the cable throughout its length in the manhole. See Figure 10.

4.4.5. Site clearing

After cable laying and its treatment have been completed, the road surface and warning signs must be removed. Cart away all rubbish made after completion.

5. LABELING

Optical cable installed in manholes, cable chambers (both at entry and leaving points and every 10 m apart), carrier room and SDF room must be marked. The marking tag shall be made of metallic or plastic (waterproof) material. It shall be fitted 7 cm away from cable joints. The example of the marking tag drawing is shown in Figure 11.

The marking tag shall consists of the following particulars:

a) Type and size of cable b) Route name c) Contract number d) Date of installation e) Cable section code.

Note: Cable section code comprises of:

a) Network code i.e. Nxx - where, x is numeric b) Cable section number

(Refer to Planning Specs PL 0301)



TELEKOM MALAYSIA BERHAD

TYPE SINGLE MODE OPTICAL

FIBRE CABLE

SIZE 12 CORES

ROUTE NAME TAR WISMA BERNAMA

CABLE SECTION CODE N01 9

CONTRACT NUMBER K 1062/91

DATE OF INSTALLATION 20 JAN 1993

FIG. 11 : SAMPLE OF MARKING TAG

Appendix I-a



STANDARD ACCESSORIES REQUIRED FOR BOTH EXISTING AND NEW MANHOLES The drawing of the specified height (H) and length (L) of accessories in Tables 1 and 2 shall be referred to figure 8a.

Side Wall End Wall Manhole Type H1 L1 H2 L2

JC9 & JC9C 800 mm 245 mm 240 mm 167 mm R1B(M) & R2A 1280 mm 345 mm 560 mm 245 mm R2A(M) & above 1280 mm 500 mm 560 mm 345 mm Table 1 : Cable bearer and cable bearer brackets for existing manhole

Side Wall End Wall Manhole Type H1 L1 H2 L2

JC9 & JC9C 800 mm 245 mm 240 mm 167 mm R1B(M) & R2A 1520 mm 345 mm 560 mm 245 mm R2A(M) 1520 mm 500 mm 560 mm 345 mm Table 2 : cable bearer and cable bearer brackets for new manhole Material requirement :- a) High quality mild steel b) The surface shall be smooth and continuously hot-dip galvanised according to B.S. 729 with minimum thickness of 86 microns.

Appendix I-b Note :- 1. For existing manholes, cable bearers and cable bearer brackets specified in Table 1 shall

be installed above the duct nest whenever is required.



2. For new manholes, cable bearers and cable bearer brackets specified in Table 2 shall be installed above the duct nest as basic accessories.

3. The cable bearer and cable bearer bracket sizes are as follows:-

Cable bearer a) Type 1 = 800 mm b) Type 2 = 1280 mm c) Type N1 = 240 mm (new) d) Type N2 = 560 mm (new) e) Type N3 = 1520 mm (new)

Cable bearer bracket a) Bracket No. 6 = 167 mm b) Bracket No. 8 = 245 mm c) Bracket No. 12 = 345 mm d) Bracket No. 8 = 500 mm



SECTION VI

INSTALLATION OF AERIAL OPTICAL FIBRE CABLE NO. CONTENTS PAGE

1. GENERAL 1

2. TOOLS AND MATERIALS 1

3. GENERAL PRECAUTION 2

4. SITE PREPARATION BEFORE INSTALLATION OF AERIAL CABLE

3

5. TECHNICAL REQUIREMENTS FOR CABLE ERECTION 3

6. PRECAUTIONS DURING INSTALLATION PROCESS 4

7. PROCEDURE OF INSTALLATION 5

8. TERMINATION OF IB OPTICAL CABLE 6

9. TENSIONING AND SAGGING 6

10. INSTALLATION OF AERIAL CABLE JOINT 7

11. INTEGRAL BEARER WIRE EARTH SYSTEMS 8

12. LABELING OF OPTICAL FIBRE CABLE 9


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INSTALLATION OF AERIAL OPTICAL FIBRE CABLE 1. GENERAL The specification below describes the details of installation of aerial optical fibre cable and

the precautions to be taken during installation of the cables to avoid any mishandling and damaging of optical fibre cable. Its jointing and splicing procedures are described in Section IX and X respectively.

2. TOOLS AND MATERIALS The following main tools and materials are required for aerial IB optical fibre cable

installation.

2.1. Tools

No. Tools & Mechanical Aids Usage

1. Cable Cutter. For cutting cable or bearer wire of optical fibre cable.

2. Bearer Wire Grip. To grip bearer wire cable for tensioning.

3. Cable Grip. To grip the cable pulling end.

4. Swivel. To prevent twisting when cable is installed.

5. Cable Pulley no. 2. Cable Pulley no. 4.

For reducing the stress on the cable while tensioning at intermediate and corner poles.

6. Pulling Rope. For pulling the cable.

7. Cable Jacking For cable drum jacking.

8. Cable Trailer. For carrying cable drum to the site.

9. Crowbar. For temporary anchor when tensioning the cable.

10. Dynamometer / Tension Meter. To measure cable tension.

11. Tirfor TU 16 Machine. For tensioning of IB optical fibre cable.

12. Cable Tensioning Hoist. For tensioning short spans of cable termination. For holding tensioned cable temporarily.

12. PVC Sheeting. (6m X 3m)

For cable protection while working on Figure 8.



2.2 Materials:

No. Materials Usage

1. PVC Tape. For protection of IB optical fibre cable sheath and

for miscellaneous use. 2. Bracket Tabular Pole For mounting of IB cable suspension clamp to pole.

3. Cable Clamp. For holding the optical fibre bearer wire on pole.

4. Steel Clamp. For clamping GI pipe (riser) to pole.

5. Support Hook. For mounting of IB cable clamp to bracket tabular pole.

6. Thimble Small Open. To attach the IB optical fibre cable bearer wire with bracket tabular pole.

7. Preformed Grip. To anchor the bearer wire of IB optical fibre cable on the bracket tabular pole. To joint the bearer wire.

8. Preformed Splice. To joint the bearer wire of IB optical fibre cable.

9. Openable Wire Jointing Connector.

For connecting bearer wire to earth.

10. Line Spacer (Steel type). To hold optical cables at jointing locations and prevent the cable from swinging and twisting during strong wind.

11. Cable Tie no. 3 For tying cable at termination points. Cable Tie no. 6 For tying jointing closure at termination points. 12. GI Support Wire To support jointing closure between pole span at

jointing point. 3. GENERAL PRECAUTION To reduce the pulling tension, bi-directional pulling in the form of Figure 8 is chosen for

the installation of aerial optical cable. When working on Figure 8, a PVC sheeting with minimum size 6m x 3m shall be used to protect the cable from damage. Fig. 1 shows this operation. Other general precautions are similar to the laying of optical fibre cable into sub-ducts.

4. SITE PREPARATION BEFORE INSTALLATION OF AERIAL CABLE



i. Provide the safety guards and warning sign in order to provide safeguards and warning for pedestrians and vehicles.

ii. Where the aerial cable route is expected to pass over private land, get the owner's

agreement in advance and care should be taken to minimise their inconvenience. iii. Before erecting cable all permanent staying must be completed, fit temporary stays

where necessary at intermediate terminating points. Ensure that all poles are safe to climb.

iv. Fit the necessary fittings on the poles and place cable pulleys with the opening

sides as near as possible to the pole fittings.

v. Note the location of all power wires crossing the route and take the necessary precautions to ensure safe working condition during erection of the cable.

5. TECHNICAL REQUIREMENTS FOR CABLE ERECTION i. Aerial cable shall be suspended on the side of the pole facing the road. New cable

shall be suspended underneath the existing cable on pole line. In case of new pole, the aerial cable shall be suspended 230mm from the top of the pole (first hole of concrete pole).

ii. The minimum clearance from the ground to the lowest point of the cable at the

different locations stated below shall be as follows:-

NO LOCATION MIN. DISTANCE

1. Along road. 4.5 m.

2. At road crossing. 5.5 m.

3. At railway crossing. 6.7 m above rail

4. From power cables : a) Less than 600 Volt b) More than 600 Volt

60 cm. 200 cm.

Table 1

iii. The allowable sag of optical fibre cable for average span of 40 to 50 meters shall be

up to 1 meter (2% of the span length) between the poles. Note:- In the case of using Kevlar optical integral bearer cable, the span between the poles

shall be according to the specified recommendation by the supplier.



iv. The erection tension shall be selected so as not to exceed 50% of the tensile strength of the suspension strand under the most unfavorable loading conditions. A maximum pulling force for the present contracts (Tomen, Marconi/Hesfibel Opcom and Perwira Ericsson) are stated below:


FORCE

TOMEN 4,6,8,12,24&36 8 KN

MARCONI/HESFIBEL 4,6,8,12,24&36 1.1 KN

OPCOM 4,6,8,12,24&36 15 KN

PERWIRA ERICSSON 4,6,8,12,24,36&48 9KN

Table 2 v. Suspension strands (bearer wire) shall be electrically continuous throughout the

cable length. vi. Splicing shall be carried out immediately after placing the cable. The splices shall

always be located in the vicinity of the pole. 6. PRECAUTIONS DURING INSTALLATION PROCESS i. Uncoiled fibre cables shall always be lifted up when carrying it. Do not drag cables

on the ground, nor contact the fibre cable with power lines, trees, buildings etc. during erection. When working near power lines adequate safety measures should be taken.

ii. All cables shall be handled with care to avoid damaging the insulation. Do not tread

on cable, pull over rough ground, fences or run over it with vehicles.

iii. The laying speed shall be lower than 15 meter per minute. The bending radius of cable should be kept at more than 20 times the outer cable diameter.

7. PROCEDURE OF INSTALLATION

The length of cable laid depends upon the span lengths, terrain and other field conditions. However, in straight sections, a maximum of seven spans or approximately 350 meters shall usually be laid at any one time.

Comment [x1]:



A supervisor must be positioned to places where abrasion against buildings, trees, ground and especially power lines is anticipated. It is recommended to plant another pole or take other adequate counter measures in such places.

i. There are two methods of placing the cable drum:

a. The cable drum is placed on vehicle/cable trailer. As the vehicle moves along the road side, the cable pulling end is carefully uncoiled and laid onto the ground. The cable shall be carefully lifted by hand. It must not be dragged along the road or run over by other vehicles.

b. For a cable drum length of 3 km and straight route, place the cable drum at the

midpoint of the cable length. Carefully pull the cable towards one of splice location, then make a Figure of 8 until all the cable is uncoiled.

ii. The cable is raised and placed onto the pulley which is attached to the pole

manually (as in Figure 2).

iii. Terminate the free end (pulling end) of the cable and ensure sufficient length is available for testing and splicing as described in para 8 below.

iv. Using a Tensioning Hoist or Tirfor TU 16 Machine with Dynamometer, follow the

procedure as described in para 9 for cable tensioning and sagging.

v. Fixing of Bearer Wire to cable clamp. Bearer wire shall be fixed to the cable clamp as follows:-

a) Insert the bearer wire to the bearer wire fixing groove provided in the

clamp. b) Tighten it with two clamp bolts. c) Fix the fitting bolts to the clamp as shown in Figure 3.

d) Fix it to the support hook attached to bracket tubular pole as shown in

Figure 4. 8. TERMINATION OF IB OPTICAL CABLE

At the end of cable installation, terminate the bearer wire with preformed grip as shown in Fig. 5(a) and 5(b) at the following:

a. Beginning and the end of route;



b. Distribution poles; c. Angle poles where deviation of the route is greater than 45o; d. All river and railway crossings; e. Poles where two cables are jointed; f. Each end of isolated long spans greater than 200 m.

8.1 Through double termination

The bearer wire is terminated on both sides of pole with thimbles and preformed grip. Whenever possible, the IB optical fibre cable is terminated without cutting the cable as shown in Figure 6.

8.2 Connection of Bearer Wires.

When connecting the bearer wires of IB optical fibre cable, use a preformed splice

or preformed grip as shown in Fig.7(a) and 7(b). 9. TENSIONING AND SAGGING

i. The procedure of cable tensioning shall be as follows: a. Ensure that the bearer wire at the starting point is first terminated with preformed grip as in Fig. 5b. b. After binding the pulling rope on the top of the pole and grasping the bearer

wire with a cable grip, attach cable tensioning hoist (as shown in Figure 8) between the pulling rope and cable grip. Refer Fig. 9.

c. The metal pulleys shall remain on the poles except those at the starting and

ending points. Tensioning of the bearer wire shall be controlled by the cable tensioning hoist until a balanced tension can be obtained as specified in Table 2.

d. In order to obtain the correct sag of each span, measure the depth of the

sagging and adjust the tension with the cable tensioning hoist by repeating it several times.

ii. For a long section of termination, attach the Tirfor TU 16 Machine and

Dynamometer as illustrated in Figure 10 for tensioning the cable.



iii. After completing the tensioning work and tearing the bearer wire from the cable web at the ending point, the preformed grip shall be stranded firmly on the peeled bearer wire in same manner as mentioned in para 9(i) above.

iv. Removing of all temporary stays, struts and pulleys.

The maximum pulling force of optical fibre cable for aerial installation, 4 to 48 cores must follow the specified force as in Table 2.

10. INSTALLATION OF AERIAL CABLE JOINT

The three major activities are as follows: a. Preparation of sufficient cable length for jointing. b. Fixing of support wire for holding jointing closure. c. Installation of jointing closure.

10.1. Excess cable for jointing.

In this case, sufficient cable length must be left for jointing as shown in Table 3 and

Figure 11.

Extra Length on Light-Source side 1300 cm

Extra Length on Light-Receiving side 1400 cm

Table 3

10.2 Fixing support wire for holding jointing closure.

a. Install bracket tabular poles and stays 50 cm below the aerial cable at both poles of the jointing position.

b. Fix GI stranded supporting wire between the poles and securely fasten to the poles. Refer to Fig.12.

10.3 Install joint closure.

Splicing is performed at ground level. Method of splicing is similar to other splicing of optical cables. (Refer to Section X for splicing of fibre ends). After IB optical fibre cable is jointed, the closure is brought up and tied to the support wire about 50 cm below the aerial cable by using cable tie no.6.



The extra maintenance length cable is arranged in a loop formation and a steel line spacer is installed on both sides of closure to prevent cable bending beyond permissible radius.

The fixing of closure is as shown in Figure 13. 11. INTEGRAL BEARER WIRE EARTH SYSTEMS

i. The importance of earthing system for aerial optical cable installation is to prevent

power surge along the metallic conductor at both ends of a cable route and jointing locations.

ii. The required grounding locations shall be as follows:- a. Dead-end or terminal pole b. Poles holding supporting wire for jointing closures c. At every interval of approximately 250 m d. Other locations than those mentioned above where grounding is considered

to be necessary from the electrical point of view.

iii. Jointing the bearer wires at terminating points. The bearer wires on either side of a terminating point shall be jointed to each other

to provide the necessary continuity. The connection could be done by a suitable size openable wire jointing connectors, type HD 10 or HD 12A.

iv. Connecting earth wire to bearer wire.

a. Connect `tail' of bearer wire to an earth wire 7/1.04 mm (tinned) with a suitable size bimetallic openable wire jointing connector as shown in Fig. 14.

b. At the identified earthing locations, slide the bearer wire through the riser

to the earth.

c. At the existing copper route, earthing can be done by connecting the optical fibre bearer wire to the copper bearer wire.

12. LABELLING OF OPTICAL FIBRE CABLE All optical fibre cables should be labeled using the identification tag (collet) so that they

can be easily identified.



12.1 Label information. The label should contain the following information: i. Type and size of cable. ii. Route name. iii. Contract number. iv. Date of installation.

v. Cable section code. Note:

Cable section code comprises of: a) Network code i.e. Nxx - where, x is numeric b) Cable section code

12.2 Fixing of labels The labels are fitted at:

i. Starting points. ii. Every 350 meters or 7 spans (both sides). iii. Every jointing points. iv. Ending points.



SECTION VII

INSTALLATION OF DIRECT BURIED OPTICAL CABLE NO. CONTENTS PAGE

1. GENERAL 1

2. PRECAUTIONS 1

3. ROUTE DESIGN 2

4. TRENCHING 2

5. INSTALLATION OF DIRECT BURIED OPTICAL CABLE 3

6. CABLE LAYING INTO TRENCH 5

7. JOINT BOX 8

8. CABLE JOINT 8

9. EARTHING 8

10. ARMOURING TREATMENT 8


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INSTALLATION OF DIRECT BURIED OPTICAL CABLE

1. GENERAL

This section describes the methods and practices used in direct buried optical cable installation. This application is mostly used in providing services to rural areas.

2. PREPARATIONS AND PRECAUTIONS

The following preparations shall be made and precautions taken when installing direct buried optical cables.

2.1. Permits

Permits shall be required for the following works:

a) Excavation of land belonging to the highway authorities, local authorities

and other road authorities. b) Excavation of private land. c) Temporary use of the roads or private land for construction work. d) Blasting (At Rocky Terrain). e) Jacking pipe under streets or railway. f) River or stream crossing. g) Bridge crossing. h) Temporary traffic close/diversion.

2.2 Safety

a) While excavation or cable laying work along or across highways, streets

or alleys, special care must be taken to minimise traffic interference. It may be necessary to provide adequate structure to support ground opening suitable for any traffic which is likely to pass over it.

b) All ground openings, construction materials, excavated soils, cable drum,

machinery on streets, highways or other accessible locations shall be protected with standard warning devices, in compliance with the requirement of the Police Department, Public Works Department, the municipality or any local authority and the Rules of Traffic Ordinance 1958.



c) Workmen working on the roadway shall wear blazed orange vests to alert traffic. All vehicles parked near the workmen must have suitable warning devices such as flashing or rotating amber lights.

3. ROUTE DESIGN

Detail route survey is required to ascertain the following points in order to ensure smooth execution of the project.

3.1. Location

Select a permanent location for buried plant and consider factors such as right-of-way limitations, soil type, natural obstacles, other utilities and services, future road expansion and natural land movements.

It is important to select cable routes on the same side of the road but opposite of power cables. As far as possible avoid crossing the road frequently.

3.2 Test Digging (Pilot holes)

After confirming the cable route, test digging shall be executed along the route at every corner and at the places where other underground facilities are likely to exist.

3.3 Measuring Route Length

After recognising the condition of the existing underground facilities, the suitable digging position must be determined.

4. TRENCHING

Trenching is usually the method used in areas where other buried facilities are located.

4.1. The machineries required for underground cabling such as excavators, trenching machines shall be decided according to local conditions including soil types.

4.2. At the start of construction, verify clearly defined object such as edge of curb,

pole, fire hydrant etc. for the centre line of excavation. Then indicate the direction and distance on the blue print.

4.3. Before starting burying operations, avoid exposing or making contact with the

underground facilities belonging to third parties. 5. INSTALLATION OF DIRECT BURIED OPTICAL CABLE



5.1. Dimension of trench

The size of trench shall have the following dimension:

Normal Soil Rocky Terrain

Width Depth

20cm 80cm

20cm 60cm

5.2. Installation in normal soil

5.2.1 In normal soil condition the optical cables shall be buried to a depth of

80cm and UPVC / concrete (complete with marker tape) slabs (as shown in Figure 1(a) and 1(b) or 1(c)) shall be buried continuously at a depth of 30cm below ground level along the cable length.

5.2.2 Cover the bottom of trench with 10cm sand before laying optical cable.

Then fill up another 10cm to a total 20cm thick. 5.2.3 Backfill the trench with excavated earth free from stones and carefully

compact it around the cable. Refer to Fig.2(a). Refer to Specification WE 304 - Construction of manholes, jointboxes and laying of ducts for definition and quality of soil.

5.3. Installation in Rocky Terrain

5.3.1. Extreme care shall be taken when burying optical cable in rocky

terrain. Avoid contact with rocks, stones and other similar heavy and sharp objects in the trench.

5.3.2. The bottom of trench shall be covered with sand before laying the

cable and cover the cable again with sand to a depth of 20cm from the bottom of trench. Refer to Fig. 2 (b).

5.3.3 In places where the original depth cannot be maintained for a long

period, uPVC slabs shall be laid halfway in between ground level and sand. See Figure 2 (b).

5.4. Protection of Optical Buried Cable against existing utilities

Before laying cables along highways or ordinary roads protective measures must be taken to protect the cable against damage at the crossing over water culverts and existing utilities such as water mains, sewage, etc. especially when digging the soil around them.

i. Where burying depth is between 40cm to 80cm, a layer of UPVC/concrete

slabs shall be laid 30cm above the cables. The minimum clearance



between optical fibre cable and the culvert shall be 15cm as shown in Fig. 3(a).

ii. In places where burying depth is between 20cm to 40cm, optical fibre

cable is laid in 1 inch GI pipe until reaching the depth of 80cm as shown in Fig.3 (b). The minimum clearance between culvert and GI pipe shall be 15cm apart. Refer to Table 1 for the clearance with other utilities in laying of direct buried optical cable.

Utilities Parallel Crossing

Power Line 30cm (Low Voltage) 100cm (High Voltage)

30cm 30cm

Water Supply Pipes 30cm 15cm

Sewage Pipes 30cm 15cm

Table 1. Summary of clearance between existing facilities and optical

buried cable.

5.5. Preparation for cable Laying

5.5.1. Reeling of Cable Drum

The cable shall be reeled off from the cable drum according to the arrow mark indicating the direction of rotation of the drum.

5.5.2. Arrangement of cable

In case where more than two cables are laid in parallel, such as going into or coming out from the exchange, they shall be spaced at minimum by 10cm. These cables shall be tagged with collets for detail identification.



5.5.3. Bending radius

Optical cables shall not be bent repeatedly and shall always be handled carefully according to the allowable bending radius (20 times of outside diameter) during installation. During preparation for jointing the optical cable bending may be reduced to 10 times the outer cable diameter.

Optical cables shall never be twisted and to avoid it happening, use swivels during installation work. (Refer to section V - Laying of Optical Cable).

5.5.4. Laying tension

Optical cables shall be pulled with constant and smallest possible tension. Any impact shall be avoided. Allowable tension strength specified for each cable shall be followed.

The allowable tension strength for present contract (Marconi & Hesfibel) are as stated below:


TENSION MARCONI 4, 6, 8, 12, 24, 36, 48 & 96 1.1 KN

HESFIBEL 4, 6, 8, 12, 24, 36, 48 & 96 1.1 KN

5.5.5. Laying speed

Laying speed of cables shall be less than 15m/minute. 6. CABLE LAYING INTO TRENCH

6.1 Site investigation

Before laying cables, investigation shall be made for the condition of trench.

a) Confirm whether direct laying of cables into trench is possible or cable has to be first laid on the ground prior to laying in trench.

b) Check and confirm whether any obstruction exist on the route of cable which

requires detouring or passing underneath.

c) Investigate bypass and underground surface conditions along cable route.



6.2. Selection of laying method

Upon the results of foregoing investigation and in consideration of the location of drum placing and necessity of rollers, select the most suitable laying method from the following:-

a) Movable Cable Drum Method In cases where there are no obstruction in the trench, or conditions of bypass

and/or ground surface allow easy cable laying in the trench. b) Fixed Cable Drum Method In cases where some obstructions exist in the trench and conditions of either

bypass or ground surface is unfavourable to force cable route to detour or to pass underneath.

6.3. Cable laying by Movable Cable Drum Method

i) Load cable on a truck equipped with fixed jacks or use cable carrier. ii) Cable shall be laid directly into the trench or onto road surface alongside

the trench avoiding occurrence of twisting. iii) Utmost care shall be taken not to twist the cable when it is shifted into

trench from ground level.

6.4 Cable laying by Fixed Drum Method

i) Setting of drum.

a) Set cable drum at the selected positions such as beginning of trench or at the intermediate point (using Figure 8 technique).

b) Axis of cable jack shall be set horizontally. c) Set cable drums correctly in consideration of cable laying direction.



ii) Preparation for pulling end.

Similar method for cable pulling into sub-duct shall be applied. Refer to Section V.

iii) Arrangement of rollers and wire rope.

Rollers shall be arranged at 5m to 10m apart on ground surface along trench line. Pulling rope with its terminal wound to a winch is laid on the rollers.

iv) Cable laying.

a) Optical cable shall be pulled on to the rollers manually or by using

suitable winch. b) A workman shall be assigned at the terminal and laying shall be

continuously made with a speed of 15m/min. c) When excessive tension occurs, the trench, rollers and optical cable

shall be checked and if there is no trouble, the cable shall be pulled very carefully by hand or machine.

d) In case where rollers are arranged on the ground, utmost care shall be

taken not to give twisting and/or extreme bending to the cable while laying it into the trench.

v) Liaison between workmen during laying operation.

a) Close contact between workmen at both cable ends shall be kept

during operation to respond to any minor happening through transceivers or ATUR set.

b) Observe carefully and ensure the cable sheath is not damaged when it

passes the edge of excavation.

vi) Post laying treatment and check.

a) Check at both ends that sufficient lengths including for excess cable length have been provided for jointing.

b) Check for exterior damage, and if any report the situation to the

superintendent officer immediately.



7. JOINT BOX

It is recommended to use joint box JC9 (modified), drawing no. 19647, with concrete frame and cover for convenient access to install spare cable portion and closure. The cable inlet to the joint box shall be protected by PVC pipes up to a length of 2m measured from the joint box wall. A supporting plate shall be used to hold jointing closure. Refer to Fig. 4(a) and (b). Five cable ties no. 3 shall be used to hold the cables together and at the cable bearer brackets and one cable tie no. 6 shall be used to hold the closure with the supporting plate.

Anti-floating device shall also be installed on cable bearer brackets to prevent it from floating when water in the manhole rises. All duct entry must be installed with duct sealing ring for protecting duct entry from silt and dirt from coming into joint boxes. When there is cable to be installed, loosen bolts, remove the rubber cable holder and push the cable into it.

Refer details to Figure 4 (a, b, c, d,e and f) for cable arrangement in Joint Box.

8. CABLE JOINTING

The cable jointing closure shall be set on cable bearer bracket. Splicing work must be done above ground.

9. EARTHING

All directly buried optical cables shall be continuously connected through at each joint location (as described in para 10) and then earthed at both end of Central Office Terminal (COT) and Remote Terminal (RT). It is important to check and ensure the required exchange MDF and cabinet or customers premise have sufficient earth resistance for lightning protection system.

10. ARMOURING TREATMENT

Refer to section VII A for armouring treatment using Fujikura closure.



SECTION VII A

TREATMENT OF ARMOURING FOR OPTICAL FIBRE CABLE

NO. CONTENTS PAGE

1. GENERAL 1

2. TREATMENT PLAN 1

3. MATERIALS 1

4. PROCEDURE 2


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TREATMENT OF ARMOURING FOR OPTICAL FIBRE CABLE

1. GENERAL

This specification shall apply to the optical fibre cable jointing work usage Fujikura made closures. It further describes the treatment and method of an electrical connection (bonding) between the armouring of the optical fibre cables to be jointed. The treatment made at the outside of closure will protect the water running between the armouring and inner cable into the closure when the outer sheath and armouring are broken without inner cable damage. The procedure in this specification applies to the steel wire armouring cable as well as thecorrugated metal armouring cable indicated in Figure 1.

2. TREATMENT PLAN

a) Figure 1 (a & b) represents the cable structure and the length of the completed treatment portion.

b) Figure 2 represents the cable length to be prepared when using Fujikuras

standard closure type FSCO-SB (length: 600mm)

When using another closure, the prepared length of cable shall change according to required closures dimension.

3. MATERIALS

The closure kit shall contain the following additional items : a) Self-Bonding Tape (Fujikuras FB-W Tape)

This tape covers the connecting portion for water sealing.

b) PVC Tape This tape is wound over the self-bonding tape for mechanical protection.

c) Insulated Wire This wire connects the armouring of cable.

4. PROCEDURE

a) Decide the jointing position. Remove the outer sheath and armouring to the required length.


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Do not remove the inner sheath at this time. ( The treatment of the armouring connection is performed before splicing and assembling of the closure.)

b) Remove the outer sheath of the armouring, to connect the wire.

If there is a painted compound between the outer sheath and armouring, clean this compound with solvent. (petrol, gasoline)

c) Wind the stripped wire twice around the cleaned armouring.

Fix the wound wire by soldering. Perform the soldering work quickly with a soldering iron (100 watts or more are required) before the inner sheath is melted.

d) Wind two layers of self-bonding tape to shape the covering.

Gradually fill the gaps between the outer sheath, armouring and inner cable by winding the self-bonding tape. Stretch the wire protruding position well.

e) Wind two layers of the PVC tape and cover the shaped portion.

f) Joint the inner cables and optical fibres.

g) Complete.


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