ACS-WI-812-02

Installation Instructions
AFL All Dielectric Self-Supporting Optical Cable (ADSS)

NOTE: EXCEPT AS MAY BE OTHERWISE PROVIDED BY CONTRACT,

THESE DRAWINGS AND/OR SPECIFICATIONS ARE THE PROPERTY
OF AFL TELECOMMUNICATIONS, ARE ISSUED IN STRICT
CONFIDENCE, AND SHALL NOT BE REPRODUCED OR COPIED OR
USED AS THE BASIS FOR MANUFACTURE OR SALE OF PRODUCT
WITHOUT PERMISSION.

CERTAIN INFORMATION SUCH AS THE DATA, OPINIONS OR

RECOMMENDATIONS SET FORTH HEREIN OR GIVEN BY AFL
REPRESENTATIVES, IS INTENDED AS A GENERAL GUIDE ONLY.
EACH INSTALLATION OF OVERHEAD ELECTRICAL CONDUCTOR,
UNDERGROUND ELECTRICAL CONDUCTOR, AND/OR CONDUCTOR
ACCESSORIES INVOLVES SPECIAL CONDITIONS CREATING
PROBLEMS THAT REQUIRE INDIVIDUAL SOLUTIONS AND,
THEREFORE, THE RECIPIENT OF THIS INFORMATION HAS THE SOLE
RESPONSIBILITY IN CONNECTION WITH THE USE OF THE
INFORMATION. AFL DOES NOT ASSUME ANY LIABILITY IN
CONNECTION WITH SUCH INFORMATION.

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AFL ALL DIELECTRIC SELF-SUPPORTING CABLE (ADSS)

INSTALLATION INSTRUCTIONS

Contents Section

General Information 1.0

Safety Issues 2.0
Cable Precautions 3.0
Installation Equipment 4.0
Installation Methods 5.0
Installation Considerations 6.0
Sagging and Tensioning 7.0
Cable Support Hardware 8.0
Route Identification 9.0
Records 10.0

1.0 GENERAL INFORMATION

This practice provides general information for design engineers and construction forces
on the methods for placement of all dielectric, self-supporting (ADSS), fiber optic cable.
These methods and instructions are intended as guidelines only, as each installation will
be influenced by local conditions, customers’ existing procedures and requirements.

Information such as minimum separation and clearance, sag tables, and specific cable
data are found in other documents provided by AFL. This information is generally
provided to customers based on specific applications of ADSS fiber optic cable, and can
be obtained by contacting AFL.

Installation equipment or methods not mentioned in this practice are not approved for use
with ADSS and its use without specific approval by AFL shall be at the risk of the
customer. Please contact your AFL representative with questions about any specific
method or for specific equipment recommendations.

Methods used for placement of aerial, all dielectric, self-supporting, ADSS fiber optic
cable are essentially the same as those used for placing power utility phase conductors.
Refer to ANSI/IEEE Std. 524-1980, IEEE Guide to the Installation of Overhead
Transmission Line Conductors for additional detail on installation techniques.

2.0 SAFETY ISSUES

Crew safety is of the utmost importance when placing any fiber optic cable. When in
question, follow the precautions and safety requirements of the respective company, and
take no unnecessary risks.

When placing ADSS, all precautions and safety requirements of the respective company
shall be followed. When required, use of warning signs and traffic warning cones shall
clearly define the work area to safely channel the traffic. On streets or highways, always
place the cable in the same direction as the traffic flow and use flagmen to control traffic.

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All crew members should have the appropriate tools and personal protective equipment to
properly perform the job. Installation of the cable without the proper equipment may place
personnel and the cable at risk.

When placing ADSS on active structures, or structures involving power crossings, observe
the safety precautions outlined in your company’s applicable procedures. When pulling
up and tensioning self-supporting cable, observe the same precautions used when pulling
up and tensioning metallic phase conductors or any other aerial cables. When aerial lift
equipment is used for placing self-supporting cable, all precautions outlined for placing
phase conductors, as well as the instructions covering the equipment must be observed.

Although ADSS is an all-dielectric cable, some conductivity can result from moisture on
the cable and in the surrounding air. As a precaution in high voltage environments, it is
recommended that the installed cable and metallic attachment hardware are grounded
prior to touching. For cables installed in other situations, the National Electric Safety
Code (NESC) should be consulted for recommendations. The cable can be classified as
either a “fiber optic-supply” or “fiber optic-communications” cable, and meets the
requirements for an effectively grounded neutral as defined in NESC rule 230E1. The
precautions in the following paragraphs must be observed to assure safety during and
after the cable installation.

Leakage current can be induced onto ADSS and attachment hardware even when the
cable is a relatively long distance from the phase conductors. AFL Telecommunications
can calculate the leakage current based upon the cable position relative to the phase
conductors and to the ground, the transmission voltage and the surface resistivity of the
cable jacket. The cable surface resistivity is dependent on the moisture and contaminants
on the cable. A clean, dry cable has a surface resistance of 1014 /ft and a dirty, wet
cable has a surface resistance of 10 6 /ft, therefore, DO NOT INSTALL CABLES ON
ACTIVE TOWERS DURING WET ENVIRONMENTAL CONDITIONS.

When the cable is too close to the phase conductors, scintillation can occur through the
air from phase conductors to the cable. This scintillation from a phase conductor to ADSS
cable can occur only when the resistance of the cable sheath to the grounding location is
low enough to lower the induced voltage. In the worse case condition, the cable
resistance is zero, at which time it will be similar to a grounded metal rod. A grounded rod
configured in air has a flashover voltage of 15kV/in. for large gaps. Hence, the safe
approach distance to keep the phase conductors away from the ADSS cable can be
calculated by:

SD = E/15

where, SD = distance (inches), and E is the phase-to-ground voltage (kV). Note: The
work rules of the NESC Section 43 and 44 should be used to determine safe
approach to live systems.

Specific safe approach distance to active phase conductors are defined in the National
Electrical Safety Code (NESC) Work Rules sections. The safe approach distance is
different for electrical personnel and telecommunications personnel. The values listed in
this section should be the minimum safe approach distances to active phase conductors.

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When splicing ADSS cable during wet/rainy conditions near active high voltage phase
conductors, it is advised to ground the cable between the work area and the spans (such
as at the attachment hardware). This will prevent dangerous leakage currents and
transients from flowing through personnel. In dry weather there is little induced charge on
the cable; however as a personnel safety practice, the cable should be grounded between
the work area and the spans.

During Routine Maintenance:

a. Dry Weather Conditions. When the cable is suspended by insulators or on

wooden poles, a voltage potential maybe induced in the metal suspension grips and
support hardware. To avoid dangerous electrical shock, GROUND THE METAL GRIPS
BEFORE TOUCHING. The cable can be touched anywhere when it is dry, because there
is little charge induced on the small area that is touched.

b. Wet Weather Conditions. When the cable is wet, the resistance to ground is low
near the tower or grounded structure, so there is little voltage potential on the metal grips
or cable at these points. However, at distances of 10 to 15 feet or further from the metal
grips, a voltage potential may exist. To avoid dangerous electrical hazards, GROUND
THE CABLE WITHIN 3 TO 5 FEET ON BOTH SIDES OF THE AREA TO BE TOUCHED.

Adequate electrical protection must be established at all work sites. The method required,
and the equipment used, will be determined by the degree of exposure to electrical
hazards and the soil conditions at the site. All metallic equipment, hardware, anchors and
structures within such work sites must be common bonded together, and then grounded
to assure worker safety.

3.0 CABLE-RELATED PRECAUTIONS

Upon receipt of the cable reels, remove all reel lagging and packing material from the reel
and inspect the lagging, reel, and outer coils of cable carefully for any shipping damage.
Check the inside edges of the reel for any sharp edges of the reel for any sharp edges or
obstructions that may have occurred during shipment and could potentially damage the
cable sheath, or interfere with turning the reel and the cable deployment.

Prior to starting construction, use an optical time domain reflectometer (OTDR) to verify
that the cable has not been damaged during shipment. Readings obtained may be useful
later for comparison with test acceptance data and as part of a records package that will
assist in emergency restoration.

ADSS fiber optic cable is very strong and robust. However, care must be taken to assure
the cable is not mishandled or installed improperly causing subsequent damage. Ensure
that the cable is not kinked or that the minimum bend radius (typically 20 times the cable
diameter plus 2 inches for dynamic (installation) conditions, and 10 times the cable
diameter for static situations, (such as cable stored in a vault) is not exceeded. Take all
precautions that the cable is never crushed or twisted. Any such damage will alter the
transmission characteristics of the fiber and may require replacement of that cable
section.

Prior to starting construction, survey the proposed cable route to assure that the right-of
way is clear of obstructions that may interfere with the installation. During installation, be

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sure that the cable jacket is not damaged due to abrasion. Do not drag the cable over
obstructions in the span or on the ground. It is recommended that if obstructions are
observed, they should be removed, or a series of hold-down blocks be used to prevent
contact with the obstruction. Before installing the cable, be sure all installation personnel
understand the cable parameters such as handling requirements, cable bending limits,
and maximum pull tensions.

Do not over-tension the cable. Sag and tension charts are available for all AFL-ADSS
fiber optic cables. These charts list the Maximum Rated Cable Load (MRCL) under the
appropriate weather loading situation. If the cable is over-tensioned beyond the MRCL,
fiber damage may occur that will alter the transmission characteristics of the fiber and/or
require replacement of the cable.

When placing ADSS, all precautions and safety requirements of the respective company
shall be followed. When required, use of warning signs and traffic-warning cones shall
clearly define the work area to safely channel the traffic. On streets or highways, always
place the cable in the same direction as the traffic flow and use flagmen to control traffic.

Do not allow the cable to twist as it is pulled through travelers or sheaves. If continuous
twist in a constant direction is observed, stop the installation immediately, ease off the
tension, and readjust to traveler. Due to the light weight of ADSS in relation to most
sheaves, and the relative low stringing tensions used during installations, the traveler will
require support at the base to help prevent the cable from riding out of the groove of the
traveler or excessive twisting during installation. Proper feed of the cable through
travelers or sheaves as showed Figure 1.

Pole
Structure Pole
Structure

Support Rope
ADSS Cable

ADSS Cable

Properly Adjusted Pulley Improperly Adjusted Pulley

(Note twist present as cable leaves pulley)

Figure 1 Proper Pulley Adjustment

Twist should be monitored using either a cloth “tail” wrapped around the cable, by spray
painting a broad and visible stripe on the cable, or by watching the cable markings. A
cable with a cloth “tail” is shown in Figure 2.

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ADSS Cable Pulling Grip Pull Rope

Flag
Figure 2 Flag to Monitor Cable Twist

Control the rotation of the payoff reel to prevent over running. Apply only a minimal
amount of braking. Braking should be applied to the reel through the support shaft, and
not by methods such as wedging a 2 x 4 under the reel flange. As the reel empties, the
tension will have to be periodically adjusted. More information about tensioners and
pullers is included in section 4.02 of this document.

Do not sag/tension the cable around heavy angles. Tensioning the cable around heavy
angles will cause a large crushing force to be placed on the cable at the angle sheave.
This crushing force can damage the fibers. Always sag/tension the cable from dead end
segment to dead end trying to avoid sagging or tensioning around angles greater than 30
degrees.

DO NOT CUT THE CABLE under any circumstances without prior approval of the
engineer responsible for the transmission of the project. Changes to the total number of
splice points can potentially degrade quality of transmission of the system. The number
and location of splices are usually determined in the initial system design.

Do not allow vehicles to pass over the cable. At road crossings, the cable should be
suspended above roads, driveways, etc. during installation. Placing travelers or sheaves
on a temporary slack span of rope, or steel strand, is a way to suspend the cable above
such road crossings.

When placing ADSS on active structures, or structures involving power crossings, observe
the safety precautions outlined in your company’s applicable procedures. When pulling
up and tensioning self-supporting cable, observe the same precautions used when pulling
up and tensioning metallic phase conductors or any other aerial cables. When aerial lift
equipment is used for placing self-supporting cable, all precautions outlined for placing
phase conductors, as well as the instructions covering the equipment must be observed.

Choosing Cable Location:

a. It is recommended that on medium to high voltage applications AFL

Telecommunications suggest the desired mounting location of ADSS in relation to the
phase conductors at the structure. AFL Telecommunications has developed a computer
program to determine the optimum position for ADSS cable. The program investigates
the physical relationship of the structure and the electrical phenomena of the phase
conductors and provides a profile with plotted equi-potential contours, as shown in Figure
3. When placing ADSS cable on systems greater than 115 kV, it is critical that an
electrical stress analysis be performed to determine the proper cable placement position.
When performing the analysis, AFL will provide a recommendation for cable placement on
the structure, and an evaluation as to whether corona control is necessary. For the
electrical stress analysis, it is recommended that all structure types for the route in

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question (dead end and suspension) be analyzed. For systems lower than 115 kV,
contact AFL to determine the need for an electrical stress analysis.

V
10 k

25 k
V

20
kV

12
kV

Figure 3. Equi-potential Contours Surrounding Power Lines

b. Careful selection of the attachment position of the ADSS cable prevents

dangerous scintillation. Scintillation is a surface arc that may pose a cable and personnel
hazard. These scintillations occur mainly at the attachment points of the cable; therefore,
minimum clearance between the cable and phase conductors should be determined at
this point. The separation and clearance requirements on distribution poles for ADSS
cable is found in the National Electric Safety Code, section 230.

c. The recommended position must be such that there will be no contact between the
ADSS cable and the phase conductors or static wires, either at the pole or mid-span,
during installation or under maximum environmental load conditions. If during a rare case
of galloping conductors, contact should occur, there may be a potential for scintillation.
However, the potential for subsequent cable damage is minimal.

Permanent or temporary guys must be used when needed at any location where self-
supporting cable is tensioned to avoid placing any unbalanced load on those support
structures.

Wire mesh grips are intended only for pulling the cable through the system. DO NOT
USE WIRE MESH GRIPS TO TENSION OR TO HOLD CABLE UNDER TENSION.
These grips are not designed to support ADSS cable sagging tensions and are only
designed to pull the cable through the system. USE ONLY APPROVED GRIPPING AND
PULLING DEVICES WHEN TENSIONING, OR TEMPORARILY HOLDING FULLY
TENSIONED SELF-SUPPORTING CABLE. Please see section 4.0 for more information
about tensioning grips.

4.0 INSTALLATION EQUIPMENT

ADSS fiber optic cable is normally supplied on non-returnable wooden reels. The cable is
covered with protective covering and the cable reels are lagged with wooden lagging to
provide additional protection during transportation. Contact your AFL representative for
the reel dimensions and weights for the cable to be installed. Also, if the cable is not to be
installed for a period of over four months from the delivery date, it is recommended that
the cable be provided on a steel reel. Please contact AFL for more details or to request
shipment on steel reels.

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a. Reel Handling. The type and construction of the reel stand determines the
method and tools for handling. Reels are constructed so that they must be supported
either on an axle, supported from above, or by the reel flange. When the reels are lifted
by an axle supported from above, a spreader bar must be employed to maintain smooth
payoff and to prevent damage to the cable or reel, or both, by inward pressure on the reel
flange. Proper equipment rated for the maximum load must be available to lift the reel. If
the reel stand is not self-loading, a crane, forklift or other suitable equipment should be
used to load the cable reel into the stand.

b. Reel Stands. Reel stands are designed to be used with tensioners to supply the
necessary hold-back tension to the cable. The stand(s) should be selected to
accommodate the cable reel dimensions and gross weight. AFL standard reels are not
designed to withstand the forces developed by braking during high tension stringing
operations. Direct tension stringing from the reel at cable installation stringing tensions
should not be attempted. The cable maybe pulled directly from the reel stand only when
employing slack stringing methods that allow minimal tension to be applied directly to the
reel of cable.

c. Pulling Machines. Both bull wheel and reel type pulling machines may be used
to install ADSS fiber optic cable. Availability and previous experience with a particular
type of pulling machine should be a factor when determining the type of pulling machine
to be utilized.

d. Bull wheel Characteristics. The depth and flare of grooves in the bull wheels are
not critical; however, there are some recommended guidelines. Semicircular grooves with
depths of 50% or more than the cable diameter, and with a flare angle of 50 to 150 from the
vertical center line reference, generally have been found to be satisfactory. The minimum
diameter of the bull wheel (measuring at the bottom of the groove) should be at least 70
times the diameter of the cable. Tandem bull wheels should be aligned with the offset
approximately one-half the groove spacing. The material and finish of the grooves should
not mar the surface of the cable. Elastomer lined grooves are recommended. At least
three wraps of cable around the bull wheel are recommended to minimize slippage.

e. Puller and Tensioner Operating Characteristics. The pulling and braking

system should be operated smoothly to prevent any sudden jerking or bouncing of the
cable during deployment. Each system should be readily controllable and capable of
maintaining a constant and even tension and pulling velocity. Pullers and tensioners
should be equipped with tension indicating and limiting devices. Selection of the puller
and tensioner shall be dependent on the stringing tension and the actual cable weight and
length to be installed. Tensioner bull wheels should be retarded so that the cable
maintains a constant hold-back tension at various pulling speeds. Positive braking
systems are required for pullers and tensioners to maintain cable tension when pulling is
stopped. Fail safe type braking systems are recommended.

f. Travelers/Sheaves

Note: The terms traveler, sheave, pulley, and block are used interchangeably in
this document to reflect different industry terms for the same piece of installation
hardware.

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g. Sheave Diameter. The diameter of the sheave should not be less than 12 inches
at mid-span suspension points, See Figure 4. Where the cable line makes either a
vertical or horizontal angle of 250 or greater, and at the first position after the pay-off reel
and the final position before the take-up reel (these are generally the parameters for dead
end structures), the minimum diameter of the sheave should not be less than 20 inches,
or 40 times the cable diameter, whichever is larger. Sheave diameters that are larger
than those specified are acceptable, and offer some advantages by reducing the radial
(crushing) load applied to the cable.

Figure 4. Sheave Diameter

h. Sheave Groove Configuration. The minimum radius of the sheave groove (Rg)
is recommended to be 55% of the diameter of the cable. The minimum depth of the
groove should be 25% greater than the diameter of the cable. The sides of the groove
should flare between 150 to 200 from the vertical, to facilitate passage of grips, swivels,
etc. and to contain the cable within the groove, see Figure 5.

Figure 5 Sheave Groove

i. Traveler Construction and Material. Travelers may be made of any suitable

material, such as heat treated aluminum, with consideration for the weight. It is
recommended that the safe working load and a suitable margin be matched with the
maximum installation load of the fiber cable. The traveler should be in good working order
and properly lubricated. The cable release should work smoothly with minimal pressure.
It is recommended that the traveler be lined with an elastomeric liner that will provide

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cushioning and minimize any abrasion to the cable jacket. Linings of neoprene or
urethane are acceptable. The liner should not be torn or loose.

j. Traveler Grounds. Grounding attachments are recommended when stringing

fiber optic cable under active phase conductors. As a minimum, the first and last traveler
of a pull should be equipped with a traveler ground attached to the structure grounding
system.

k. Uplift and Hold Down Blocks. At positions where uplift may occur, it is
recommended that uplift rollers or hold down blocks be used. This will minimize any
potential for scintillation during installation on active systems and protect the cable jacket
from abrasion on non-active systems. A series of travelers 12 inches to 14 inches in
diameter will maintain minimum bend radius. These devices should have a cable
breakaway feature to easily remove the blocks.

l. Running Grounds. When installing ADSS fiber optic cable under active power
systems a running ground should be used to protect personnel from electrical hazards.
The running ground shall provide constant contact with the moving cable without
excessive tension. It should be located prior to first support structure. The spring tension
on the running ground should be adjustable, and the rollers should be sized for the
diameter of cable.

m. Chain Hoist or similar tools. Chain hoists are used to tension and sag each
dead end cable span. The hoist should be rated for the maximum installation load of the
ADSS cable, plus a desired safety factor. The hoist shall be in good working order and
properly maintained. Assure the chain is not deformed, twisted, or corroded. Inspect
release levers and cam action for proper operation. Any suspect unit should not be used.
See Figure 6 for a diagram of a typical chain hoist.

Figure 6 Chain Hoist

n. Dynamometers. Dynamometers are used to measure the tension at each

deadend-deadend segment. The dynamometer should be rated above the maximum
installation load of the ADSS cable. Typically, the accuracy of the dynamometer is 0.5%
of the full scale rating. If the full scale rating is too high above the installation load the
degree of accuracy is questionable. To assure a high degree of accuracy, two
comparable dynamometers can be attached in tandem, and the two readings averaged.
Dynamometers should be used in conjunction with sight sagging to ensure proper
tensioning of the cable.

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Figure 7 Dynamometer

o. Pulling (only) Grips. Wire mesh grips are utilized to pull the fiber optic cable
through the travelers. The grip should be a double or triple weave design and be rated to
match the cable diameter. The load rating shall match the maximum anticipated load on
the cable during cable pull-in. This is typically well under the sagging tension, but is
dependent on cable design. The grip should have a swivel link that will minimize cable
twisting that may be induced by the pull rope, See Figure 8. Grips should be applied per
the manufacturers instructions. DO NOT USE THE WIRE MESH GRIP TO TENSION OR
TO HOLD CABLE UNDER TENSION, ONLY FOR PULLING.

Figure 8 Wire Mesh Pulling Grip and Swivel

p. Tensioning Grips. A separate tensioning grip must be used to temporarily grip

the cable during the sagging and tensioning process. This grip can either be a formed
wire deadend specified for the cable, or AFL’s “Temporary Tensioning Grip (shown below
in Figure 9). If formed wire grips are used, follow the re-use instructions in the package.
Typically, formed wire grips may be re-used no more than three times.

Figure 9 AFL Temporary Tensioning Grip

Formed Wire Installation Tools (FIT). The use of a Formed Wire Installation Tool is highly
recommended to reduce the probability of installation damage to the cable that may occur
when installing formed wire installation hardware. NOTE: THE USE OF
SCREWDRIVERS IS PROHIBITED FOR THE INSTALLATION OF FORMED WIRE
DEADENDS OR SUSPENSIONS DUE TO THE POTENTIAL FOR CABLE JACKET
DAMAGE.

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T
FI
L
AF
Figure 10 AFL Formed Wire Installation Tool (FIT)

5.0 INSTALLATION METHODS

Methods used for placement of aerial, All-Dielectric, Self-Supporting, ADSS fiber optic
cable are essentially the same as those utilized to place power utility phase conductors or
other aerial cables. However, there are handling and bend radius requirements that are
more restrictive for ADSS fiber optic cable. The two basic methods for the placement of
ADSS fiber optic cable are; the stationary reel, sometimes called the “Back-pull Method”,
and the moving reel, sometime called the “Drive-off Method”. The drive-off method is
acceptable but is generally used only when the cable is the lowest on the structure.

Drive-off Method. As stated in previous paragraphs, this method is not utilized very
frequently. Its primary application is in construction of new lines with clear right-of-way
and no obstacles. A brief schematic of the method is shown in Figure 11.

Figure 11 The Drive-Off (Moving Reel) Installation Method

a. Place cable reel in a reel trailer or line truck equipped with reel carrier, supported
by the arbor holes. The cable should pay off the top of reel from the back for reel trailers
and off the bottom of the reel to the front quadrant for the line trucks. A braking device,
set on minimum, is utilized to slow the reel rotation by friction on the arbor shaft. This is
used to prevent overrun of the reel when stopping at the support structures.

b. Holes are drilled and machine bolts, or comparable hardware, are placed on the
structures at the appropriate mounting height. At dead-end and tensioning locations,
down-guys of an appropriate loading factor are placed.

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c. Travelers are placed above or below the desired framing location of each support
structure and the cable is dead-ended at the starting location.

d. With minimal tension applied to the reel brake, the reel of cable is transported
along the construction route and the cable is played out. As the reel empties, the back
tension will have to be periodically adjusted to account for the difference in reel mass.

e. As the moving reel passes a support structure, the pulling is stopped and the cable
is placed into the traveler attached to the structure at the desired framing height.

f. The reel proceeds on to the next support structure where the process is continued
until the cable is completely deployed.

g. With the cable deployed, starting at an end location, each dead end segment can
be sagged and tensioned and support hardware applied according to the installation
requirements. An alternative procedure is to sag and tension each span and install
permanent hardware as the cable is being deployed.

Back-pull Method. This method of cable installation is most frequently used for ADSS
fiber optic cable. Its primary application is for long spans on EHV power facilities. It also
is most effective for application on distribution facilities, where there are many obstacles,
such as lateral branches or taps. This method is very economical in urban areas and
offers the fastest deployment of cable. A brief method of the “Back Pull” or “Stationary
Reel” method is shown in Figure 12:

Figure 12 The Back-Pull (Stationary Reel) Installation Method

a. The cable reel is placed on a reel stand or reel trailer, supported by the arbor
holes, at a stationary location. A braking device applies minimal tension to the reel to
prevent overrun.

b. At the same location as the cable reel, the bullwheel is placed in-line between the
cable reel and the first two structures. The ADSS cable is then fed through the bullwheel.

c. Holes are drilled and bolts or comparable hardware are mounted to the structure at
the appropriate mounting height. At dead-end and tensioning locations, down-guys are
placed at the desired framing location of each support structure.

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d. Travelers are placed just above or below the desired cable framing location of
each support structure.

e. Small pilot lines are run through the travelers at each support structure. The
pulling line is pulled from the pulling location back through each traveler using the small
pilot lines. After the pulling line is fed through the entire section to be pulled, it is attached
to the ADSS cable with a swivel link and a wire mesh grip as seen in Figure 4.

f. The ADSS cable is then pulled through the entire section with the puller and
tensioner. Care must be exercised to keep the cable under minimal load. Several pulling
stages may be required to place the cable through the entire system.

g. With the cable deployed, starting at an end location, each dead-end to dead-end
cable segment can be sagged and tensioned and support hardware applied according to
the installation requirements.

Communications. Proper communications during fiber cable deployment are critical to

assure safe and efficient installations.

a. The “Drive-off Method” requires minimal communication between different

personnel on the installation crew. It is recommended to have good communications
between the operator of the vehicle used to deploy the cable, and the individual at the
cable reel. If traffic control is necessary, the flagman shall also have communication with
the vehicle operator to assure safe traffic routing.

b. The “Back-pull Method” requires good communications between the operator of

the tensioner and the operator of the puller. In addition, intermediate check points such
as road crossing and obstacles, i.e. power conflicts, should have spotters to inform the
puller and tensioner of potential problems. The types of communication devices are
dependent on local availability. Maintenance radio, cellular telephone and dedicated talk
circuits over copper pair facilities with temporary station wire, are all viable alternatives.
Systems such as citizen band radio or power line carrier systems are not recommended.

6.0 INSTALLATION CONSIDERATIONS

Reel Preparation Prior to Beginning a Pull. AFL ships the cable reels with the inner tail
securely connected to the outside of the reel flange. This connection should be loosened,
but not removed, prior to stringing. This allows the inner layers of cable to adjust
themselves to the varying tensions seen during installation. As the cable makes these
adjustments, the inner tail may lengthen, or “grow,” requiring periodic attention to ensure
that the cable continues to be in a state where it can “grow” out.

Pull, Tension, Anchor, and Splicing Sites. The selection of pull, tension, anchor and
splicing sites must consider many factors from system design issues to logistics and
capability of equipment. In the “Back-pull Method”, the reel is stationary, thus the cable
for the system is pulled in several segments. These segment lengths are dependent on
allowable splices, accessibility of the sites for vehicles, capability of the installation
equipment, obstacles in the right-of-way, and cable reel length. Other factors that will
affect the site selection are the maximum load the cable can handle, maximum structure
load and availability of adequate grounding systems when necessary.

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Equipment Locations. The location of the tensioner and puller relative to the structure
must be selected so that the structure is not overloaded. Where possible, a pulling slope
of four or five horizontal (see figure 13) to one vertical is considered good practice. This
ratio will minimize the load on the cable, traveler, and structure. Refer to ANSW/IEEE 524
for calculations of structure loads. It may also be necessary to place temporary guys to
prevent overloading the structures. The tensioner and reel stand must be placed in-line
with the first two structures to prevent twisting of the cable or any abrasion to the cable by
rubbing on the sides of the traveler groove.

Note 4:1 horizontal to vertical

distance and first two
structures in line at both ends
of the pull.

Figure 13 Proper Puller and Tensioner Placement

Anchors and Hardware. Anchors and support structure hardware shall be rated above
the anticipated environmental load of the cable, plus a safety factor. The amount of the
safety factor is dependent on the utilities existing procedures. In applications where
aeolian vibration becomes an issue, the safety factor shall be increased due to the
potential for degradation of the hardware. At locations where the cable is tensioned to
achieve proper cable sag, the structure may require a temporary down-guy and anchor to
prevent unbalance of the structure. At these locations a minimum ratio of two horizontal
to one vertical for the slope of the guy is considered good practice. Anchor types shall
match the soil conditions and loading considerations. All down-guys shall be properly
tensioned or re-tensioned prior to starting the cable installation.

Crossing Structures. When crossing roads, highways, railroads, energized lines, etc.,
some supplemental support is necessary to prevent the minimum clearance from not
being met, and posing a safety hazard. One method is to erect “H” frame structures on
both sides of the crossing point. With these guard posts, the cable can be maintained
above the minimum height. In some cases rope nets can be strung between the two
structures to provide more positive protection. Another method is to string travelers on
temporary ropes or guys at the crossing point, that will maintain clearance if tension
should be lost. It is recommended that a spotter with communications to the puller and
tensioner be at the crossing location, while the cable is being pulled into place.

Terrain Considerations. The terrain of each pull section must be analyzed to assure
there are no potential conflict areas that would impair installation. In areas where ground
clearance or minimum clearance under power facilities becomes a concern, uplift or hold
down blocks may be required. Where ground clearance is a concern, a spotter with
communications to the puller and tensioner should be utilized to assure no abrasion to the
cable.

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Traveler Installation. Travelers are typically attached directly to the structure. On pole
structures, a standoff pole bracket may be considered to allow free movement of the
traveler. The socket eyes, used to support the traveler, shall be consistent with ultimate
working load and rating of the traveler. Shackles used on towers to support the traveler
shall be rated above the ultimate working load. When electrical hazards exist, observe
local practices for the placement of traveler grounds. As a minimum, traveler grounds
should be installed at the first and last tower between the tensioner and puller.

Grip Installation. The pulling grip, as described in the apparatus section, shall be rated
above the maximum pulling tension anticipated. Use the manufacturer’s instructions for
the proper application. When installed properly, no special preparation of the cable end,
or aramid yarns, are required. It may be recommended by the grip manufacturer to band
the end of the grip to prevent slippage. Apply vinyl tape over the banding to minimize
damage to the traveler coatings. A layer of friction tape can be used under the grip to
provide an additional level of protection.

A matched double-clevis type swivel is recommended to help prevent twisting of the cable
during pulling. The swivel should be matched to load rating of the grip. It is not
recommended to pull the swivel through bullwheels under any significant tension. When
removing the grip after the cable has been pulled in, cut off a minimum of fifteen (15) feet
past the end of the grip to assure no stressed cable is used.

Cable Pulling. Pulling rates of 2 to 5 miles per hour usually provide safe, smooth,
efficient passage of cable. Once the cable movement has started, it should be maintained
at a constant rate until the cable segment has been pulled into place. At all times during
the pull, the tensioner operator should monitor the tensionometer to assure that the
maximum pulling tension is not exceeded. The maximum tension during the pulling
operation should not exceed that which is necessary to clear obstacles. In general,
pulling tension should not exceed more than one-half the maximum initial sagging tension.
If greater tensions are required, consideration must be given to the fact that when long
lengths of cable are pulled, the tension at the pulling end may exceed the tension at the
tensioner by significant amounts. This difference is due to the length of cable to be
strung, changes in the line angle, number of travelers and differences in elevation of the
route and structures. Light and steady back tension is required at the cable pay-off reel to
prevent overrunning of the reel. It may be necessary to periodically loosen the brake on
the pay-off reel as it empties. As the reel empties, the moment arm available to overcome
the brake drag is reduced, and the tension rises.

Aeolian Vibration. Aeolian vibration is a resonant vibration caused by low velocity wind
blowing across a cylindrical conductor under tension, see Figure 14. Although the
vibration will not typically effect the optical or mechanical performance of the ADSS fiber
optic cable, it can cause severe degradation to the cable support hardware. Vibration
dampers can be very effective in controlling aeolian vibration when used on ADSS fiber
optic cable. Both resonant and interference type vibration control systems will work when
properly applied.

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Lift Component

Wind Direction

Drag Component

Figure 14. Aeolian Vibration Effect

AFL recommends that vibration dampers be utilized to protect attachment hardware when
the cable spans exceed 350 feet and/or the cable tension exceeds 15% of the calculated
cable breaking strength, and there is a prevailing laminar wind between 2 and 20 mph.
Please contact your AFL representative for specific vibration damper recommendations.

Splicing. At the locations where a splice is required, additional cable must be provided to
provide extra fiber and cable to physically accommodate the splicing process. In the
outdoor environment, AFL recommends that splicing be accomplished on the ground and
not in an aerial bucket. Consideration must be made to the type of splicing, mechanical or
fusion, and the respective environmental requirements of each. If fusion is the method, a
splice vehicle may be required and enough cable will be required to reach the vehicle. In
general, enough cable should be provided to reach the base of the structure and reach
the intended splicing site. DO NOT FORGET TO REMOVE 15 FEET OF CABLE FROM
THE GRIP TO REMOVE ANY STRESSED CABLE. AFL also recommends that the spare
cable at splice points be stored in an enclosure, either mounted to the pole or in an
underground housing, See Figure 15.

After the excess cable length is determined, coil the cable

and store at the structure until the splice housing has been
installed (be sure to maintain the minimum bend radius of
the cable). Be sure to place end caps on the exposed
cable ends or seal with vinyl tape to prevent water
penetration.

7.0 SAGGING AND TENSIONING

General. After the cable has been placed throughout the entire length of the system,
sagging and tensioning can now be started. Sagging and tensioning of a system is
worked progressively from one end of the system towards the opposite end. Typically, the
cable slack is worked back toward the payoff reel in order to recover as much cable as
possible.

Termination Point. Pull enough extra cable to assure that the termination location is
reached and enough fiber optic cable is spared to facilitate cable splicing. The spare fiber
required in the splice tray is dependent on type of fiber organizer and splicing method.
Typically, four to six feet of fiber is required to facilitate splicing. Assure that 15 feet of
cable is cut off at the wire mesh grip to assure no damaged fiber is used. Excess cable
may also be required to provide sufficient cable to splice it on the ground.

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Termination Structure. At the last structure establish a dead-end assembly. Assure that
the bend radius requirements are maintained where the cable is run down the structure. If
the ADSS fiber cable is run down the structure, it is recommended that cable riser guards
are used to protect the cable as it makes the transition of aerial cable to the building
entrance conduit.

Remove all excess cable slack out of the span; or if in the case of several in-line
structures, series of spans. This is not pre-stressing or even tensioning. This removal of
excess cable slack is necessary to properly position the temporary dead-end pulling grip.
To remove the slack, reverse the tensioner and pull the cable back toward the reel, being
careful not to exceed the pulling criteria of one-half the maximum installation tension. Do
not attempt to tension the cable using the tensioner and the cable on the reel; this
may exert an excess crushing force on the cable. The actual tensioning process is
described in the next step.

With the cable slack removed, apply a temporary dead-end assembly 1.5 to 2 dead-end
assembly lengths (approximately six to ten feet) from the structure. In many cases, the
AFL Temporary Tensioning Grip (Please see figure 8) can be used and will save time and
money in comparison with the use of standard formed wire dead ends. This will be
utilized as a tensioning grip to achieve the proper span sag and tension, prior to installing
the permanent dead-end assembly. Attach the tensioning rig, comprised of a sufficiently
rated chain hoist, dynamometer and bull chain, to the structure and the temporary dead-
end. Take up the load and begin to tension the span per the provided sag and tension
charts. Please note the pictures of these pieces of equipment in the “Installation
Equipment” section of this document.

Typically, the cable is worked dead-end to dead-end segment back to the payoff reel and
trying to avoid angles greater than 30 degrees. After the spans are at proper sag and the
dead-ends attached, the suspension or tangent hardware is installed and attached to the
structures by working back to the dead-end, a span at a time.

Once the permanent dead-end is installed, and the hardware is attached to the structure,
the tension can be released on the tensioning rig or chain hoist and the temporary dead-
end removed. As the next permanent dead-end is installed on the adjacent span, make
sure that the expansion loop under the dead-ends is properly formed, maintaining
minimum bend radius. This means the cable is typically 14 inches lower than the cable
framing location. This process is repeated until all spans are sagged and tensioned for
the complete system.

8.0 CABLE SUPPORT HARDWARE

Hardware Types. The hardware used to support the cable at the structure is similar in
appearance and application to the type used for power utility metal conductors. AFL can
provide specific recommendations and procure the hardware for customers. In general,
there are three are three basic types of supports; dead-ends, suspension and tangent
assemblies. NOTE: PLEASE SEE THE LATEST VERSION OF AFL APPLICATION
NOTE 100, “CABLE SUPPORT HARDWARE DESCRIPTION AND ASSEMBLY
INSTRUCTIONS” FOR HARDWARE ASSEMBLY PROCEDURES.

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Dead-end Assemblies. Dead-ends are used at points of cable termination, on structures

where the line angle is greater than 300 (or 220 when used with the AFL Trunion clamp), or
across road, river or railroad crossings. There are two basic types of dead-end
assemblies: formed wire dead-end assemblies, and AFL’s Mechanical Dead-End
assembly.

a. Formed Wire Dead-End Assembly. The basic elements that are included in a
AFL-supplied formed wire dead-end assembly, refer to Figure 16., are the Structural
Reinforcement Layer (SRL), the dead-end grip, the thimble clevis an extension link.
Formed wire dead end assemblies should be applied no more than two (2) times
due to the fact that the grit and glue used to provide friction will degrade with
multiple uses, and the dead end loses its holding power.

Figure 15. Formed Wire Dead-End Assembly

Structural Reinforcement Layer (SRL) -The SRL is a formed wire subset of armor rods
that are the first layer applied to the ADSS cable. They are spiraled in a precise twist
lay to address the diameter and maximum anticipated load of a specific cable.
Typically, they are grouped together in a sub-set of 3 or 4 individual rods, with grit
applied to the inside for better slip resistance.

Dead-end Grip -The dead-end grip is a set of armor rods that have been formed with a
loop in the center. It, too, has a precise twist lay that matches the diameter of the SRL
and cable. Its length is dependent on the maximum anticipated load. It has grit
applied to the inside and also has a color band 18 inches from the loop.

Thimble Clevis -The thimble clevis, sometimes called the clevis shackle, is a cast
aluminum or steel piece of hardware used to maintain the seat diameter of the dead-
end loop and attach the dead-end loop to the extension link, and ultimately the
structure.

b. Mechanical Dead End. The AFL Mechanical Dead End (Figure 17) is an
assembly designed specifically for use with AFL’s ADSS fiber optic cables only. This non-
formed-wire dead end dramatically increases the speed of installation by using fitted
wedges to grip the cable instead of formed wire. Dead end assembly time for the
mechanical dead end is approximately 1/3 the time compared to formed wire assemblies.

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Figure 16. AFL Mechanical Dead End Assembly

Mechanical Dead End Parts

Main Dead End Body - The main dead end body is designed to enclose the wedges
which grip the cable.

Wedges - Tapered wedges are sized specifically to match the cable diameter. These
wedges slide into the body of the dead end.

Bail - The bail is designed to ensure the proper bending radius, eliminating the need
for an extension link. The bail is most often draped around a common guying
attachment, also known as a “Ram’s Head” or a “Goat’s Head”.

AGS Suspension Assembly. Suspension assemblies are used where the line angle is
from 00 to 300, and most often on longer spans (See span limits in next page) where
tangent clamps cannot be used. Typical suspensions have rated slip strengths of
approximately 1500-2000 lbs. The suspension assembly is typically attached to an eye
nut on a pole using a Y-clevis eye (90).

The basic elements that are included in the suspension assembly, refer to Figure 18, are
the Structural Reinforcement Layer (SRL), the AGS rods, the neoprene insert, the
housing, strap, and nuts/bolts.

Y-Clevis Eye
(90, optional)
ADSS Cable Outer
Support
Rods

Structural
Reinforcing Suspension
Rods Clamp Assembly

Figure 17. Suspension Assembly

AGS Parts

Structural Reinforcement Layer (SRL). The SRL for the suspension assembly is very
similar in function as the SRL for the dead-end. However, the color band is at the
center of the rods.

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Armor Grip Suspension (AGS) Rods. The AGS rods are individual rods that are
typically larger in diameter than the SRL rods. They too have a color code band at the
center of each rod.

Insert, Housing, Strap and Nuts/Bolts. The neoprene insert cushions the load transfer
from the SRL to the AGS rods. The housing is a cast steel clamp that acts as the
main support element with the strap, nuts and bolts completing the assembly.

Tangent Support Assemblies. Tangent support

assemblies come in several varieties, some as dielectric
blocks and others as metal housing with an insert that
pad and protect the cable. The AFL “trunion” clamp is
shown in the figure to the right, and is used in
applications where the line angle is from 00 to 220. The
following chart:

NESC
Dia Heavy Medium Light
<0.875” 600’ 850’ 1200’
>0.875” 500’ 750’ 950’
Figure 18
AFL Trunion Clamp

Vibration Dampers. Vibration dampers are recommended in various quantities for span
lengths greater than 350 feet. Please contact your AFL representative for specific
vibration damper recommendations. A spiral vibration damper, the most often used
damper type for low voltage applications, is shown below in Figure 21.

Damping Gripping
Section Section

Note: Smaller Helix

Figure 19 Spiral Vibration Damper

Downlead or Guide Clamps. These clamps are used to secure the cable to the pole.
Typically, one clamp is used every 8-10 feet down the length of the pole. Pictures of
clamps for wooden poles and for lattice steel poles are shown below in Figures 22 and 23.

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ADSS
Cable
Wooden
Pole

Figure 20 Cable Clamp for Wooden Poles

For applications on lattice steel towers, an adaptor is used to attach the cable to the lattice
steel angle as shown below in Figure 23.

ADSS Cable

Tower Guide
Clamp

Lattice Steel
Angle

Figure 21 Cable Clamp for Lattice Steel Towers

9.0 ROUTE IDENTIFICATION

General. Identification of the fiber optic cable and the cable route with warning signs,
helps prevent inadvertent cable damage caused by company personnel or the general
public. This is most important on joint-use distribution pole lines where more than one
company may have facilities on the structure. The proper warning signs should use
industry accepted wording and visual indicators stating warnings.

Fiber Optic Cable Warning Signs. At each structure the cable should be tagged with a
cable warning sign. These signs can be a snap around plastic tag in high visibility orange,
stating “WARNING-FIBER OPTIC CABLE” or similar wording. The tags are typically
applied to the expansion loop under the double dead-ends. Other type of cable warning
signs are small plastic or painted metal signs with the same type of wording, but are
affixed to the structure at the cable framing locations.

Fiber Optic Cable Route Warning Signs. At locations where the cable may go
underground or change to a different structure type, it is recommended to identify the
cable route direction with a fiber optic cable route warning sign. This helps to identify the
route during an emergency restoration and during preventative maintenance programs,
when the cable route is periodically inspected. Again, the use of industry accepted
wording and colors are recommended.

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10.0 RECORDS

General. Records are an integral part of the equipment required to maintain and restore
a fiber optic system. During an outage condition, having a records package readily
available eliminates unnecessary delays locating and accumulating information required
for the restoration process.

Coordination. Due to the number of departments involved in the design, construction,

turn-up, and maintenance of fiber optic systems, records can be lost or misplaced after
the initial installation of the fiber optic system. This can be a catastrophe during a system
outage, because this information is necessary for comparison against trouble-shooting
information.

Documentation. AFL Telecommunications recommends that for each fiber optic system
the following information be included in a records documentation package.

a. Key Map. The key map is a geographical map showing the system route in
relation to roads and highways. Its purpose is to provide general bearings to quickly
access key areas of the system, such as field splice points and major road crossings.
Sheath meter marks should be indicated on the map for splice points, road crossings,
river crossings, etc.

b. Composite Schematic. The composite schematic is a straight line schematic

identifying the construction sequence of cable reels by reel number, meter markings to
major construction points such as splice points, and major road crossings. The cable reel
section length and a cumulative cable length should be marked at each of these points.
Also, the cable and fiber type and count shall be identified for each reel section.

c. As-Built Construction Sheets. The construction sheets identify the actual

apparatus units at each structure. Other information such as the structure type and
dimensions, cumulative distance to each termination point from the structure, any
grounding or bonding detail, etc. These sheets are typically the construction detail sheets
that have been corrected to reflect any changes during construction.

d. Circuit Diagram. The circuit diagram is a schematic that identifies the actual fiber
circuits, system number, working and protect fibers, fiber/buffer colors, priority sequence
during restoration and other pertinent information such as transposed fibers.

e. Test Acceptance Sheets. The test acceptance sheets are the recorded values of
the transmitter output power, receiver input power, and measured attenuation levels at the
receiver. Other information to be included in the test acceptance package are the Optical
Time Domain Reflectometer (OTDR) plots or photographs of each fiber and its terminated
pigtail, shot in both directions at both 1300nm and 1550nm. Other recommended
documentation include the bi-directional average of the loss of each splice, including
pigtail splices with connector insertion loss.

f. Manufacturer Provided Documentation. The manufacturer provided

documentation would include, cable data sheets of each cable reel, documentation

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provided on the fiber, equipotential plots of the field strength levels relative to different
structure types, and sag and tension charts provided for construction.

g. Emergency Restoration Plans An emergency restoration plan is extremely

critical in network operation. These plans should include well-defined responsibilities, as
well as procedures and locations for all restoration materials.

The original copy should be maintained by the engineering group and a copy distributed
to the maintenance group. One copy of the records package should be placed at each
end of the termination points to the fiber optic system. When changes in the system are
required due to supplemental construction or emergency restoration, the records package
should be revised and redistributed.

Annual System Check. Periodically, the system attenuation level shall be verified
against the turn-up attenuation measurement. If this attenuation level has changed more
than 3 db, it is recommended that the cause be investigated and corrective action taken.

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