Broadband Applications and Construction Manual ConQuest Conduit Products ®
Table of Contents ConQuest® Conduit Applications and Construction Manual Table of Contents Section 1 ................Introduction 1.1 ConQuest Conduit Product Line 1.2 Cable-In-Conduit 1.3 Toneable Conduit 1.4 Empty Conduit 1.5 Quality and ISO 9001 Certification Section 2 ................Handling - Receiving a Shipment 2.1 Inspection of a Shipment 2.2 Unloading 2.3 Unloading with a Forklift 2.4 Product Identification Section 3.................
0.1 Table of Contents ConQuest® Conduit Applications and Construction Manual Section 6 ...................Aerial Installation 6.1 Introduction 6.2 Back-Pull/Stationary Reel Method 6.2 Setup Chute Placement 6.2 Trailer Setup 6.3 Cable Puller Setup 6.4 Passing the Cable Puller at Poles 6.4 Corner Block Placement 6.4 Power Winching Method 6.5 Overlashing Existing Cable 6.6 Attach Lashing Wire Clamp 6.6 Passing the Lasher at a Pole 6.
Introduction ConQuest Conduit® Product Line Introduction to the ConQuest Product Line ® CommScope’s ConQuest product line features select grade highdensity polyethylene (HDPE) conduit with value-added products such as factory pre-assembled CommScope Cable in Conduit (CIC) and Toneable Conduit . TM ConQuest includes a complete line of empty conduit and conduit accessories including cutters, couplings, and an environmentally safe cable pulling lubricant. 1.
1.2 Introduction ConQuest Cable-in-Conduit (CIC) ® ConQuest® Cable-in-Conduit (CIC) Product Family ConQuest Cable-in-Conduit is factory pre-assembled HDPE conduit with CommScope’s superior cable products such as QR®, Parameter III® (P3®), Subscriber Drop, PowerFeeder®, LightScope ZWP®, Fiber Optic, and/or MultiReach® cables. ConQuest CIC provides enhanced cable protection, saves installation time and costs, and makes cable replacements faster and more efficient.
Introduction ConQuest Toneable Conduit ® ConQuest® Toneable ConduitTM ConQuest Toneable Conduit is a select grade high-density conduit with an integrated 18-gauge copper clad steel (CCS) tone wire. The tonewire is attached to the outside of the conduit with a figure eight style web. This design provides easy access to the tone wire.
1.4 Introduction ConQuest Empty Conduit ® ConQuest Empty Conduit ® ConQuest Empty Conduit is select grade HDPE conduit with or without factory pre-installed pull lines. Empty conduit is available with a variety of pull rope/tape options with various pull strength ratings. Install Empty ConQuest Conduit for Future Cable Placements Sometimes conduit needs to be installed ahead of cable; such as for developing neighborhoods and for some long fiber optic cable placements.
Introduction Quality / Certification Quality CommScope goes the extra mile to insure you receive quality conduit. Dimensional measurements shall be performed on samples removed from each complete length of finished conduit, unless otherwise specified. Not only will the dimensions be examined, ovality and physical appearance will also be checked. The inner and outer surface area shall contain virtually no signs of cracks, roughness; melt fracture or any other surface defect.
2.1 Handling Inspection of a Shipment Handling - Receiving a Shipment Trouble-free unloading begins with letting your CommScope Customer Service Representative know of any special packaging or delivery requirements (reel must be shipped on rolling edge, no shipping dock available, call before delivery, etc.). CommScope will make every reasonable effort to comply with your shipping needs. When the shipment arrives, inspect every reel and pallet of material for damage as it is unloaded.
Handling Unloading ConQuest® Products Unloading ConQuest® Products Unloading at a Dock Use a pallet jack or forklift to remove all products on pallets. Remove any blocking materials for the individual rows of conduit and roll the reels onto the dock. If the back of the trailer and dock are not the same height, use an appropriate loading ramp to compensate for the difference. NOTE: See table for product weights beginning on page 8.9.
2.3 Handling Unloading with a Forklift Unloading ConQuest® Products Unloading With a Forklift When unloading or moving reels with a forklift care must be taken. First check that the forklift can lift at least 200 lbs. more than the weight of the reel. Then verify that the forks are long enough to completely cover the distance from one flange of the reel to the other flange of the reel.
Handling Product Identification Product Identification (Reel Tag) Each reel tag for CIC (as shown below) shall provide the following information and instructions: CommScope’s Shipping Address CommScope’s Product Code Length of the Cable inside the Conduit Product Description Reel Number Reel Size Special Comments (if needed) Shown: typical reel tag for CIC with P3 500 JCASS Product.
3.1 General Conduit Installation Practices Pay-Off Pay-Off When installing ConQuest, pay-off the reel from underneath and in as direct a line as possible to the trench to avoid unnecessary bending of the conduit or rubbing of the conduit against the reel flange. When feeding ConQuest into a manhole, pay-off should occur from the top of the reel with the manhole on the opposite side from the direction of pull.
General Conduit Installation Practices Attachment Attaching to ConQuest® Some installation methods require an attachment to the ConQuest conduit to facilitate pulling. The following tools work particularly well for this: the “basket pulling grip”, the “thread in eye”, and expansion eye. Basket Pulling Grip When using the basket pulling grip it is important to remember, the tool is designed to compress and grip the surface of the object it is pulling.
3.3 General Conduit Installation Practices Cutting ConQueust ® Cutting ConQuest® Several tools have been found useful for the purpose of cutting ConQuest conduit. While selection of the tools is usually defined by the users preference, there are some application restrictions based on tool designs. For ConQuest up to 1.25” (3.2cm), use a ratchet sheer (such as the CQARS1 from CommScope). To cut ConQuest, open the tool and place it around the conduit at the point where the cut is to be made.
General Conduit Installation Practices Bending ConQuest® Bending ConQuest® (Underground) ConQuest can be easily shaped by rolling a bend into it. Take 10 – 12 feet (3 – 3.5 meters) of conduit and pull the free end of it toward you forming a “horizontal U.” Push into the bend lightly and roll the entire radius of the conduit forward. DO NOT bend the conduit any further if it begins to show signs of ovality, i.e. begins to bulge. DO NOT press down on the conduit with your foot as you bend it.
3.5 General Conduit Installation Practices Mechanical Stress Mechanical Stress Regardless of the installation method, mechanical stress is of great concern during conduit and cable placement. Exceeding the maximum allowable pulling tension can damage conduit and cable. Pulling tensions for ConQuest conduits can be found in specifications at the end of this manual.
Underground Installation Methods Introduction Underground Installation Methods Conduit was designed for underground installations. Making it possible to easily and quickly access buried cables that would otherwise be bounded by earth and inaccessible. Most underground environments are extreme environments. Conduit, when properly installed following the procedures outlined in this manual, will provide years of protection for the cables inside guarding against rocks, rodents, and dig-ins.
4.2 Underground Installation Methods Open Trench Methods Open Trench Installation Method Trenching is accomplished with specialized trenching tractors which cut the trench and remove the soil in a single action. A trench can be used to place multiple conduits over long or short distances. The construction equipment manufacturer specifies detailed equipment operation and excavation procedures. Excavate the trench to the desired depth.
Underground Installation Methods Open Trench - Moving Reel Open Trench - Moving Reel Installation Method Moving Reel Installation Prior to installation, make sure to account for cable withdrawal by providing adequate excess length. Make sure the conduit is capped. NOTE: See Cable Withdrawal in General Conduit Installation Practices - Page 3.1. Place the reel on a trailer with pay-off underneath and to the rear of the trailer. Secure the free end of the conduit outside of the trench.
4.4 Underground Installation Methods Open Trench - Stationary Reel Method Open Trench - Stationary Reel Installation Method Stationary Reel Installation Mount the reel so the conduit pays off the bottom of the reel, along the direction of pull. Make sure the conduit is capped. Cable withdrawal can be determined as you reach the far end of the trench. MAKE SURE YOU FIND THE END OF THE CABLE AT THE FAR END BEFORE YOU CUT THE CONDUIT AT THE REEL END.
Underground Installation Methods Open Trench - Backfilling Open Trench Backfilling Method It is best to place the softest soil directly on and around the conduit. DO NOT place large rocks directly on the conduit. Allow at least 2 – 4 inches (5 - 10 cm) of dirt to cushion the conduit. Best practice to insure long-term protection of underground facilities is to utilize sand for padding the conduit.
4.6 Underground Installation Methods Boring (Conventional Bores) Conventional Boring Installation Method Mechanical Boring Machines may be utilized to push an auger (jack and bore) to make an adequate conduit passage. The auger diameter should be 1 inch (2.5 cm) larger diameter than the conduit being installed. The equipment manufacturer should support the operation instructions for this equipment.
Underground Installation Methods HDD - Horizontal Directional Boring Directional Bores* Directional boring is accomplished by using a steerable drill stem. The equipment operator can control the depth and direction of the boring. Very long bore lengths can be accomplished by using directional boring devices. Subsurface crossings are generally accomplished by digging a trench on each side of the crossing to allow guiding and retrieval of the drill stem.
4.8 Underground Installation Methods The Drilling Square The Drilling Square* The factors that make a successful bore are too interrelated to be able to point a finger at any one of them as being the cause of a problem in all cases. Therefore these factors are best placed in the form of a square. The drilling square is a simple and useful tool to remembering the four factors affecting fluid flow, which is the key to successful horizontal directional drilling.
Underground Installation Methods The Drilling Square Fluid There is no universal soil therefore there is no universal drilling fluid. Drilling fluid provides soil stabilization, lubrication, a means to carry away the cuttings, and suspend cutting when fluid is not in circulation. To achieve this requires the proper blend of material for the type of soil(s) being drilled through. Your material supplier should be able to provide you with appropriate mix rates of the various materials to achieve this.
4.10 Underground Installation Methods Static Plowing Static Plowing Method A tractor moves slowly forward as the blade splits the earth and places the conduit at the required depth. Because terrain and soil types vary, contact your plow manufacturer for their equipment recommendation. CommScope strongly recommends a professionally engineered single or double feed tube plow blade with a tube at least 0.5 inch (1.
Underground Installation Methods Vibratory Static Plowing Vibratory Plowing Method Vibratory plowing can offer substantial productivity gains over other direct burial methods. A tractor (usually smaller than that used in static plowing) moves slowly forward as a vibrating blade splits the earth and places the conduit at the required depth. Because terrain and soil types vary, contact your plow manufacturer for their recommendation.
4.12 Underground Installation Methods Handling Underground Obstructions Handling Obstructions If obstructions (tree roots, large rocks, etc) are encountered, disengage the transmission, turn the engine off and then disengage the clutch. NEVER BACK PLOW WITH THE CONDUIT IN THE FEED TUBE. This will damage the conduit and pack dirt in the feed tube. Carefully dig a pit behind the blade. REMOVE THE CONDUIT FIRST, then remove the obstruction. Replace the conduit and proceed with the installation.
Underground Installation Methods Pull Plow Method Pull Plow Method This method requires the use of a vibrator box attachment. Select a plow blade with a circular area at least 1 inch (2.5 cm) larger than the conduit. This expanded area will provide a path for the conduit that will reduce the amount of pulling tension associated with side wall pressure. A tag-behind bullet can also be used. Attach the bullet to the plow blade with a short length of chain.
4.14 Underground Installation Methods Rip and Plow Method Rip and Plow Method Rip and Plow (using two tractors) If you anticipate obstructions (like roots and large rocks) along the installation path, you may want to consider a rip and plow installation. In rip and plow, a lead tractor rips the ground by pulling a plow without conduit several hundred yards / meters ahead of the tractor with the conduit. The first tractor clears the route and permits the second tractor to work more efficiently.
Underground Installation Methods Existing Conduit Existing Conduit Installation ConQuest products are also designed to be placed into existing conduit systems. An example is the placement of one or more conduits inside a larger conduit. Multiple conduits should be placed at the same time. ALWAYS test and ventilate manholes prior to entering into them and follow OSHA confined space requirements. An important step that should be taken prior to this type of work is “proofing” the existing conduit.
4.16 Underground Installation Methods Submarine Installation Submarine Construction Occasionally there will be a need to install conduit underwater, crossing a tidal basin, lake, or river. While conduit is suitable for this application, it requires special installation procedures to address the buoyancy of the conduit. A logical route must be planned based on what is believed to be down there awaiting the conduits.
Underground Installation Methods Submarine Installation Submarine Plowing Method There are two basic methods of submarine construction used, Sub-Aqueous Terrain Plowing and Floor Surface Placement. Sub-Aqueous Terrain Plowing Construction with this method can be accomplished with one of several technologies designed for this special task. Installation with this method can eliminate the issues of buoyancy if the conduit is buried deep enough.
4.18 Underground Installation Methods Submarine Installation Floor Surface Placement In this method of construction, the conduit is placed on the floor of the body of water. Conduit must be weighted to increase its displacement volume to overcome the effects of buoyancy. This chart lists the displacement volume for ConQuest conduits. Conduit Size Displacement Volume 1 inch 1.25 inches 1.50 inches 2 inches .0094 cubic feet .0150 cubic feet .0197 cubic feet .
Underground Installation Methods Submarine Installation So How Much Weight is Needed? To calculate the weight needed to overcome buoyancy the appropriate displacement volume is first multiplied with the appropriate weight per cubic foot of water to obtain the gross buoyancy of the conduit. The next step is to factor in the weight of the conduit and the cable, which will offset some of the buoyancy. Conduit weights can be found in the specifications section.
4.20 Underground Installation Methods Underground Placement Equipment Underground Equipment Shoe, Cable This equipment is used to route conduit through manholes while the conduit is being pulled into place. Placement of the cable shoes will prevent the rubbing of the conduit on obstacles within the manhole. Sheave This equipment is used to facilitate the movement of conduit that is being pulled into place through a manhole.
Pulling Cable into Conduit Overview Pulling Cable into Conduit There are many variables to consider when pulling cables, and each pull is considered unique. The most important variable to consider is the maximum pulling tension of the cable, which may be found in one of CommScope’s product catalogs.
5.2 Pulling Cable into Conduit Route Geometry Route Geometry Route geometry is an important contributor to pulling tension. The lowest pulling tensions are found in straight sections of conduit. Low sidewall pressure (LSWP) occurs in horizontal straight sections of conduit. SWP is caused by the weight and friction of the cable against the conduit, with a minimal amount of force being applied to the cable’s jacket. For calculating LSWP see Section 8.14.
Pulling Cable into Conduit Fill Percentage Fill Percentage The fill percentage, sometimes referred to as fill ratio, is the amount of space that cable(s) occupy inside the conduit as a percentage of the inner diameter of the conduit. The greater the fill percentage the higher the sidewall pressure will be. This is critical when constructing the conduit run. Bends should be made more gradual when fill percentages are high. ConQuest Cable In Conduit products are typically designed not to exceed 30% fill.
5.4 Pulling Cable into Conduit Pulling Multiple Cables Pulling Multiple Cables Slings or harnesses are designed to attach multiple cables or innerducts to a single pull line. They can be built for any number and size of cable/inner duct.
Pulling Cable into Conduit Pulling Multiple Cables Back Tension Back tension is the amount of force needed to pull cable directly from the reel. Since the amount of cable on the reel, the weight of the reel and the friction of the reel on its setup through bar will vary, it is difficult to provide a rule of thumb for back tension.
5.6 Pulling Cable into Conduit Pull Calculations Pull Calculations Maximum pull lengths, pulling tension at the end of a straight section of conduit, pulling tension at the end of a bend, and sidewall pressure can be calculated quite easily. However, it is important to remember that these calculations are only estimates.
Aerial Installation Overview Aerial Installation There are many applications for aerial conduit, some of which are road crossings, rail crossings, trolley line crossings, and water crossings. Aerial conduit provides an efficient means for supporting cable and is easily accessed without requiring encroachment in hazardous or difficult spaces. When selecting aerial conduit, it is important to consider the environment where it will be placed.
6.2 Aerial Installation Back-Pull/Stationary Reel Method Back-Pull/Stationary Reel Method The back-pull / stationary reel method is the usual method of aerial conduit placement. This method is also best suited for locations where the strand changes from the field side of the pole to the street side of the pole and where there are excessive obstacles to work around.
Aerial Installation Back-Pull/Stationary Reel Method Cable Puller Set-Up Place an appropriate cable grip on each conduit. Secure the grip to the conduit with tape to keep the conduit from backing out of the grip should the pulling tension be relaxed. Place the cable puller on the strand and close the puller gates to secure the puller to the strand. Attach a hand pulling line to the cable puller, or a pulling line from the cable puller to a winch. Place cable blocks to support the conduit as it is pulled.
6.4 Aerial Installation Back-Pull/Stationary Reel Method Passing the Cable Puller at Poles Pull the cable puller to the pole and release the tension in the pulling line. Pass the conduit across the pole face and the pole/line hardware, and attach the cable puller back to the strand. Place cable blocks on each side of the pole. At corner block locations, pass the cable puller to the opposite side of the pole and route the conduit through the corner block.
Aerial Installation Lashing Installation – Overlashing Existing Cable Overlashing conduit onto existing cable plant is similar to installing conduit onto new strand. However, there are some unique aspects. A sag and tension analysis should be performed to see if the new load will overwhelm the strand. Use special overlash cable puller blocks and continuously maintain and monitor the pulling line tension.
6.6 Aerial Installation Lashing Attach the Lashing Wire Clamp Place the lasher on the strand. Wrap the lashing wire twice around the strand in the same direction as the twist in the strand and in the lay of the strand. Pass the lashing wire between the washers of the lashing wire clamp (bugnut) without overlapping the wire. Wrap the wire around the clamp to the post on the opposite side of the clamp and wrap it twice around the post.
Aerial Installation Lashing Aerial Equipment Set-Up Chute A set-up chute is used to guide the conduit from the reel trailer to the strand. Single Roller Block Used to support conduit prior to lashing. Cable Lifter This tool may be used to lift conduit into place and is helpful to ensure that the conduit being lifted is not damaged by exceeding minimum bend radius. Cable Block Lifter Used in conjunction with a lay-up stick to place assorted cable blocks mid-span.
7.1 ConQuest Toneable Conduit™ ® Product Overview CommScope toneable conduit utilizes an embedded 18 AWG tone wire to facilitate conduit location once installed. The 18 AWG copper-clad tone wire is applied to the outside of the conduit during the manufacturing process. The tone wire is embedded in a layer of HDPE for corrosion and electrical protection. Narrow webbing connects the wire to the conduit for ease of access for splicing. A cross-section of toneable conduit is shown in Figure 1.
ConQuest Toneable Conduit™ ® Coupling Table 1 Nominal Inner Diameter (inches) Min. Bend Radius Unsupported (inches) Max. Pulling Tension (lbs.) Weight (lb/ft) 0.095 ± 0.020 0.84 20 687 0.128 1.315 ± 0.007 0.097 ± 0.020 1.101 26 894 0.166 18 1.660 ± 0.008 0.123 ± 0.020 1.394 34 1,425 0.263 18 1.900 ± 0.010 0.141 ± 0.020 1.598 38 1,867 0.344 2.00" SDR 11 18 2.375 ± 0.012 0.216 ± 0.026 1.917 48 3,515 0.
7.3 ConQuest Toneable Conduit ® TM Coupling To install ConQuest® toneable conduit, employ standard HDPE conduit installation procedures. When conduit needs to be coupled, be certain to over pull the two ends by a minimum of two feet so the tone wire can be spliced at the coupled joint. To couple the conduit and splice the tone wire to maintain electrical continuity, these procedures are recommended: The tone wire should be separated from the conduit end for a minimum length of 12 inches + 2.
ConQuest Toneable Conduit ® TM Coupling Figure 4 Join the conduits with an approved coupler according to the manufacturer’s directions. Strip back 5/8” of the HDPE jacket from around the tone wire (Figures 5 and 6). Figure 5 Figure 6 CommScope recommends the use of large direct-bury waterproof connectors for joining the tone wires and providing environmental protection (Figure 7). These can be purchased off the shelf at most home improvement stores.
7.5 ConQuest Toneable Conduit ® TM Coupling Insert the tone wires into the gel-filled connector fully onto both wire ends, and twist (clockwise) until it becomes tight (Figure: 8). Figure: 8 Fold the excess slack of the tone wire back onto the conduit, and tape or tie wrap to the conduit (Figure: 9).
ConQuest Toneable Conduit ® TM Toning The Function of Toning Toning is a method of using a generated signal, or ‘tone’, that is transmitted over a conductor so that the portion of the conductor buried below the earth’s surface can be located without digging. The tone is produced at a very low frequency with a transmitter tuned to a particular frequency. The frequency range available on the transmitter varies between manufacturers but often ranges from 400Hz to about 80KHz.
8.1 Appendix Conduit Cutting Tools and Accessories Conduit Cutting Tools and Accessories Basket Grip / Pulling Grip This reusable grip, woven from strands of stainless steel, acts like ‘Chinese finger cuffs’ and compresses upon being relaxed. It provides an evenly distributed hold on the conduit or cable. Innerduct Puller This equipment is often used for innerduct pulls because they do not increase the outer diameter of the conduit. Ratchet Shears Used to cut conduits up to 1¼ inches (3.
Appendix Underground Placement Equipment Underground Equipment Shoe, Cable This equipment is used to route conduit through manholes while the conduit is being pulled into place. Placement of the cable shoes will prevent the rubbing of the conduit on obstacles within the manhole. Sheave This equipment is used to facilitate the movement of conduit that is being pulled into place through a manhole. Sheaves are free wheeling and accordingly add little drag to the conduit that is being installed.
8.3 Appendix Aerial Placement Equipment Aerial Equipment Set-Up Chute A set-up chute is used to guide the conduit from the reel trailer to the strand. Single Roller Block Used to support conduit prior to lashing. Cable Lifter This tool may be used to lift conduit into place and is helpful to ensure that the conduit being lifted is not damaged by exceeding minimum bend radius. Cable Block Lifter Used in conjunction with a lay-up stick to place assorted cable blocks mid-span.
Appendix Aerial Placement Equipment Multiple Cable Puller Allows multiple cables to be pulled into place when lashing cables directly to strand. It’s equipped with a strand brake to prevent sagging of cables as the pulling tension is released. Allows pulled cables to independently swivel. Pulling Sling Used to prevent both excessive pulling tension and twisting of conduits in multiple conduit installations. It is designed to break should it exceed a pre-set tension limit. 8.
8.5 Appendix Packaging and Shipping A D C B ConQuest products can be packaged and shipped on either wooden reels (A), ReelSmart® Composite Reels (B), or lightweight steel reels (C). Drop conduit products can be packaged on “reel-less” coils (D), making them light weight and easier to handle. ConQuest Reel Dimensions and Weight Chart (Standards in Bold) Lengths* ½” ¾” 1” 1¼” 1½“ 2” 3” 500 1,000 4” 102x74x43 217 lbs. 35x16½x18 60 lbs. 42x24x24 130 lbs. 50 x 24 x 24 54 x 28 x 43 182 lbs.
Appendix Toneable Conduit Specifications Outside Diameter (inches) Nominal Inner Diameter (inches) Min. Bend Radius Unsupported (inches) Max. Pulling Tension (lbs.) Weight (lb/ft) Conduit Size CU-Clad Wire Size AWG 3/4" SDR 11 18 1.050 ± 0.005 0.095 ± 0.020 0.84 20 687 0.128 1.00" SDR 13.5 18 1.315 ± 0.007 0.097 ± 0.020 1.101 26 894 0.166 1.25" SDR 13.5 18 1.660 ± 0.008 0.123 ± 0.020 1.394 34 1,425 0.263 1.50" SDR 13.5 18 1.900 ± 0.010 0.141 ± 0.020 1.598 38 1,867 0.
8.7 Appendix Conduit Cable Specifications Conduit Specifications SDR 11 Nominal Size Nominal Outside Diameter (inches) Minimum Wall Thickness (inches) Nominal Inner Diameter (inches) Min. Bend Radius Unsupported (inches) Max. Pulling Tension (lbs.) 1/2” 0.840 0.076 0.668 10 390 85 3/4” 1.050 0.095 0.840 12 605 130 11/4” 1.660 0.151 1.338 18 1,520 320 11/2” 1.900 0.173 1.533 20 1,760 416 Weight* (lb/kft) 2” 2.375 0.216 1.917 26 3,105 640 3” 3.500 0.318 2.
Appendix Coaxial Cable Data Conduit Specifications SCH 40 Nominal Size Nominal Outside Diameter (inches) Minimum Wall Thickness (inches) Nominal Inner Diameter (inches) Min. Bend Radius Unsupported (inches) Max. Pulling Tension (lbs.) Weight* (lb/kft) 1” 1.315 0.133 1.029 14 1,050 219 11/4” 1.660 0.140 1.360 18 1,420 295 2” 2.375 0.154 2.
8.9 Appendix Fill Percentage Calculation Coaxial Data Sheet This data is provided as a means to determine the number of cables that will fit into a conduit. Product Diameter (DOJ) Inches mm X-Sectional Area Inches mm Pulling Tension Lbs kgf P3412 0.485 12.32 0.185 119.19 150 68 P3500 0.570 14.48 0.255 164.63 300 136 P3565 0.635 16.13 0.317 204.32 350 159 P3625 0.695 17.65 0.379 244.75 475 215 P3700 0.775 19.69 0.472 304.34 500 227 P3750 0.830 21.08 0.
Appendix Maximum Pull Distance Fill Percentage Calculation The fill percentage can be calculated using this formula: • Single cable Where: ACa ACo OD ID FP = = = = = Area of the cable Area of the conduit Outer diameter of the cable Inner diameter of the conduit Fill percentage ACa = π* ( OD / 2 ) * ( OD / 2 ) ACo = π* ( ID / 2 ) * ( ID / 2 ) FP = 100 * ( ACa / ACo ) Example: QR 715 in 1.5” Schedule 40 conduit ACa = π* ( 0.881 / 2 ) * ( 0.881 / 2 ) = .610 ACo = π* ( 1.580 / 2 ) * ( 1.580 / 2 ) = 1.
8.11 Appendix Calculated Pulling Tension Maximum Pulling Length The maximum pulling length is the longest distance that a cable can be safely pulled through a straight and level conduit. This formula is used as an independent measure for route engineering purposes. Lm = Tm / ( W * f ) where: Lm = maximum pulling length in feet Tm = maximum pulling tension in pounds W = weight of cable in pounds per foot f = coefficient of friction (if unknown use 0.
Appendix Calculated Sidewall Pressure Calculated Pulling Tension – Bend Section of Conduit (HSWP) This formula is used to determine the amount of tension placed on a cable at the end of pull in a bend section of conduit. The formula is used in conjunction with the calculated pulling tension for a straight section of conduit to calculate an estimated pulling tension for an entire conduit run.
8.13 Appendix Calculated Sidewall Pressure Calculated Sidewall Pressure This formula is used to calculate the sidewall pressure in bends. The longer the bend is the lower the sidewall pressure will be, this will also be true for smaller angles of bend. P = Tb / l where: P = Tb = l = Sidewall pressure Pulling tension at end of bend in pounds Example: QR 715 Tb l P P = = = = 79 10 79 / 10 7.
Appendix Installation Safety Reel Setup At ‘A’, Pulling From ‘H’ Pulling Tension Tension @ A = 0 = 0 Tension @ B (Ts1) = 100 * 0.144 * 0.5 = 7 Tension @ C (Tb1) = 7 * 1.48 = 10 Tension @ D (Ts2) = 10 + ( 80 * 0.144 * 0.5 ) = 16 Tension @ E (Tb2) = 16 * 2.19 = 35 Tension @ F (Ts3) = 35 + ( 75 * 0.144 * 0.5 ) = 40 Tension @ G (Tb3) = 40 * 1.48 = 59 Sidewall Pressure PB-C = 10 / 10 =1.0 lbs/ft PD-E = 35 / 10 =3.5 lbs/ft PF-G = 59 / 10 = 5.
8.15 Appendix Installation Safety Installation Safety Construction of underground facilities require a substantial amount of manpower, tools and equipment. Underground and aerial construction will expose the manpower, tools and equipment to hazards, dependent upon field conditions and circumstances. The Occupational Safety and Health Administration (OSHA) defines a qualified employee as “any worker who by reason of training and experience has demonstrated his ability to safely perform his duties.
Appendix Installation Safety Underground Safety Telecommunication construction is typically done within right-of-way dedicated for the routing of other underground systems – municipal and utility pipes, wires, cables, and conduits. Damage to any one of these utilities could cause a disruption of services. At worst, it may cause catastrophic harm to personnel and surrounding property.
8.17 Appendix Installation Safety Occupational Safety And Health Administration (OSHA) Standards OSHA Standards were established in 1970 to help ensure workplace safety. The Standards are federal regulations that are intended to enable employees to recognize, understand and control hazards in the workplace. Standards have been established for general industry while some sections of the Standards are dedicated to specific industries such as telecommunications.
Appendix Installation Safety National Electric Code (NEC) Standards The NEC typically identifies the construction techniques and materials necessary in building wiring requirements, (i.e., inside plant construction, of fiber optic, coaxial cable, or twisted pair systems). The NEC has been developed by the National Fire Protection Association’s (NFPA’s) National Electric Code committee. Committee members are professionals from the electrical industry. The NEC addresses safety from fire and electrocution.
8.19 Appendix Installation Safety National Electric Safety Code (NESC) Standards The NESC covers supply and communication cables and equipment in underground buried facilities. The rules also cover the associated structural arrangements and the extension of such facilities into buildings. The NESC typically identifies the construction techniques and materials necessary in outside plant construction of electric supply or communication cable systems.
Appendix Installation Safety Conduit and Tracer Colors CommScope manufactures conduit and tracers in a variety of colors to meet your specific requirements. However, please note that the most common colors are black, orange or terra cotta. Orange/terra cotta conduit is recommended for telecommunication conduit in buried applications. Black is recommend for applications where the conduit is exposed to direct sunlight. For other colors see the chart at right.
Disclaimer Legal Disclaimer THIS MANUAL IS PROVIDED FOR GUIDANCE PURPOSES ONLY AND SHOULD NOT BE USED OR IN ANY WAY RELIED UPON WITHOUT CONSULTATION WITH AND SUPERVISION OF EXPERIENCED CONSTRUCTION PERSONNEL, ENGINEERS OR NETWORK DESIGN SPECIALISTS. COMMSCOPE MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING ANY REPRESENTATION OR WARRANTY REGARDING THE QUALITY, CONTENT, COMPLETENESS, SUITABILITY, ADEQUACY OR ACCURACY OF THE DATA CONTAINED HEREIN.
www.commscope.com Visit our website or contact your local CommScope representative for more information. © 2014 CommScope, Inc. All rights reserved. All trademarks identified by ® or ™ are registered trademarks or trademarks, respectively, of CommScope, Inc. This document is for planning purposes only and is not intended to modify or supplement any specifications or warranties relating to CommScope products or services. CO-107146.
