Objectives: From this chapter you should learn:
The types of fiber optic cables and their applications Differences between outside plant and premises cables Specifications for fiber optic cables
Fiber Optic Cable Design
Fiber optic cable provides protection for the optical fiber or fibers within it appropriate for the environment in which it is to be installed. Cable refers to the complete assembly of fibers, strength members and jacket. Fiber optic cables come in many different types, depending on the number of fibers and how and where it will be installed. It is important to choose cable carefully as the choice will affect how easy the cable is to install, splice or terminate, what it will cost and how long it will last in the field.
Cable’s job is to protect the fibers from the environment encountered in any installation. Outdoors, it depends on whether the cable is buried directly, pulled in conduit, strung aerially or even placed underwater. Will the cable become wet or moist? Will it have to withstand high pulling tension for installation in conduit or continual tension in an aerial installation? Will the cable be exposed to chemicals or have to withstand a wide temperature range? What about being gnawed on by a squirrel, woodchuck or prairie dog? Indoors, cables don’t have to be so strong to protect the fibers, but they have to meet all fire code provisions so the cable jacket has to be flame-retardant,
Outside plant cable designs are optimized for the application type. In OSP installations, cables may be underground, direct buried, aerial or submarine (or simply underwater.)
Underground cables are generally installed in conduit which is usually a 4 inch (10 cm) conduit with several innerducts for pulling cables. Here cables are designed for high pulling tension and lubricants are used to reduce friction on longer pulls. Automated pulling equipment that limits pulling tension protects the cables. Very long runs or those with more bends in the conduit may need intermediate pulls where cable is pulled, figure-8ed and then pulled to the next stage or intermediate pulling equipment is used. An alternative is to install duct lines and blow special lightweight cables into the ducts which can be faster and less stressful on the cable.
Splices on underground cables are generally stored above ground in a pedestal or in a vault underground. Sufficient excess cable is needed to allow splicing in a controlled environment, usually a splicing trailer, and the storage of excess cable must be considered in the planning stage.
Direct buried cable is placed underground without conduit. Here the cable must be designed to withstand the rigors of being buried in dirt, so it is generally a more rugged cable, armored to prevent harm from rodent chewing or the pressures of dirt and rocks in which it is buried. Direct burial is generally limited to areas where the ground is mostly soil with few rocks down to the depth required so trenching or plowing in cable is easily accomplished. Splices on direct buried cables can be
stored above ground in a pedestal or buried underground. Sufficient excess cable is needed to allow splicing in a controlled environment, usually a splicing trailer, and the storage of excess cable must be considered.
Aerial installations go from pole to pole, but the method of securing cables can vary depending on the situation. Some cables are lashed to messengers or other cables, such as CATV where light fiber cables are often lashed to the heavy coax already in place. Cables are available in a “8”
configuration with an attached steel messenger that provides the strength to withstand tension on the cable. Some cables are made to directly be supported without a messenger, called all-dielectric self-supporting cables that use special hardware on poles to hold the cables. Optical ground wire is used by utilities for high voltage distribution lines. This cable is an electrical cable with fibers in the middle in a hermetically-sealed metal tube. It is installed just like standard electrical conductors.
Splices on aerial cables can be supported on the cables or placed on poles or towers, Most splices are done on the ground, although it is sometimes done in a bucket or even on a tent supported on the pole or tower. Hardware is available for coiling and storing excess cable.
Sometime OSP installations involve running cables across rivers or lakes where other routes are not possible. Special cables are available for this that are more rugged and sealed. Even underwater splice hardware is available. Landings on the shore need to be planned to prevent damage, generally by burying the cable close to shore and marking the landing. Transoceanic links are similar but much more complex, requiring special ships designed for cable laying.
Since OSP applications often use significant lengths of cables, the cables can be made to order, allowing optimization for that particular installation. This usually allows saving costs but requires more knowledge on the part of the user and more time to negotiate with several cable manufacturers.
Cable Construction
All fiber optic cables are comprised of multiple layers of protection for the fibers. Most all start with standard fiber with a primary buffer coating (250 microns diameter) and add:
Tight Buffer Coating
(for tight buffer cables like simplex, zipcord, distribution and breakout types)
A soft protective coating 900 microns outside diameter is applied directly to the 250 micron coated fiber to provide additional protection for the fiber, allowing easier handling and direct termination by applying a connector on the fiber.
Loose Tubes (loose tube cables)
Small, thin plastic tubes containing as many as a dozen 250 micron buffered fibers are used to protect fibers in cables rated for outside plant use. They allow the fibers to be isolated from high pulling tension and can be filled with water-blocking materials (gel, dry tape or powder) to prevent moisture entry.
This ensures that the strength members will not stretch and then relax, binding the fibers in the cable.
The proper method of pulling fiber optic cables is always to attach the pull rope, wire or tape to the strength members.
Some cables also include a central fiberglass rod used for additional strength and to stiffen the cable to prevent kinking and damaging the fibers. When included, these rods should be attached to swivel
pulling eyes for pulling and clamps in splice closures or patch panels when spliced or terminated.
Few cables today use metallic strength members since it complicates installation by requiring the cable to be properly grounded and bonded.
Cable Jacket
The outermost layer of protection for the fibers which is chosen to withstand the environment in which the cable is installed. Outdoor cables will generally be black polyethylene (PE) which resists moisture and sunlight exposure. Indoor cables use flame-retardant jackets that can be color-coded to identify the fibers inside the cable. Some outdoor cables may have double jackets with a tough layer of armor between them to protect from chewing by rodents or Kevlar for strength to allow pulling by the jackets.
Indoor cables usually have a flame-retardant PVC (polyvinyl chloride) jacket for general or riser use and some other special plastic for plenum use in air handling areas. Indoor-outdoor cables usually have a PE outer jacket that can be removed to expose a flame-retardant inner jacket for use within buildings.
Protection Against Water and Moisture
Cables installed outdoors require protecting the fibers from water. Either a gel or as is becoming more common, absorbent tape or powder, is used to prevent water from entering the cable and causing harm to the fibers. Generally, this applies to loose tube or ribbon cables, but dry water-blocking is used on some tight buffer cables used in short outdoor runs, such as building to building on a campus or to an outdoor wireless antenna or CCTV camera.
Protection Against Crushing or Rodent Penetration
Some cables have armor, usually metallic but sometimes hard plastic, under the outer jacket resist crushing loads, such as cables installed under floors in data centers or in rocky soil, as well as to prevent rodent penetration. Metallic armor requires that the cable be properly grounded and bonded.
Fiber Optic Cable Types Tight Buffer Cable Types
There are two basic types of cables, generally defined as tight buffer and loose tube. Tight buffer cables (simplex, zipcord, distribution and breakout) are used in premises applications where cable flexibility and ease of termination are important, more so than ruggedness and pulling strength which characterize loose tube and ribbon types of cable. Generally, tight buffer cables are used indoors and loose tube/ribbon cables outdoors, but some tight buffer cables with moisture protection are used in short runs like on a campus or between buildings.
Simplex And Zip Cord
These types are used mostly for patch cord and backplane applications, but zipcord can also be used for desktop connections. Simplex cables are one fiber, tight-buffered (coated with a 900 micron buffer over the primary buffer coating) with Kevlar (aramid fiber) strength members and jacketed for
indoor use. The jacket is usually 3mm (1/8 in.) diameter, but some 2 mm cable is sometimes used with small form factor connectors. Zipcord is simply two of these joined with a thin web.
Distribution Cable
Distribution cable is the most popular indoor cable, as it is small in size and light in weight. They contain several tight-buffered fibers bundled under the same jacket with Kevlar strength members and sometimes fiberglass rod reinforcement to stiffen the cable and prevent kinking. These cables are small in size, and used for short, dry conduit runs, riser and plenum applications. The fibers are double buffered and can be directly terminated, but because their fibers are not individually reinforced, these cables need to be broken out with a “breakout box” or terminated inside a patch panel or junction box to protect individual fibers.
Breakout Cable
Breakout cable is a favorite where rugged cables are desirable or direct termination without junction boxes, patch panels or other hardware is needed. They are made of several simplex cables bundled together inside a common jacket. This is a strong, rugged design, but is larger and more expensive than the distribution cables. It is suitable for conduit runs, riser and plenum applications.
It’s perfect for industrial applications where ruggedness is needed. Because each fiber is individually reinforced, this design allows for quick termination to connectors and does not require patch panels or boxes. Breakout cable can be more economic where fiber count isn’t too large and distances too long, because is requires so much less labor to terminate.
Loose Tube Cable Types Loose Tube Cable
Loose tube cables are the most widely used cables for outside plant installation because this type of cable offers the best protection for the fibers under high pulling tensions and can be easily protected from moisture with water-blocking gel or tapes. These cables are composed of several fibers together inside a small plastic tube, which are in turn helically wound around a central strength member, surrounded by aramid strength members and jacketed, providing a small, high fiber count cable. This type of cable is ideal for outside plant trunking applications, as it can be made with the
loose tubes filled with gel or water absorbent powder to prevent harm to the fibers from water. It can be used in conduits, strung overhead or buried directly into the ground. Some outdoor cables may have double jackets with a metallic armor between them to protect from chewing by rodents or Kevlar for strength to allow pulling by the jackets. Since the fibers have only a thin buffer coating, they must be carefully handled and protected to prevent damage. Loose tube cables with singlemode fibers are generally terminated by spicing pigtails onto the fibers and protecting them in a splice closure. Multimode loose tube cables can be terminated directly by installing a breakout kit, also called a furcation or fan-out kit, which sleeves each fiber for protection.
Ribbon Cable
Ribbon cable is preferred where high fiber counts and small diameter cables are needed. This cable has the most fibers in the smallest cable, since all the fibers are laid out in rows in ribbons, typically of 12 fibers, and the ribbons are laid on top of each other. Not only is this the smallest cable for the most number of fibers, it’s usually the lowest cost. Typically 144 fibers in ribbons only has a cross section of about 1/4 inch or 6 mm and the jacket is only 13 mm or 1/2 inch diameter! Some cable designs use a “slotted core” with up to 6 of these 144 fiber ribbon assemblies for 864 fibers in one cable! Since it’s outside plant cable, it’s gel-filled for water blocking or dry water-blocked.
Another advantage of ribbon cable is Mass Fusion Splicers can join a ribbon (12 fibers) at once, making installation fast and easy. Ribbon pigtails are spliced onto the cable for quick termination.
Premises cabling also uses some ribbon cables, often in preterminated cabling systems where 12 fibers are terminated in one MTP connector. These cables are common in LAN backbones and data centers.
Armored Cable
Armored cable is used in direct buried outside plant applications where a rugged cable is needed and/or for rodent resistance. Armored cable withstands crush loads well, for example in rocky soil, often necessary for direct burial applications. Cable installed by direct burial in areas where rodents are a problem usually have metal armoring between two jackets to prevent rodent penetration.
Another application for armored cable is in data centers, where cables are installed under the floor and one worries about the fiber cable being crushed. Indoor armored cables may have nonmetallic armor. Metallic armored cable is conductive, so it must be grounded properly.
As with other fiber optic components, there are different names or meanings used. “Armor” in some companies’ jargon denotes a twisted heavy wire rope type cable surrounding the entire poly cable sheath/jacket. Single or double armor (two opposite ply layers of the steel wire) is typically used underwater near shore and shoals. Inner metallic sheath members of aluminum and/or copper are used for strength and for buried cable locating with a tone set.
Aerial Cables
Aerial cables are for outside installation on poles where consideration must be given to continual
tension from the cable weight as well as wind and ice loads. Regular outdoor loose tube cables can be helically lashed to a messenger or another cable (common in CATV.) Some cables have heavier jackets and stronger metal or aramid strength members to make them self supporting (called all-dielectric self-supporting or ADSS cable if the strength members are nonconductive.) Self-supporting cables use special hardware to handle the installed tension on the cables caused by the weight of the cables and environmental factors like wind. Aerial hardware to store slack cable can be mounted on the cable itself or on utility poles.
The cable known as a figure 8 cable has a cable bonded to an insulated steel or all dielectric messenger for support. The messenger is supported at each pole. If the messenger is steel, it must be grounded properly. You can also get figure 8 conduit which can be installed then cable pulled into the aerial conduit.
A widely used aerial cable is optical power ground wire (OPGW) which is a high voltage distribution cable with fiber in a metallic tube in the center of the wire surrounded by electrical conductors. The fiber is not affected by the electrical fields and the utility installing it gets fibers for grid management and communications. This cable is usually installed on the top of high voltage towers but brought to ground level for splicing or termination.
Underwater and Submarine Cables
It is often necessary to install fibers under water, such as crossing a river or lake where a bridge other above water location is not possible. For simple applications a rugged direct burial cable may be adequate. For true undersea applications, cables are extremely rugged, with fibers in the middle of the cable inside stainless steel tubes and the outside coated with many layers of steel strength members and conductors for powering repeaters. Submarine cables are completed on shore, then loaded on ships and laid from the ship, often while operational to ensure proper operation.
Other Types of Cable
There are many other types of fiber optic cable available, many unique to one manufacturer. Every manufacturer has it’s own specialties and sometimes uses their own names for common types of cable, so it’s a good idea to get literature from as many cable makers as possible. Don’t overlook the smaller cable companies; often they can save costs by making special cable just for you, even in relative small quantities.
Air-Blown Cable
Of course the advantages of fiber optic cable includes small size, light weight and flexibility. These advantages have allowed some cables to be installed by blowing into special ducts called duct lines, micro-ducts or sub-ducts which have been installed in larger conduit or even pipes for carrying water, sewage or gas. High pressure compressed air provides an aerodynamic effect, floating the
cable on the air stream and carrying it down the duct, allowing installation lengths as long as 2 km (6,500 feet.) Air-blown cable needs to be designed for lightness and flexibility and the jackets are designed to help the air lift and carry the cable down the duct. This method involves less stress on the cable, allowing it to be made lighter and smaller than traditional outside plant cables.
Air-Blown Fiber
Another cable type is not really cable at all. By installing a “cable” which is just a bundle of empty plastic tubes, you can “blow” fibers into the tubes as needed with special equipment using compressed gas. If you need to upgrade, blow out the old fibers and blow in new ones. Both indoor and outdoor versions of air-blown fiber cables are available and it has even been used in FTTH.
Special fibers are required that have been coated for easier blowing through the tubes, but any singlemode or multimode fiber is available. It’s more expensive to install since the tubes must be installed, special equipment and trained installers are needed but can be cost effective for upgrades.
Hybrid and Composite Cables
These two types of cables are often confused, but almost everybody and the NEC defines them as:
Hybrid cables: Cables that contain two types of fibers, usually multimode and singlemode. These cables are often used in campus and premises backbones where the singlemode fibers may be used in the future.
Composite cables: Cables that contain both fibers and electrical conductors. Underwater tethered
Composite cables: Cables that contain both fibers and electrical conductors. Underwater tethered