Cable Installation Guide
Cable Installation Guide
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1.3 Sag tensions greater than those shown in the sag and tension 3. Characteristic Benefits:
tables are not to be used unless specifically authorized by OFS
Brightwave Carrollton. a) All Dielectric - no metallic or electrically inductive cable
components.
1.4 Hardware not listed within this practice or the b) Circular Cross Section - minimizes effects of vibration and
PowerGuide® Hardware Ordering Guide is not approved for use ice loading compared to figure 8 designs.
and is not to be used unless specifically authorized by OFS c) Self-Supporting - integral messenger eliminates need for
Brightwave Carrollton. lashing.
d) One step installation process.
1.5 It is understood that a site survey should be performed for
any installation requiring OFS Brightwave Carrollton 4. Electrical Stress Mechanisms : Dry Band Arching and
PowerGuide® Cable with a complete understanding of this Corona
practice to ensure it's proper use.
4.1 Dry Band Arcing - Over time the surface of the
PowerGuide cable jacket may become conductive due to rain or
1.6 Application notes and installation practices which are
pollutants.
referenced in this document can be obtained by contacting the
Technical Services “hotline” at 800 889 3203or by visiting OFS
Brightwave Carrollton web site at www.fitel.com.
IP014 PowerGuide Installation Guidelines
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a) Dead end assemblies are used for line angles > 20° or 30°
(which occur as a result of changes in direction or
elevation), for cable splice locations, and cable start and end
points.
b) Figure 1 identifies the associated hardware to be used with
the dead end assemblies. Through bolts, washers and nuts
are usually standard pole line hardware items that may be
purchased through any local hardware distributor. For
IP014 PowerGuide Installation Guidelines
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Figure 1
EQUIPMENT
IP014 PowerGuide Installation Guidelines
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6.1 Single wheel type stringing blocks (Sherman Reilly 6.8 Chain hoist, winching device or equivalent - used to
type) are recommended for all applications. Multiple wheel sag cable at the appropriate tension between dead end locations.
quadrant blocks are not recommended. This type of block is
often referred to as a “3 block”. Cable Stringing Blocks - the
sheave (wheel) diameter of the stringing block is determined by 7.0 Installation Procedure
the minimum cable bend radius. PowerGuide® loose tube cable
minimum bend radius is 15 times the outer diameter during 7.1 This procedure assumes a stationary reel method of
installation and 10 times the cable outer diameter after the installation where a pulling rope and stringing blocks are
installation has been completed. PowerGuideribbon cable installed prior to the installation of the cable (see Figure 4). The
designs have a minimum bend radius of 15X the OD during procedure also assumes that the cable is being installed on a
installation and 15X after the installation has been completed. distribution pole line. Alternate methods such as the moving reel
Select stringing blocks for your applications accordingly. Use method or the stationary method (see Figures 5 6, & 7) where
of permanent attachment hardware as a substitute for stringing the cable and stringing blocks are placed from structure to
blocks is not recommended. Select stringing blocks for your structure before sagging is completed should be considered.
applications according to Tables 1 through 3. Determination of the installation method will depend upon local
conditions. Moving reel methods are generally associated with
Note: OFS Brightwave Carrollton recommends the use of distribution pole lines whereas the stationary reel method (install
unlined rollers whenever possible. If lined rollers are to be used, block, install rope, pull cable) may be used for both distribution
urethane lined rollers are recommended over neoprene lined and transmission line applications.
rollers.
7.2 Route Survey
6.2 Mid-span blocks - used to support cable in mid-span
over all roadways and obstructions. a) A route survey shall be made whether use is made of an
existing pole line or whether a new pole line construction is
6.3 Pulling grip with swivel - used to secure pulling rope to planned. During the survey determine the most effective
cable for installation. Breakaway swivels are recommended method of installation.
when other forms of load measurement are not being used.
b) Deviations from straight either horizontal or in elevation
6.4 Pulling rope- used to pull cable through the stringing shall be noted to enable ordering of required hardware.
blocks. The pulling rope to be used must be as long as the Depending on the hardware being used, any line angle
installation run, if the cable is to be installed in one continuous changes due to changes in direction or elevation over 20o or
section. High quality torque balanced ropes with minimum 30o should be double dead-ended. This will be very
elongation properties, which provide adequate tensile strength important when ordering the required amount of hardware.
capabilities for cable design to be installed, are recommended. c) A route survey shall indicate if route clearing is necessary.
This may imply pruning of tree branches, etc.
6.5 Take-up machine - used to pull the rope with the cable
attached through the stringing blocks. The take up should have Note: It should be apparent that small sags imply high tensions
tension and speed controls to ensure proper installation. It may and therefore end poles as well as out of line poles may require
also be used for the sag & tension procedure. The take up additional guying
equipment to be used should have an accurate means of .
monitoring the line tension in foot-pounds. This will insure d) If the length of the route will require more than one reel of
compliance with the recommended maximum installation cable;
tensions and corresponding stringing block sizes detailed in • Locate the splice or splices in a position that will
Tables 1through 3. minimize the number of turns in each section, which
will facilitate cable installation.
6.6 Pay off machine - used to pay off cable during
installation. The pay off should possess an automatic or manual
braking device to prevent the cable from running free. Trailers • Locate the splice at a point which will be easily
equipped an over spin brake device are generally acceptable for accessible for maintenance and splicing purposes
span lengths up to 800 and installation tensions up to 800 thereby minimizing the amount of slack cable required.
pounds. For longer span lengths and higher installation tensions
generally associated with transmission line applications bull e) When surveying attachment points for the fiber optic cable,
wheel tensioners are recommended (see photos 1,3, &4) insure that grade changes in the route are considered. The
IP014 PowerGuide Installation Guidelines
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Winch
Communication Communication
Figure 4 Stationary Reel Method Using a Pre-Installed Rope
Attach Hardware
Set Sag/Tension
7.3 Stringing Blocks, Rope and Pole Framing for Note: The Minimum Bend Radius for OFS Brightwave
Hardware Carrollton standard loose tube and Accutube™ fiber optic
cables during the installation process is 15 times the cable
a) Structure types: wood poles, concrete poles, steel poles, and outer diameter. For standard loose tube cables under
steel lattice towers are the main types of structures installed conditions the minimum bend radius is 10 times
associated with utility distribution and transmission aerial the outer cable diameter and for Accutube ribbon cable
routes. designs the minimum bend radius under installed conditions
b) Placing appropriate hardware for the structure type to is 15 times cable outer diameter.
support the ADSS cable suspension hardware, installation
of stringing blocks, and installation of pulling rope can be Example: Roller size calculation
accomplished in one pass throughout the installation route. Standard Loose Tube Cable O.D. = 1.00”
Bend Radius = 1.00” x 15 = 15” Radius
c) Secure the proper sized stringing block on the pole at an Pulling Block Diameter = 15” x 2 = 30”
attachment height relative to grade changes. Tables 1, 2, &
3 shows the proper stringing block groove diameter relative d) When selecting a stringing block, be aware that the outside
to the cable O.D., line angle change, and estimated diameter given by the manufacturer does not reflect the
installation and sagging tensions. actual O.D. of the stringing block. Most manufacturers
measure the diameter from the flanges of the stringing block
and not the groove.
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e) The bottom groove diameter of the stringing block should i) Use mid-span supports where necessary to clear all
be used when selecting the correct stringing block for the roadways and obstructions.
cable size being installed. Table 2 shows the bottom groove
diameter for typical stringing blocks relative to the j) Continue steps b - e throughout the installation route.
manufactured cable outer diameter and line angle.
Check the manufacture’s specifications for the correct 7.4 Payoff Set Up
groove diameter of the stringing blocks to be used.
f) The use of unlined stringing blocks is recommended. When a) Remove all lagging material from the reel Be sure to
selecting blocks for specific line angles due to changes in remove the lagging that protects the tail of the cable.
direction and elevation: Failure to remove this lagging could result in cable damage.
The total line angle change at a specific structure is b) The plastic guides over the tail should not be removed but
determined by the position of the previous structure in lifted out of the flange grooves. During the installation
the back span and the position of the next structure in process a phenomenon called “cable walkout” occurs. This
the route. The maximum line angle for either side of the is when cable tail is forced out of the cable slot during the
structure must not exceed 10° for tangent hardware for installation process causing the tail length to increase. The
line angles up to 20° and 15° for tangent hardware for purposes of the plastic guides are to allow the cable to move
line angles up to 30°. Use the same criteria regarding freely while the cable is being installed. If the tail of the
line angle changes for the selection of stringing blocks. cable is restricted so that cable walkout cannot occur, then
the excess cable length is forced into the cable winds which
could result in cable damage.
g) When large diameter stringing blocks are placed (i.e. > 16"
in diameter), secure the block in such a way that it remains
parallel to the ground during cable placement. This will
prevent the block from excessive movement during cable
placement, which in turn will prevent the cable from riding
up or "jumping" out of the groove of the stringing block. It
is the responsibility of the installer to make sure that
stringing blocks are placed on the structures in a manner
Photo 1
which will facilitate the cable installation without causing
e) Insure that the cable is paying off the top of the reel.
mechanical damage to the cable. Inspect the stringing block
surfaces to insure that there are no burrs or defects which
f) Attach the pulling grip and swivel to the PowerGuide®
could cause mechanical damage to the cable sheath during
Cable. See OFS Brightwave Carrollton Installation Practice
placement.
IP-013 for pulling grip attachment procedure.
h) Once the block has been secured, place the pulling rope
through the block and continue to the next pole location.
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Photo 2 Photo 4
g) Check the cable reel flanges for any obstructions that may
interfere with the cable payoff. Bull Wheel Tensioner
h) The reel payoff should have a breaking mechanism to i) Brake tension should be set as low as possible while still
control the payoff during the installation by applying back maintaining cable clearances over roads and other areas
tension to the cable. The breaking system will keep the were cable clearance may be a concern during the
cable from back lashing when sudden stops occur as well as installation.
control the cable sag during the installation
7.5 Cable Installation
Photo 3
a) Start the take up device and pull the cable at a speed of no
more than 40 meters per minute (130 ft. per minute).
b) From the sag and tension table the tensions required to meet covers general precautions when using a hydraulic
sag requirements for each span can be determined. Because tensioner/puller.
sag and tension tables are different for each PowerGuide®
cable design, the appropriate sag and tension tables for the
PowerGuide® cable being utilized should be obtained from
OFS Brightwave Carrollton.
d) At the first dead end location from the finished end attach a
temporary dead end for sagging. Make sure the temporary
dead end is installed far enough out from the structure to
take up all of the slack required for final sag and tension.
Depending upon the structure type, the span lengths and the
final tension, it may be necessary to secure the cable on the
opposite side of the structure to maintain the clearance in
the adjacent span or to provide slack for configuration of
the cable and hardware on the structure.
Note: There are several tensioning devices available from your g) Use the tensioning device to pull the cable to the desired sag
local distributor. The most common type used is a cable/chain or tension.
hoist. If a hydraulic tensioner (Puller) is used, care should be
taken to insure that the minimum bend radius of the cable is not h) The location of the permanent dead can know be
compromised by using too small a stringing block at the dead determined using the extension link and heliformed dead
end or intermediate attachment locations. Tensioning method 2
IP014 PowerGuide Installation Guidelines
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end. Once this location is determined install the permanent e) It may be necessary to use a temporary dead end to pull
dead end at this location and attach it to the structure. enough slack to configure the cable from the first dead on
the structure to the second.
i) Once the permanent dead end has been placed release the f) Once an adequate amount of slack has been pulled, install
tension on the temporary dead end and remove it from the the second dead per the manufacturer’s recommendations.
cable. The cable should now be at the preferred sag and g) Move to the next double dead location and repeat steps b
tension. through f.
h) For a double dead end on a structure where cable slack will
j) Mark the cable on the other side of the structure where the be coiled for maintenance or future access, the cable slack
second dead end is to be attached. must be pulled back before the second dead end is installed.
The tension on the cable when the slack cable is pulled
Note: When installing a double dead end (two dead end back should be minimal. Maintain only enough tension to
assemblies on one pole) enough cable slack should be provided clear obstructions during this process. Utilize proper
so that the cable assumes a gentle and uniform curvature equipment during this process to maintain cable minimum
between the two dead ends without contacting any obstructions. bend radius.
A double dead end should be placed at each splice location, i) Once the cable slack has been pulled in, secure the second
locations where maintenance slack will be accumulated or when dead.
line angles exceeding 20 or 30 degrees due to changes in
direction or elevation are encountered. Note: long span lengths sometimes require high tensile loads for
long term tension. When long term tension of >1500 pounds is
k) Once the double dead end is completed, move to the next required adequate size stringing blocks must be used to prevent
location requiring dead end assemblies and repeat the excessive side wall pressure and subsequent mechanical damage
tensioning procedure per paragraph 7.6 for each location to the cable. Please consult Table 3 page 11 in this guideline for
requiring dead end assemblies until the entire installation recommendations.
run is complete.
Note: If the sagging tensions are over 600 lbs the cable should
l) When sagging has been completed secure the cable at each not be left in the stringing blocks for an extended amount of time
tangent (intermediate pole) location with the appropriate at full tension. If it is not possible to install the tangent supports
hardware based on changes in direction or elevation. within a reasonable amount of time (i.e. 24 hours), reduce the
tension on the cable below 600 lbs or to a minimum tension to
Method 2 – Tensioning Cable Using a Hydraulic Tensioner maintain clearances over obstructions until the hardware can be
Puller installed.
This method utilizes the tensioner/puller to tension the cable for Note: Tangent supports can be placed as soon as the spans are
the entire length of cable installed. tensioned between dead ends. If an installation crew has the
man power, one crew can install the tangent supports while
a) Once the entire length of cable has been installed, cable another crew is sagging the next section between dead ends.
slack from the reel must be pulled to the necessary This procedure can significantly speed up the installation
locations. Once the necessary cable slack has been pulled, process.
secure the cable on the structure with the appropriate dead
end assembly j) Repeat steps for method 2 until all the dead ends where line
b) Consult the OFS Brightwave Carrollton sag and tension angles exceed 20° or 30° (depending upon tangent hardware
table for the appropriate long term tension for the section of selected) have been installed.
cable between dead end locations. Using the k) Once the cable has been secured at all the dead end
tensioner/puller and an in line dynamometer, pull the cable locations, secure the cable at intermediate poles using the
to the desired long term tension per the OFS Brightwave appropriate hardware and assembly instructions.
Carrollton sag and tension tables.
c) After the cable tension has been reached, the stringing block
must be removed at the first double dead end location
before the dead end assembly can be installed. The cable
will be under final tension. Do not exceed the minimum
bend radius for the cable design when removing the cable
from the stringing block. Once the cable has been removed
from the stringing block the dead end assembly may be
installed per the manufacturer’s recommendations.
d) Once the first dead end has been installed , release the
tension on the cable with the puller tensioner.
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Table 1
<= 600 Lbs Installation Tension
Table 3
1.25 8 18 36
1.20 8 18 36 Sag Tension 1000 - 1500 lbs
1.15 8 18 36 1.25 24 30 36
1.10 8 18 36 1.20 24 30 36
1.05 8 18 30 1.15 24 30 36
1.00 8 18 30 1.10 24 30 36
Cable O.D. 0.95 6 18 30 1.05 24 30 30
( Inches) 0.90 6 16 30 1.00 24 30 30
0.85 6 14 30 Cable O.D. 0.95 24 30 30
0.80 6 14 30 ( Inches) 0.90 24 24 30
0.75 6 14 24 0.85 20 24 30
0.70 6 12 24 0.80 20 22 30
0.65 4 12 24 0.75 18 22 24
0.60 4 12 18 0.70 18 18 24
0.55 4 8 16 0.65 16 18 24
0.60 16 16 18
0.50 4 8 16
0.55 12 16 16
0-20 21-45 46-90
0.50 12 16 16
Line Angle
0-20 21-45 46-90
Line Angle
Table 2
Table 4 – Sherman Reilly Stringing Block Diameter vs.
600 Lbs. to 1000Lbs. Installation Tension Groove Diameter.
1.25 18 30 36
1.20 18 30 36
Typical Sheave Sizes
1.15 18 30 36
Bottom
1.10 18 30 36
Outside Groove
1.05 18 24 30
Diemeter Diameter
1.00 18 24 30
(Inches) (Inches)
Cable O.D. 0.95 18 24 30
7 4.8
( Inches) 0.90 16 24 30
10 7.5
0.85 14 24 30
12 9.5
0.80 14 24 30
14 12
0.75 14 18 24
16 14
0.70 12 18 24
20 16
0.65 12 18 24
22 18
0.60 12 16 18
28 24
0.55 8 12 16 35 30.5
0.50 8 12 16 42 36
0-20 21-45 46-90
Line Angle
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IP014 PowerGuide Installation Guidelines
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To obtain documentation please contact OFS Brightwave Carrollton Technical Services “Hotline” at 800 889
3203 or through Customer Service at 800 366 3483 or visit OFS Brightwave Carrollton website at
www.fitel.com.