4-Cable Design & Installation

Lesson 4.
1: Cable Design & Installation
1: Welcome To This Lesson.
Welcome to Lesson 4 - Fiber optic cable design. This lesson covers in detail the design and
construction of fiber optic cables to suit a wide variety of environments. We will take this lesson
in two parts: Part 1 will include basic cable structure and design and OSP loose tube cable
design. Part 2 will include a review of tight buffer and indoor/outdoor cable design.
Copyright © 2018 CommScope Inc and Cabling Science Ltd. All rights reserved.
2: Design Objectives For Optical Cable.
Fiber optic cables have great ability to transmit information, but their ability to withstand physical
and environmental stress is much less impressive. Factors that these cables might have to
endure include, tensile forces, crushing, twisting and flexing and compression. Added to that
they need to be impervious to water and chemicals but at the same time need to be easy to
handle during installation. This lesson will show and explain the cable design and installation
techniques used to overcome these threats to the integrity and performance of optical fibers.
3: Stress.
Glass fiber is often used as a reinforcing material in plastics - so why is the fiber in a
communication cable in need of protection from physical stress? All fibers have minute flaws
that when they are subject to repeated stress will grow to a point where the fiber's optical
properties are affected. When thousands of glass fibers are used as re-enforcement in plastics,
some damage to a few of them does not matter. But, fiber optics links can be impaired or
disabled by damage that may not even be visible to the naked eye.
4: Environmental Considerations.
As well as bending, stretching, crushing and other mechanical forces, optical fiber has to be
protected from water. In the longer term moisture can change the properties of the glass in the
fiber and degrade its protective coatings. In outside plant, ice formation is also a potential threat
since water expands when it freezes. This expansion can generate forces that will damage the
fiber and its coatings. Extreme temperature variations are another potential threat since the
difference in thermal expansion coefficients between the fiber and its plastic coating can create
stress in the fiber.
5: NEC Codes.
Most fiber cables have NEC ratings on them that define the fiber construction and the areas
they are approved to be used in. The first two letters of the code are OF for Optical Fiber! The
next letter is either an N, for non-conductive construction meaning that it has no conductive
metal in it, or a 'C' for a cable with conductive metal in it. In this instance the cable must be
properly grounded or bonded at each end. 'G' is for general purpose use. 'R' Riser rated, 'P'
Plenum and 'LS' Low Smoke Zero Halogen rated. These ratings will be found on the fiber jacket.
6: Fiber Identification.
Fiber cable construction is standardized with regards to color coding of individual fiber strands
under the TIA-598 Optical Fiber Cable Color Coding. These are based on the same 10 colors
used for copper cables but with two extra, rose and aqua. When there are more than that from
13 to 24 they usually have stripes or dashes on them. Note that for hybrid cables containing
both single-mode and multimode fibers, it is common to place the single-mode fibers first, but
the fiber types are not color coded separately.
7: Loose Tube.
There are two basic types of fiber cable design - 'loose tube' or 'tight buffered'. As the name
implies, the loose tube type gives the fibers some freedom to move inside the protective tubes
that contain them and this helps to minimize stresses on the fibers. There are also two variants
of the loose tube design being 'stranded' loose tube where the fibers are in 2mm or 2.5mm
tubes inside the outer jacket or just a central tube with 'bundles' of fiber. The bundles are
normally 12 fibers together. Being loose tube, further options are available depending on the
fiber construction or design. These tubes can be 'dry', gel filled or contain a moisture blocking
textile. From an installation perspective, dry filled fibers are the quickest to prepare.
8: Tight Buffered.
In the tight buffer type, a thick thermoplastic buffer is bonded to the acrylate coating on the
optical fiber, which brings the 'OD' up to 900 micron which is about 1mm or the same as a single
core of UTP twisted pair. Aramid yarn surrounds them, giving them little freedom to move in
relation to each other or the buffer, before being over-jacketed with an LSOH or plenum rated
jacket. This type of cable is most commonly used internally and could also be a riser rated type
cable.
9: Loose Tube Design.
The coated fibers inside a loose tube cable are generally of 250 micron diameter, so when the
outer tube is opened, the fibers have little protection. At the cable ends, buffer tube fan-out kits
must be used when fitting connectors to the individual fibers. If these fibers are to be spliced, no
further protection or over sleeving is required as 900 micron pigtails or 900 micron fibers can be
directly terminated to them. Spliced fibers would normally be protected in a splice holder.
10: Loose Tube Design: Buffer Tubes.
In loose tube cables, the fibers inside are typically between 2 percent and 9 percent longer than
the jacket (cables are sold by jacket footage). Higher fiber count loose-tube cables will have
more of this 'extra fiber length', which means that when the outer jacket stretches, due to stress
or temperature, it will not stress the fibers inside. As well as the fibers, the newer style fibers
may be 'all dry', so will only contain the fibers or the tubes could contain gel or water absorbent
textile in the form of thread or tape.
11: Central Member Surrounded By Buffer Tubes.
Loose tube cables with higher fiber counts generally are a similar design to this, with several
individual loose tube cables positioned around a central strength member. 12 fibers per tube is
the standard for all fiber counts. To make the consolidated cable round in shape, filler tubes are
included to ensure a minimum of 5 tubes around the central member. The central member can
be made of fiberglass or steel and sometimes the fiberglass rods are also over-coated with a
plastic coating.
12: Environmental Factors.
As we have said, a key function of cable design is to protect the fiber against damage from
environmental factors and this not only requires careful design of the cable but also correct
choice of materials. Outer jackets are best made of plastics that do not change their properties
greatly according to temperature or humidity. They should also resist degradation by ultra violet
light and hence OSP cables have black jacket color. As well as having high strength and some
ability to absorb impacts, jacket materials should be abrasion resistant and have a low
coefficient of friction to make them easier to pull though cableways. Moisture blocking materials
inside the outer jacket with the fibers - be they threads, tapes or whatever - should resist the
entry of and migration of water inside the cable. Ideally, loose tube cables should be flame
resistant, but there are products on the market that do not meet the NEC/CEC codes in this
respect.
13: Protection From Water Migration.
Larger cables may have two levels of protection to minimize the impact of water ingress, as
shown here. The first is a layer of water absorbent tape under the outer jacket. The second level
of protection is water absorbent material within the individual buffer tubes carrying the fibers.
So, even if the outer jacket is punctured, the cable still gives the fibers some moisture
protection.
14: Loose Tube Design: Stranded.
Now let's compare the two loose tube design variants - stranded and central tube. There is little
difference in the optical or mechanical performance, but they have advantages and
disadvantages when it comes to purchasing, installing and maintaining them. The stranded type
offers better segregation of fibers and is better for high fiber counts. It also makes it easier to
split cables to form two or more separate runs of fibers, and to have 'drop-offs' at points along
the cable's length. In the main picture here, the strength member is in the center of the cable
and consists of a glass re-enforced plastic rod. Armored (rodent resistant) versions are also
available which still have the central rod but also have a corrugated steel barrier between the
outer jacket and the fiber.
15: Loose Tube Design: Central Tube.
The central tube type is less expensive to purchase and smaller in diameter than the stranded
type for a given cable count. It can also make splicing and terminations quicker and easier. In
the center tube the fibers are bundled in groups of 12 with a colored core binder around each
bundle. A 72 core fiber would have 6 bundles with the first bundle being blue corded, the
second orange, and so on, following the standard color codes. The main picture here shows the
steel strength members along each side of the fiber for added strength with the small pictures
showing a version without the rodent resistant armor but steel strength members and lastly a
central tube fiber with no strength members. There is a large selection available to suit most
requirements.
16: Stranded Dialectric.
Here is a closer view of a high fiber count stranded fiber with dielectric strength members. This
has buffer tubes that are compatible with standard hardware, cable routing and fan-out kits.
Single-mode, multimode and Laser Optimized multimode versions of this type of cable are
available with fiber counts from 4 to 288. The cable core has dry, water blocking material,
making access to and handling of individual tubes much easier and faster.
17: Stranded With Metallic Armor.
This armored cable is similar to the one we have just seen but is equipped with a layer of
polymer coated steel tape that gives added crush protection. As you can start to see there are
many versions of fiber cables with different degrees of protection depending on the environment
the cable is ultimately going into.
18: Self-Supporting Cable Designs.
Self-supporting outside plant cables are the same construction as the loose tube versions
shown earlier, but have a messenger wire bonded to the jacket of the fiber cable to allow it to be
used in an aerial type installation for physical support, but the cable has easy rip cord properties
to separate the messenger cable if required when running down walls or into the buildings. This
cable style is available in armored and all dielectric versions. The loose tube version in this
environment is critical because as the cable moves constantly in different weather conditions,
the fiber can move inside the tubes without being too tight or snapping.
19: Self-Supporting Cable Designs.

These are two more versions of self supporting cables. The top one is a 'mini drop' version with
the solid steel messenger wire, while the lower one is a self-supporting All-Dielectric Drop
Cable. This has two non-metallic strength members either side of a 12 core fiber, making it a
fairly compact design. These are just some of the styles of fibers available we have seen in this
lesson and with a range of different jacket and varied construction types, there is usually one
ideally suited to your individual application.
20: That Completes This Lesson.
1: Welcome To This Lesson.
Welcome to Lesson 4 - Fiber optic cable design part 2 where we will look at tight buffer and
indoor/outdoor cable design.
2: Tight Buffer Design.
The other main type of fiber cable construction we mentioned is the tight buffer design. The
most common types have a buffer coating of 900 micron outside diameter wrapped around a
250 micron coated fiber. This type is easy to handle. Connectors can be terminated directly to
the 900 micron fiber, allowing them to be plugged into rack or wall-mounted hardware. The tight
buffer design has some disadvantages though, because the buffer coating adheres directly to
the fiber. This increases the chance of microbending that can attenuate signals in the fiber
which in most cases results in a cable that has higher losses than the loose tube equivalent. In
addition, the PVC buffer normally used has a coefficient of temperature expansion 100 times
greater than the coefficient for the fiber itself. As a result, tight buffer cables have relatively poor
temperature tolerance, generally only from -40°C to +70°C, but this broad enough to meet
almost all inside plant applications.
3: Tight Buffer Design.
This shows the design detail of a multi-fiber tight buffered cable. The outer jacket can be made
of polyvinyl chloride or PVDF to meet the NEC/CEC code for plenum and riser cables but is also
available in LSZH designs too. These cables are available with 2 to 24 cores of fiber. Strength
elements are aramid yarn located under the outer jacket and because there is no water
absorption gel or powder, the cable is clean to work with. Due to differential expansion issues
and their lack of water absorption material, PVC tight buffered fiber cables should only be used
in dry, temperature controlled locations. PVC jackets are also unsuitable for outside use
because they are soft, can be easily abraded, having a high drag on pull through, and a shorter
life than other plastics.
4: Tight Buffer Design: Indoor/Outdoor.

This is an indoor/outdoor tight buffered cable and is normally used for short runs between
buildings on a campus style site. It can run through the buildings and externally in a continuous
run between the comms rooms. The jacket is black (UV stabilized) covering a water blocking
tape and the aramid yarn, surrounding the tight buffered fibers. In this version the central
strength member is a fiberglass plastic coated rod.
5: Jacket Color Codes.
Fiber premises cable jacket color codes are specified by the TIA-598 standard. External cables
are normally black as we have just seen, because the jackets are UV stabilized. Internal fiber
colors are standardized as follows: OM1 Multimode cables are usually slate or orange. OM3 or
OM4 Multimode cables are aqua. The text on the jacket itself identifies the OM3 or OM4 rating.
Single-mode fiber, either OS1 or OS2, are both yellow. Again the text on the jacket is used to
identify the difference. Interlocking armored jacket is the same color as the fiber type it contains
within. The text on the jacket also displays the relevant flame rating (CEC/NEC code Ofxx).
6: Distribution Cable.
This is tight buffered distribution cable. The design shown here offers a compact and cost
effective solution as it can be directly terminated but is not suitable for connections to the
desktop. The construction of these cables for an 18 core fiber would have three 6 core fiber
units surrounding the center strength member with 3 filler tubes to retain the 'shape' of the fiber.
At the other end of the scale a 144 core fiber would have twelve, 12 core fiber units. These
distribution type fiber cables are slightly larger than the standard tight buffered fibers we saw
earlier so if the requirement is for up to 24 cores, the standard cable may be an easier option,
being considerably smaller, more flexible and less expensive.
7: Simplex & Duplex Cables.

Tight buffer simplex and duplex cables are typically used as connectorized patch cords to
interconnect active equipment and patch panels and/or different ports on a patch panel. They
are also used as connectorized pigtails to terminate outside plant cable and as a light duty
horizontal distribution cable. To maintain high performance of a component that is frequently
moved, most experts do not recommend field termination of fiber patch cords. The simplex and
zipcord types should not be used as distribution cables.
8: Interlocking Armored Cables.
Interlocking Armored Cable is another option available in fiber cable construction. This is where
a standard tight buffered fiber is encased in a spirally wound aluminum protective flexible
conduit. This interlocking armored casing is then over-jacketed with a plenum rated sheath
which is over printed with the cable specification. Where would it be used? A good example of
this would be in a high rise office where there are communal risers and a company has offices
on different floors passing through common areas. A link made using this type of interlocking
armored cable fiber would provide protection from damage by other contractors or service users
in the same riser and space savings versus plastic innerduct. The cable is straightforward to
install using pipe clips for support in the riser or cable tie fixing to cable trays and protection
from bending and excessive pull tension is combined with time and labor reductions. It can be
used in building backbones, zone distribution, raised floor, data centers and storage area
networks. Interlocking armored cable is available in the full range of fiber type solutions and
environmental space ratings.
9: Installation with Traditional Cabling.
This schematic illustrates how a building installation would be implemented using traditional
fiber cabling. Depending upon local and national codes, within 15 meters of the building
entrance there has to be a transition from outdoor to indoor cabling. This is because of the gel
filling compound in the external fiber. Also if the fiber is an armored version earthing/grounding
will be required.
10: Installation with Indoor/Outdoor Cable.
With indoor/outdoor cabling, there is no need for a transition point. The cable from outside can
go directly to the main cross-connect saving time and money, as these fibers are normally dry
filled or may even be tight buffered, allowing fast and easy termination.
11: Application Guideline.
To summarize the cabling and applications we have covered, here is a table showing what
types are preferred for particular applications. Generally, tight buffer types are used internally
and loose tube types preferred for harsher conditions outside, but cable selection is always
dependent on local and customer requirements. Armored cable for example may be
recommended in places such as underground ducts or walkways where cable damage has
been known to have been caused by rodents or similar pests!
12: Cable Design.

In this lesson we have seen many variants of fiber cables with differing constructions, including
jacket types, tight buffered and loose tube fibers, dry and gel filled, armored and twin jacketed.
To add to that list, there are also hybrid fibers available. This one here is an external cable and
includes fiber and power in the same sheath. There are many choices of fibers and there will
probably be one to exactly suit your requirements.
13: That Completes This Lesson.
Quiz
A
It will be a lower cost cable meter for meter than outdoor cable.
Incorrect Answer - It will not necessarily be a lower cost cable than the outdoor fiber
cable but it may overall save labor and other costs.
B
It does not require a transition point to indoor cable on or near entry to the building.
Correct Answer - The main reason for using indoor/outdoor cable is that you can bring
the cable on into the building and into the riser etc. Outdoor cable is not fire rated and
will have to have a transition to indoor at or close to the entry point.
C
Like indoor building cable it is always 900 micron buffered and so can be directly
terminated with connectors without additional buffer tubing.
Incorrect Answer - Indoor/outdoor cables are available in BOTH loose tube and tight
buffered and only the tight buffered comes in 900 micron and is ready to terminate to
connectors directly.
D
All answers.
Incorrect Answer - Two of the other answers are incorrect.
Question 2:
In loose tube cable the fibers are up to ?
A
12% longer
Incorrect Answer: Please review the other answers and try again
B
20% longer
Incorrect Answer: If they were 20% longer they would never fit in the tubing
C
5% longer
Incorrect Answer: They are longer than this
D
9% longer
Correct Answer: In loose tube cable the fibers are up to 9% longer
Question 3:
Which of the following statements regarding Outdoor cable is NOT correct ?
A
Outdoor cable moisture protection will be maintained by the use of Tape, Thread or on
legacy fibers gel-filled or powder filled tubes depending upon cable type.
Incorrect Answer - This statement is TRUE.
B
The fiber inside the tube is longer than the tube itself.
Incorrect Answer - This statement is TRUE, In loose tube cables, the fibers inside are
typically between 2 and 9 percent longer than the jacket (Cables are sold by jacket
footage) Higher fiber count loose-tube cables will have a more of this 'extra fiber length'.
This extra length means that when the outer jacket stretches, due to stress or
temperature, it will not stress the fibers inside.
C
You are required to put 900 micron buffer tubing over the cladding when terminating
connectors directly to the outdoor fiber.
Incorrect Answer - This statement is TRUE. Connectors are designed for 900 micron
buffered fiber and Outdoor cables only have a coating of 250 micron so buffer tubing is
required for support.
D
Outdoor loose tube fiber has a 900 micron thermoplastic buffer bonded to the acrylate
coating on the optical fiber to protect it in the loose tube.
Correct Answer - This statement is NOT true. Outdoor cables only have a coating of
250 micron. The Loose tube the fibers are placed in is thermoplastic.
Question 4:
Which color fiber according to the TIA/EIA 598 color code comes after yellow in the
sequence?
A
Violet.
Correct Answer - Violet comes after yellow in the sequence.
B
Rose.
Incorrect Answer - Wrong color!
C
Aqua.
D
Black.
Question 5:
What is the industry standard jacket color for singlemode internal fiber cables ?
Aqua
Incorrect Answer - Aqua is used for OM2+, OM3 and OM4 low modal delay fibers.
B
Slate
Incorrect Answer - Slate is used for some multimode fibers but this color will only
usually found in military specified cables.
C
Yellow
Correct Answer - Yellow is used for indoor singlemode applications.
D
to expand
Orange
Incorrect Answer - Orange is usually used for OM1 multimode fibers.

4-Cable Design & Installation

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Lesson 4.

1: Cable Design & Installation

1: Welcome To This Lesson.

2: Design Objectives For Optical Cable.

9: Loose Tube Design.

11: Central Member Surrounded By Buffer Tubes.

12: Environmental Factors.

14: Loose Tube Design: Stranded.

15: Loose Tube Design: Central Tube.

17: Stranded With Metallic Armor.

18: Self-Supporting Cable Designs.

19: Self-Supporting Cable Designs.

20: That Completes This Lesson.

1: Welcome To This Lesson.

4: Tight Buffer Design: Indoor/Outdoor.

5: Jacket Color Codes.

7: Simplex & Duplex Cables.

8: Interlocking Armored Cables.

10: Installation with Indoor/Outdoor Cable.

11: Application Guideline.

12: Cable Design.

13: That Completes This Lesson.

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