OSP Construction Overview

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 Out Side Plant (OSP)

In telecommunication, the term Out Side Plant

(OSP) refers to all the physical cabling and
supporting infrastructure (such as conduit,
cabinets, buildings, tower or poles) and any
associated hardware.

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 Out Side Plant (OSP)

– Ducts and accessories.

– Fibre cable
– Tower

Man Holes

Station - Station -
A B

OFC Route Tower

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 Items Used

• Duct , its accessories & its handling/cutting tools

• Cable
• Joint closure
• Chambers-MH, HH
• Route Markers
• Protection/ Clamping material
• Earthing
• FMS

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 HDPE Duct

• It is High Density Poly Ethylene duct used

for underground cable conduits
• Consists of two concentric layers,
• Outer layer being HDPE; co-extruded with
a inner layer of solid permanent lubricant,
to reduce the Internal Co-efficient of
Friction
• More than 50 years of service life of the
duct and all its accessories
• 40/33 mm size duct is used in our network.

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 HDPE Duct Accessories

• Push-fit Couplers: Used to couple two duct. They are simple, easy
to install and provide air/water tight joint between two ducts
• End Plug: Used for sealing of ends of the empty duct prior to
installation of OF cable to prevent entry of dirt, water, moisture etc.

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 HDPE Duct Accessories/Cutting tools

• Cable Sealing Plug / Simplex Plug: Used to seal the end of the duct
perfectly, after cable is installed. It is required, where cable has come
out of duct either by joint or entry into the building as required
• End Cap: Made of hard rubber/suitable plastic material, fitted onto both
end of duct coil after manufacturing the duct
• Duct Cutter: To cut duct ends squarely without any burr or notch

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 Machines/Tools

• Trenching Tools
• Decoiler
• DIT equipments
• Blowing Machines
• Splicing Machines
• Testing tools- OTDR, PMLS
• Cable locator

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 ITP

ITP Form No. 29

before
trenching
 OFC N/w Creation - Overview
Project Authorization
Route Selection of
schedule for applying
approval vendor
sign-off ROW

Requisition/
Issue of Obtaining
Execution material (Duct, Approval for RoW
Complete/Billing coupler, end issue of
plug, OFC) permission
material

Acceptance Material No Dues from Obtain NOC &

Testing/Audit and Reconciliatio return of Bank
Petty/Sub Guarantee
Clearance
n/Billing Contractors

Submission of
Retention Bill HOTO documents To
payment/Con Certificate whomsoever
tract Closure concern

9/23/2013
 RoW process

Application for RoW Liaisoning with local

Submission &
authority for joint
(Route shown on processing for
route survey &
map, SLD) payment to CPDH
demand note issued

Obtaining RoW
permission & Submission of
submission to CPDH payment to authority Approval & payment
(Photocopy of the & receipt submission release
same to vendor for to CPDH for record
execution)

BG/SD clearance
Execution of work from Authority &
Work finish
after intimation to all submission to CPDH
information to all the
the utility owner & for approval to
authorities & get NOC
local authority release retention
payment
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Installation Process

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 End-
End-to-
to-End Installation

Execution (as per IFC with ITP filled)

– Trenching
– Ducting
– Coupling
– Backfilling

Crossing the Railway, Highway, utilities by

– Clamping/ Trenchless/ Open cut

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 End-
End-to-
to-End Installation

Installation of
– Chamber
– Route Markers
– Earthing

Optical work
– DIT & Cable blowing
– Fibre splicing
– Fibre termination /tapping

ITP Preparation after each activity completion,

As Built Drawing using IFC drawing

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 Trenching
• The process of continuous digging following a single line in a specific
condition called trenching.
• The depth of the trench may vary as per soil strata &
specification.

Soil

Normal Soil Hard Rock

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 Trenching Methods

Methods

Open Trench Trenchless

Manual Machine Manual HDD

Boring Machine

Excavator Trencher

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 Prerequisite for Trenching
• Ensure safety .
• Trench should be in ROW Limits.
• Make cross pits for finding underground utilities to ensure
no damage manually.
• If damaged then inform and attend them to restore the
damages.
• A day plan trenching to be carried out
• Mark the trench line for straight trenching with lime
powder.
• Trench bed should be plain to avoid Kinks & Bends etc.
• No sharp turns and undulations to maintain the bending
radius.
• CDR to be raised if specs not met.
• Avoid electric/utility poles/trees in line of trench
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Making of Cross Pit at every
200 mtr( or as needed)

Pits to be Barricaded properly

 Normal Soil for Intercity

Ground Level Ground Level

450 mm
650 mm

Warning Tape
1650 mm
Depth

Backfilled Soil , (Free From Stone)200mm

40 mm Colored HDPE Duct

(Blue Duct on Road Side)

300 mm

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Rocky Area

• Ground Level Ground Level

450 mm
1250 mm
Depth

Warning Tape
200 mm

Backfilled Soft Soil, (Free From Stone)

40 mm Colored HDPE Duct

(Blue Duct on Road Side)

300 mm 50mm
Bedding

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Duct Sequence

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Duct Sequence

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Open Trenching
Proper way of Trenching

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 Open Trenches & Ducting
Vertical GOOD Horizontal GOOD
Undulations TRENCH Undulations TRENCH

Avoid Vertical & Horizontal Undulations as much as as possible

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Zig Zag “Faulty Trench”

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Traffic Jam due to bad planning
 Prerequisite for Ducting

• Check the roll of duct for any physical damage

• Decoil the duct along the trench using decoiler.

• No Water/MUD should be present in trench, while laying

the duct/DWC pipe.

• Place the duct in the trench properly as per specified

colors.

• The ducts should not overlap to each other.

• Ensure coupling before backfilling and cap the end.

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 Prerequisite for Ducting

• Minimum bending radius of 1300 mm for duct is to be

maintained

• Never place coupler along the bent portion of duct/trench

in both horizontal as well as vertical direction.

• When GI pipes are to be laid with suitable bends, pipe

bender is to be used or making ‘V’ cut. Also use rubber
bushes.

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 Prerequisite for Ducting

 Do not use hacksaw to cut the duct. Use duct cutter.

 Push fit couplers to be used with 200 mm of gap in b/w

two.

 All coupler locations shall be covered with Red Stone

(1000X300X25) mm / RCC slab 1000 X 300 X 40 after
200 mm sieved soil.

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Damaged Bundle of Duct

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Damaged Bundle of Duct

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Damaged Bundle of Duct

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 Proper way of Ducting
Use of Decoiler

Use of Decoiler

Duct Cutter

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Coupler Fitting

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 The Correct Method of Coupler Fitting

● Use ONLY a Duct Cutter to cut the Ducts. Do not use hacksaw /
Knife.
• Duct should be cut with about 20-30 mm overlap with duct cutter at 90
degree. Mark the “Cut Mark” using a Measuring Tape and a Marker.

• The duct overlap is to allow duct shrinkage while pressing down .

● If ducts are cut neck to neck then while pushing down ducts may

come out of the coupler.

• Remember: Before Cutting the duct push it towards the root / bore
hole.
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 The Correct Method of Coupler Fitting.......

• Coupler should not be rotated while fitting otherwise its teeth will get
damaged and it will not have proper grip to stand firm against pressure during
DIT /blowing.
• Rotating the coupler also damages the “O-Ring” and therefore air leakage
can happen also do not use hammer on Coupler while installing
O-
Ring

Teeth
Ring
Teeth
Ring
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 The Correct Method of Coupler Fitting.......
• The Chamfering tool must be used to sharpen the face of duct so
that the duct is inserted into the push fit coupler easily without
damaging the rubber (O-Ring) in side coupler.

Chamfering To Marker
ol
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 Purpose of using the Chamfering Tool

Chamfering tool
reduces the outer dia
of the duct to less
than inner dia of the
rubber “O-Ring”

As the duct is
The duct now pushed
enters the further, the O-
Rubber O-Ring Ring slips over
without any the
effort, and unchamfered
without any portion of the
damage to the Duct, and
O-Ring provides leak-
proof seal.
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 The Correct Method of Coupler Fitting.......

• Clean both the duct-ends with water and waste cloth. There should be no
dirt on the two duct-ends. Then cut the duct by duct cutter with about 20-30
mm overlap.
• Mark both duct-ends with 60mm “Insertion Mark”, with a permanent marker
pen after Chamfering the duct-ends.
• Apply “a drop of a Shampoo”, as a soap-based lubricant, on the inner side
of O-Ring inside the coupler, without opening the coupler.

60
60
mm
mm

• First insert one duct-end into the coupler. With a gentle push, the duct-end
should slip inside the rubber O-Ring, with a “tik” sound and come to the
centre of the coupler. This will be visible from other side of the coupler.
Confirm that “Insert Mark” line is just outside the coupler.

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 The Correct Method of Coupler Fitting.......

60
mm
60
mm

• Next, push the other Duct-end into the coupler and use the pressure of
the duct itself to push the duct into the coupler. The duct-end should slip
inside the rubber O-Ring, with a “tik” sound and come to the centre of
the coupler. This can ONLY be confirmed by the “Insert Mark” line if it is
just outside the coupler.

● In the same pit, separate the Push-fit couplers preferably with 200 mm
of gap in between any two.
● All coupler locations shall be covered with red stone (25 mm thick X
300 wide X 1000 mm length) after 200 mm sieved soil.

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 What are the reasons of leakage in
couplers during DIT??
Most likely reason for coupler leakage is the Damaged “O-Ring”
Push Fit
Couplers O-
Ring

Reasons of Leakage:
Use of incorrect tools, specially “Hacksaw Blade”. An unclean cut
damages the O-Ring.
Duct cut exactly at 90 degree (Square-Cut) can damage the O-Ring.
Not Chamfering and using heavy force to push the duct can damage the
O-Ring.
Penetration of dust while coupler fitting/handling. The duct should be
properly cleaned before starting the coupling process.

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 Continued….

Don’t install the couplers in ducts which are being pulled in HDD if cut
short.
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Don’t practice the pulling of duct directly from roll or without D-Coiling.
If required to open the installed coupler, then it should ONLY be opened
with the proper C-Spanner else it will get damaged.
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 Continued….

 Cutting of duct without proper planning:

● Gap in ducts- due to this the duct-ends will not cross the “O” Ring and

leakage will occur. Plan for an overlap of 20~30 mm.

(b) Shrinkage- Avoid the coupling immediately just after pulling the duct by HDD,

possibility of shrinkage may appear and leakage can occur.

(c) Do not use the “Chinese Figure” applied portion in the duct coupling.

 Coupler shall not be installed along the bent portion of duct/trench in both

horizontal as well as vertical (Zigzag) direction

 Coupler shall not be opened during fitting as it is designed for “Push-Fit”.

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 Can we open the coupler and reuse
successfully?
• Yes, coupler can be open and re-used if opening tool is used for coupler

opening so that it does not rotate on the duct while opening.

• Coupler teeth-ring is widened and removed so that teeth remained

sharp enough for grip and same way while closing precaution to be

taken for placing the teethed ring over the duct.

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Duct Decoiler

Decoiling should start only after filling ITP Form-30

Decoiler

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Proper way of ducting

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Decoiler Not Used

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Kink in the duct

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Couplers Missing

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Gap is too big to fit the couplers

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Slope Gradient Not Maintained during laying

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 Prerequisite for Back Filling
• Ensure coupling.

• Back filling should be done just after verifying the ducting and
use fine sieved soil for 200 mm and then backfill fully with
500mm layer dry compaction.

• Do not let the trench remain opened for a long period, that
cause traffic jams and life risk either human or animals.

• Total excavated soil should be backfilled in the trench.

• Crowning of 250 mm shall be done.

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 Prerequisite for Back Filling

• Lay the warning tape.

• Beware of Kinks & Punchers due to heavy damping during

backfilling.

• It is essential to have compaction when the excavation is carried

out along the road shoulders, crossing the road and foot paths.

• Clean all the debris.

• Use blockades to prevent soil erosion due to rain water.

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Back Filling

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 Warning Tape

In Normal Soil -
650 mm below
from NGL (Inter-
city)
500mm (Intra-
City)

NOTE- In Rocky Soil 200 mm above the duct

Crowning

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 Route Markers

• RM is made up of RCC 1:2:4 and placed in span of 250m normally.

• Provide route markers on both side of bridge/culvert/crossings and where

there is major diversions.

• Length shall be 1250 mm with a base of 100mm* 250mm tapering to

100mm * 200mm.

• Out of 1250 mm , 500 mm shall be below ground and 750 mm is exposed

and blue in color.

• Yellow for coupler location and red for MH/HH.

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 Route Markers
• Shall be erected straight, facing the road side and placed
0.5 m from the trench and away from the road centre.

• Name and logo of owner shall be engraved on the surface

with fluorescent white.

• If any/some normal RM fall within 50m of any

MH/HH/Coupler location RM, don’t place that.

• For intracity or where there is no feasibility to place concrete

RM use electronic RM.

• RM should be incorporated in ABD.

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Route Marker

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Route Marker

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Faulty Backfilling

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Manual Boring “Moling”

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 Horizontal Direction Drilling

• Criteria for doing HDD

– Non availability of permission for open
trenches.
– High restoration cost.
– ROW based only on HDD.
– Highly dense populated areas.
– Crossings ( Road / River / Culvert
/Railway).
– Ducts below Gas Lines / power lines

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 HDD Installation

• HDD installation involves four

main steps:
– Pre-site planning;
– Drilling a pilot hole;
– Expanding the pilot hole by
reaming;
– Pull back of pre-fabricated duct.

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77
HDD
 Reliance Industries
Confidential
Limited
 Guidelines for Railway Crossing

• Railway crossing must be done only after getting the

written permission and infront of their officers.

• Railway Crossings should be done by any one of the

Trenchless methods.

• If crossing by open trench then take care of the

protection of the Railway track first because its directly
related to the high life risk of passengers.

• Installation of a HH on both side is necessary.

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 Installation at utility crossings

• Be careful while crossing existing utilities.

• Give the intimation letter to all the existing utility owners
before the start.
• Special protective measures shall be taken to prevent
damage to other utility in future during maintenance.
• Cross by open cut or trenchless as approved by the authority
and maintain the gap.
• GI/DWC shall be used encased in 100mm thick concrete if the
location is susceptible to damage by third party in future.
• Manage min 0.5m vertical clearance from the utility or lesser if
approved by the authority.

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 Highway Road Crossing

• The Highway Road Crossing could be done either by open cut or

any one of the Trenchless methods as per ROW permission.

• The bending radius should be maintained during installation .

• During Road Crossing G.I. / DWC pipes should be extended for 2m

on both sides from the end of the road.

• When more than one GI is to be used, the section of pipe shall be

welded together to form required length.

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 Prerequisite for Clamping

• Type of clamping is depending upon the type of bridge.

• Avoid the use of DWC Pipe where in reach of
fire/human/sunlight/water.
• Rivet Bolt should be placed at the end of GI Pipe in the
bridge.
• The gap between two clamps should be 1 meter.
• The clamps should be made up of GI strip thickness 6mm,
width 50mm.The nuts bolts should be of 12mm diameter.
• The GI Socket should be properly tightened at the joints of GI
Pipes.

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Typical Installation

90
Typical Installation

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Typical Installation

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Bridges
Bridges
Clamping on Bridges and Nodes

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Clamping on Bridges

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Bad Practice

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 Manhole & Handhole

• In intercity normally MH & HH is a concrete ring of outer diameter

of 1010mm diameter and 825 mm height with a wall thickness of
55 mm.

• For intracity conical chambers are used.

• The Lid should be 100 mm thick with 1010 mm outer dia.

• The MH/HH shall be pre fabricated, transferred to the site and

placed in the trench to enable the ducts enter at 1.55m level.

• MH/HH shall be installed over well compacted ground and over a

layer of concrete base of 1110 mm outer dia with 125 mm
thickness.

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 Manhole & Handhole

• Duct length inside the chamber should between 15-30

cm.

• Cable should be looped and tied up at four places

inside the joint chamber and should not come out in
Joint chamber to avoid any damages.

• Duct entry hole in MH/HH should be sealed with

cement mortar 1:2 after duct laying.
 Manhole & Handhole

• MH/HH facilitate blowing, jointing and storing loops for

future use.

• Use end plug.

• MH/HH are basically same as per construction, they are

named to distinguish the function they perform i.e. MH for
joint and HH for loop location.

• The strength for under roads, footpath and non vehicular

shall be 25T, 10T and 5T respectively.

• For intercity the MH/HH lid shall be at least 500mm below

NGL. 103
 Manhole & Handhole

• In Intracity where adequate depth of burial is not available, the

lid shall be installed flush with NGL.

• MH/HH at the X-ings shall not encroach into casement/row of

the existing utility/facility.

• MH/HH are to be placed as per IFC. Normally in intercity the

distance b/w the two MH is 4 km and HH for every 1 km.

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Typical Hand Hole
Cylindrical Chamber
Conical Chamber

Checklist

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Typical Chamber for hilly/rocky terrain

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 Reliance Industries
Confidential
Limited
MH & HH
 Duct Integrity Test
Purpose:
Purpose of Integrity Test is to ascertain and ensure the suitability of duct for optical
fiber cable installation through jetting.

What is DIT?
DIT is a series of tests performed on the underground duct. It is the intermediate step
between duct laying and cable jetting.

What is done in DIT?

1.Check continuity of the duct
2.Clean the duct of any mud, stones, water
3.Check for Kinks, Blockages, Sharp bends
4.Check for any leakage in the duct.
5. Rectify the faults.

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 Pressure Testing Equipment

2 1

4
3

1. Valve to control the flow of air

2. Pressure regulator to regulate the air pressure
3. Drain valve to release pressure
4. End coupler for connecting the system with duct.
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 Catch box

• The catch box/ end coupler is coupled

at the extreme end of the duct.

• The catch box contains damping elements (spring and damping

rubber), which breaks the speed of the shuttle/transmitter and
catches them softly without any damage.

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Ducting
& DIT
 Blowing of OFC
• Ensure the duct Integrity test (DIT) completed.

• Ensure the OFC drum tested.

• Drum should be kept approximately at the center of two adjacent

chambers

• Cable drum should be mounted on jack, kept on a plain surface.

• Cable blowing is done with the help of compressor, hydraulic power

pack, blowing machine( Super Jet Machine)

• ITP to be filled.

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 Blowing

M 985 MTRS H 985 MTRS H 985 MTRS H 985 mtrs M

H H H H H
• Distance between MH to HH, HH to HH & HH to MH shall be 985
mtrs.
• Loop in MH shall be 15 mtrs & in HH 10 mtrs
• Duct coil shall be in 1000 mtrs length
• OFC drum shall be 4000+ mtrs ( maxi 5% )
• Duct cleaner shall be of superior quality & water is not allowed to
dilute it.(Tornado plus, Duraline)

Note : Cable blowing pressure should be <= DIT pressure

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 Salient Points During Cable Blowing :

• Availability of Line Diagram with all Coupler points/ HDD points,

Road/Rail crossings
• GI/RCC/PCC crossings clearly marked
• Site supervisor involved in Duct laying to be present on site
• Spare couplers, End plugs to be available at site
• Availability of ROW
• Drum planning chart specifying the allocation of drums to various
stretches
• Pre position of MH/HH’S
• Regular daily site meeting with the blowing team

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 Super Jet Machine

Power Pack Assembly

Speedometer

Hydraulic Hoses

Air Pressure Chamber

Hydraulic Motors Cable Pusher Assembly

128
 Super Jet Machine

• Hydraulic Super-jet Machine is driven by two hydraulic motors.

Power is supplied by a hydraulic power pack, which is driven by
Petrol Engine.

• It has a greater pushing force allowing the efficient placement of

heavier and stiffer cable such as heavily armoured optic fiber cables.

• Hydraulic Super-jet Machine can jet the cables of Dia 12 mm to

32mm at the speed upto 60m/min upto 2000m length (cable) at a
time.

129
 Push Mechanism in Super Jet Machine

Air Compressor
(12 Bar, 400 CFM) Power Pack

Pumps Hydraulic
Oil into the Motor

Cable

Air Pressure
Drum
Chambers
Hydraulic
Motor Caterpillars
Jack

130
 Proper cable blowing

Making Figure 8
Fiber Blowing

Fixing of Blowing machine inside the chamber

OFC Entry in Closure

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 Fiber optic cable fusion splicing

• A Special equipment called fusion

splicer is used.
• Provides lowest-loss connection.
• The fusion splicer performs optical fiber
fusion splicing in two steps.
– Precisely align the two fibers
– Generate a small electric arc to melt
the fibers and weld them together
– Splice protection sleeve is heated.

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Fiber optic cable splicing process - fusion splicing
Fiber optic cable splicing process - fusion splicing
 Splice Machine - Dos

• Perform ARC CHECK once in a day to get better splice loss.

• The cleave length must be set correctly as per the fiber guide.
• Select correct Fusion Program during splicing as per the type of
fibers used.
• Splicer preventive maintenance (cleaning of mirrors, microscope,
clamps, V -grooves etc) must be done regularly as per the user
guide to get the best results.
• UPS/AVR must be used while connecting Splice machine to
Generator.

143
 Splice Machine – Don’ts

• Do not clean or touch the bare fiber after it has been cleaved, and
do not let it come in contact with any surfaces.

• Never touch the electrodes when the fusion splicer is powered on.
Doing so may cause electrical shock.

• Warning symbol is placed on the windshield to notify it.

• Do not attempt to load fibers while the fusion splicer is resetting.

Load the fibers only after the reset operation is complete and the
READY screen or LOAD FIBERS screen is displayed.

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 Termination
• All fibers will be terminated on fiber distribution panel(FDP) at
aggregation nodes(AG1, AG2,AG3 and so on) or masts or
eNodeB, ILA with ROADMs(Reconfigurable optical add drop mux.)

• Approx 10m OFC shall be stored in FDP or in HH near to it.

• Proper racking and clamping of cable within the building is to be

ensured.

• The optical fiber cable should be properly clamped to the FDP.

• Optical fiber cable should be properly tagged for identification and

every fiber to be identified when spliced to the pigtails and
terminated on the frame.

145
 Termination
• End to end testing can be carried out from the FDP to FDP

• Fibers shall be neatly arranged in a fiber tray.

• Cable shall be brought into the building/container/shelter or cabinets

housing the FDP through duct/GI pipe.

• OFC entry into FDP shall be done through holes provided for this
purpose as per instruction of FDP supplier.

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Schematic of Earthing
Earthing (Typical)

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Earthing Assembly (Typical)

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Earthing Assembly (Typical)

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 Link Testing

• Once splicing and termination is completed, take OTDR traces from

both terminal stations (AB & BA) of the link for 1550nm
&1310nm to check the length, losses and continuity.
• Prepare event table, workout event averages and average splice
losses of the link
• Measure actual losses using LSPM.
• Check for the fiber mismatch using LSPM
• Highlight the high losses, and rectify them within specified SLA.

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 Link Budgeting
• Power loss in link dB/Km for 1550 nm, the average power loss of the
link = No. of connector X 0.5+No of splices X 0.1+distance in Km X
IOR of the cable=losses in dB/Km
• Power loss in link dB/Km for 1310nm the average power loss of the
link = No of connector * 0.5+No of splices * 0.1+distance in Km X
IOR of the cable =losses in dB/Km.
Note: The above 0.22 dB/km for 1550nm and 0.35 dB/km for 1310nm depends
on cable specs. It may vary.

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