Alcoa Fujikura Ltd.

Optical Ground Wire with Slotted Core

OPT-GW w/SC Installation Documentation Index

Section 1 Installation Practice

Section 2 Hardware Drawings and Installation Instructions

Section 3 Hardware Assembly Drawings

Section 4 Installation Accessories

Section 5 Vibration Protection

Section 6 Pre-Construction Checklist

AFL-OPTGW with Stainless Steel Tube(s) Installation Manual 2000 Edition, Issue 1
All contents  2000, Alcoa Fujikura Ltd.
 OPTICAL GROUND WIRE INCORPORATING
SLOTTED CORE CABLES

INSTALLATION INSTRUCTIONS

Contents Section

Introduction/Product Description 1.0

Installation Overview 2.0
Equipment / Setup 2.1
Stringing 2.2
Sagging / Clipping In 2.3
Hardware 2.4
Splicing Procedures 3.0
Splice Enclosure 3.1
Cable Preparation 3.2

1.0 Introduction

Slotted Core, AFL OPT-GW (Optical Ground Wire), comes in a wide range of diameters,
fiber counts, weights and tensile strengths. Installation procedures for OPT-GW product do
not vary significantly with product size or weight. This document is intended as a broad
guideline that should be applicable to most OPT-GW installations. AFL recommends that
the IEEE Guide to the Installation of Overhead Transmission Line Conductors (IEEE Std.
524), latest revision, be used in conjunction with this document as a guideline for the
installation of Slotted Core. This document is intended as a broad guideline for power
utilities and contractors and therefore does not attempt to cover every possible installation
configuration. Any inquiries for more detail on a specific topic relating to Slotted Core
installations should be directed to the AFL Engineering Department at 770.664.4949.

AFL OPT-GW is manufactured in accordance with IEEE Std 1138-1994, IEEE Standard
Construction of Composite Fiber Optic Overhead Ground Wire (OPT-GW) for Use on
Electric Utility Lines. This standard is recognized as an American National Standard
(ANSI).

AFL OPT-GW construction comprises a helically slotted aluminum alloy core containing
optical fibers in protective buffer tubes. Various combinations of aluminum clad steel
and aluminum alloy wires are stranded over the aluminum core as required to achieve the
required mechanical and electrical characteristics for the specific customer application.
This construction provides excellent anti-crush characteristics as well as a large fiber
tensile window (zero fiber strain to maximum working load of the cable, 60% RBS).

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2.0 Installation Overview

The recommended method for installation of Slotted Core OPT-GW is “Tension Stringing”.
This method is accomplished by stringing the Slotted Core through a series of temporary
sheave wheels located at each structure. Constant tension is applied to the Slotted Core by a
tensioner located at the payoff end. The Slotted Core is supported by the sheave wheels
until tensioning is complete and hardware is installed. Adequate tension must be maintained
to provide clearance from conductors and the ground underneath the Slotted Core. Other
methods such as the “Moving Reel/Payoff” method can be used, but are not covered in this
document. Please consult AFL Engineering Department if intending to pursue any
installation method other than “Tension Stringing”.
During installation of Slotted Core, standard shield wire support hardware must not be used
under any circumstances. Most standard shield wires are spliced using compression or
preformed type connectors. It is not possible to splice the Slotted Core with this type of
hardware due to the optical fibers existing within the cable.

OPT-GW hardware must be used during installation of Slotted Core. This includes
deadends, suspensions, vibration dampers and other attachment hardware designed
specifically for OPT-GW and the size of OPT-GW being used. Recommended hardware
and manufacturers will be covered in section 2.4.

Cable splice locations must be determined before installation of the Slotted Core. These
locations are normally determined by field investigation where access can be readily made
for splicing and future maintenance. Cable reel lengths must be engineered to allow enough
excess cable for installation handling, sagging, and splicing of the OPT-GW.

2.1 Equipment / Setup

Standard conductor stringing equipment (tensioners, pullers, etc.) are typically utilized to
install Slotted Core, however they must meet IEEE std. 524, latest version. Refer to Figure
1. for typical installation equipment setup.

One important distinction is that OPT-GW generally requires sheave wheels with larger
groove diameters than regular shield wire or conductor. This ensures bending stresses on
the OPT-GW remain low during the installation process. The following minimum sheave
wheel dimensions are required by AFL.

1. Sheaves on the first and last structures of a pulling section must have a grove diameter
of at least 24 inches.

2. For tangent structures (up to 20 degrees) the minimum groove diameter of sheave
wheels must be 25 x OPT-GW outer diameter.

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 3. For angle structures greater than 20 and up to 60 degrees the minimum groove diameter
of sheave wheels must be 40 x OPT-GW outer diameter.

4. For angle structures greater than 60 degrees, 28 inch (712 mm) or 36 inch (915 mm)
diameter sheaves must be used along with reduced stringing tension. Consult AFL for
recommendations.

These diameters are based on a maximum stringing tension of 20% of the Rated Breaking
Strength (RBS) of the Slotted Core. Reduced groove diameter of sheave wheels may be
utilized if the stringing tension is also reduced. Variations to these requirements may be
made under certain conditions. The AFL Engineering Department will assist in determining
specifications for varying conditions. Consult AFL for recommendations.

All sheave wheels must be lined with neoprene or elastomer product in order to protect the
surface condition of the aluminum clad steel wires. This lining must be continually
inspected to assure it is in good condition. The width of the sheave groove must be
sufficient to pass through the anti- rotation device applied to the OPT-GW during
installation. A groove width of 2 inches (50 mm) is typically sufficient.

On angle structures where one or two sheave assemblies are being used it is most important
that the sheave assembly be properly installed so the Slotted Core will not jump out of the
groove and be damaged.

Uplift rollers (which attach to the installation sheave wheel) or holddown blocks (which are
separate blocks) need to be placed where uplift of the pulling line is likely to occur (due to
its higher tension/weight ratio than the conductor). This will typically occur going up
inclines or at a low point in a section. These devices should also have a break away feature
in the event of fouling or incorrect installation.

The bull wheel tensioners must be of the multi-groove type. All grooves must be lined with
neoprene or an acceptable elastomer coating. Single V-groove bull wheel tensioners must
be evaluated on an individual basis to determine if they are acceptable to be used under
certain conditions.

Groove diameter of all bull wheels must be a minimum of 70 X O.D. (outer diameter of the
OPT-GW). Tandem bull wheels must be aligned so that the offset of grooves will be
approximately one half (½) of groove spacing.

The tensioner must be capable of sustaining the recommended pulling tension even when
stopped. The tensioner must have an accurate tension control system. The pulling and
braking systems should operate smoothly and must never cause any sudden jerking or
bouncing of the Slotted Core.

The reel stand should be an integral part of the tensioner or attached solidly to the tensioner
to prevent movement between the tensioner and the Slotted Core reel. If the reel stand is
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 mounted separately from the tensioner, it should be located within about 5 meters (16.4 ft)
from the tensioner. The elevation of the reel stand should be established to prevent the OPT-
GW from bending angles as it passes through any guide arms prior to the tensioner.

The Slotted Core reel must be placed on the reel stand with the Slotted Core feeding off the
top of the reel. For left hand lay outer strands (OPT-GW with single layer of wires), the
Slotted Core must enter the bull wheel on the right side and pull off from the left. This
arrangement is necessary to avoid any tendency to loosen the outer layer of strands as the
Slotted Core passes over the bull wheels.

The payoff reel and tensioner must be setup so that the horizontal distance from the
tensioner to the first structure is three times the height of the attachment point on the first
structure or a 3:1 ratio. Likewise the puller and take-up reel must be located away from the
last structure with the same 3:1 ratio of horizontal distance to vertical height. The cable reel
must not be used as a tensioning device during installation. The reels are not designed for
this purpose and the cable could be damaged.

Stringing
Block
Pulling
100’ Line
OPT-GW
100’
Pulling
Tensioner Machine

300’ Distance to Stringing 300’

from Tower is Three Times
Attachment Height

Figure 1. Typical OPT-GW Installation Setup / Tension Stringing

Wood reels with Slotted Core require special handling. To lift a wood reel a chain or cable
around the mandrel or through the arbor holes must be attached to a spreader bar to prevent
smashing the reel top and damaging the fibers.

All wood lagging must remain in place on all reels until placed on pay-out racks and rack is
in position for cable stringing.

All reels with Slotted Core must be stored and transported on edge. Never store an OPT-
GW reel on the flat of the flange. See Figure 2.

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 When Slotted Core cables are received from the manufacturing plant, they should be tested
to verify continuity and actual length of the cable. It should be pointed out that the actual
length of the Slotted Core cable is shorter than the length of the fibers due to the helix of the
fibers built into the OPT-GW.

Correct Storage Incorrect Storage

Figure 2. Proper OPT-GW Reel Storage

2.2 Stringing

AFL recommends that the maximum pulling tension be 20% of the Slotted Core Rated
Breaking Strength (RBS). The actual tension used must be kept constant and chosen such
that adequate clearance is maintained both by the Slotted Core and the attached anti-rotation
devices (see drawing FARD-001 in back of manual) over any conductors and the ground
underneath the Slotted Core Contact with the ground, buildings, trees and other conductors
could damage the cable. The maximum pulling speed is 250 feet per minute (76 m/min)
(2.85 mph) (4.6 km/h).

The speed of the pull should always be slowed considerably as an anti-rotation device
approaches a sheave wheel in order to allow the anti-rotation device to pass smoothly
through the sheave wheel.

Stranded wire or nylon ropes can be used as pulling lines. The line must also be rated strong
enough to withstand the installation tensions required. If an existing shield wire is being
replaced by Slotted Core, it can be used as a pulling line for the Slotted Core after its
condition is carefully assessed to ensure that it will withstand the pulling tensions and will
not fail during the pulling operation. In particular, all splices on the existing groundwire
must be tested for adequate strength. If the strength of the existing cable is questionable,
then it must be replaced with a pulling line.

An anti-rotation device must be attached to the Slotted Core to insure that the cable does not
rotate while being pulled. A typical device is composed of three weighted tails as shown in
the back of this book. Variations of these devices have been successfully used. Please
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 consult the AFL Engineering Department for any inquiries regarding a particular form of
anti-rotation device.

Slotted Core must be attached with Kellem type grips of the appropriate size and firmly
fastened to the cable with screw or punch clamps. The Kellem type grip is then attached to
a full swivel which is attached to the pulling line.

Traveling grounds must be installed on the Slotted Core as it leaves the bull wheel tensioner
to protect craftsmen in case the cable may inadvertently come in contact with an energized
circuit or be energized by induction from a parallel circuit or be hit by a lightning strike.
The tensioner and pulling equipment must also be grounded. Review IEEE Std 524 for a
full list of safety concerns and requirements throughout the installation process.

Guard structures or various types of rope or insulator guards must be installed over crossing
power and telephone lines, miscellaneous obstructions, and road and railroad crossings.

When handling Slotted Core, throughout the installation phase, always apply screw type
(hose) clamps at each end of the Slotted Core cable. Clamps will prevent the outer strands
from unwinding around the central channeled core.

It is possible to pull through several large angles on one stringing section. If a customer has
any concerns regarding the number/severity of angles on a stringing section they should
contact the AFL Engineering Department for advice or recommendations.

At all angles greater than 60°, AFL recommends that a lineman be positioned close enough
to the sheave wheel to assist the anti-rotation device as it passes through the sheave wheel.
If this is not feasible, position a lineman on the ground in direct communication with the
puller operator. Direct communications should be maintained between the puller operator,
tensioner operator and at each structure as the anti-rotation device passes through the sheave
wheel.

Proper communications between all craftsmen when installing Slotted Core are critical to
assure safe and efficient installations. Radio communications on a private local frequency is
the most viable mode of communications.

2.3 Sagging/Clipping In

Slotted Core is sagged in an identical manner to standard shield wires.

Three methods available to arrive at the correct sag/tension are:

1. Stop watch
2. Target
3. Dynamometer

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 The stop watch method is satisfactory for short spans only. The target method is the most
accurate method used on a wide range of spans. The dynamometer method is acceptable if
used on all sag sections.

Sag checks must be made for each 1¼ miles (2 km) of line section to assure proper sags and
tensions between deadend towers. The correct sag and tension is dependent on a number of
factors including span length and temperature. Sag tables are available from AFL for this
purpose.

When Slotted Core is to be tensioned for sagging and deadending, a pocketbook type
(come-along) grip is to be used for clamping on the cable. The grip must be specifically
sized to match the outer diameter of the Slotted Core cable. The only substitute for this
would be an OPT-GW deadened.

To fully protect the OPT-GW, Slotted Core should be clipped in and grounds installed
within 24 hours of sagging and deadending. In an emergency this may be extended to 48
hours if during the first 24 hours, grounds are installed to dissipate a lightning strike.
Aeolian vibration can cause damage to unclipped and undampered Slotted Core if left for
extended periods of time in stringing sheaves. Vibration can be at its highest at initial
installation tensions.

Always be familiar with and observe all local safety rules when working with overhead
electric lines. These installation recommendations do not supersede any local safety
practices or standards.

2.4 Hardware

Under no circumstances should standard shield wire hardware be used during installation of
Slotted Core OPT-GW. Many hardware manufacturers provide hardware designed
specifically for use with OPT-GW. AFL recommends Preformed Line Products, Dulmison
or Alcoa. If a customer wishes to use any other manufacturer they should first contact the
AFL Engineering Department.

Hardware for Slotted Core installations includes dead-ends, suspensions, vibration dampers,
down-lead cushions, splice enclosures, and miscellaneous tower attachment hardware
(anchor shackles, clevises etc.).

Dead-ends are installed at the first and last tower of any stringing section and also on angles
that are too great for suspensions. Armor Grip Suspension hardware sets are used for
tangent structures for angles up to 30°. For angles greater than 30°, dead-end sets or double
suspensions can be used. The maximum angle for double suspensions is 60°.

Down-lead cushions are used to guide the Slotted Core down the tower from the dead-end to
the splice enclosure. Down-lead cushions should be spaced approximately every five (5)
feet (1.5 m). On wood or laminated poles, lag screws or bolts are used to attach down-lead
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 cushions. On steel poles some utilities will allow holes to be bored and tapped, while others
will require stainless steel banding be used. Concrete poles require stainless steel banding
for all down-lead cushions and attachments. On lattice steel towers, down-lead cushions are
installed by boring and installing bolts or the use of clamps over the steel members.

OPT-GW

OPT-GW

Down-lead
Cushions

Tower
Splice Box

OPT-GW Loops

Figure 3. Typical Lattice Tower Build with OPT-GW

When appropriate down-lead cushion extensions must be utilized on lattice structures so the
Slotted Core will clear all steel members. Lattice steel towers tend to vibrate under certain
atmospheric conditions. If the Slotted Core is allowed to touch the steel members the
vibration could cause abrasion resulting in accelerated wear of the outer cable wires.

On certain power lines the shield wire is insulated. This could require down-lead cushions
to be mounted on insulators and must assure there is no contact with steel tower members.
A special investigation and/or design is required for each installation. Contact AFL
Engineering for questions regarding insulated, or sectionalized, OPT-GW systems.

The splice box enclosure contains the trays for mounting the optical fiber splices. Most
utilities require the enclosure to be placed inside a bullet-resistant container. This container
is either bolted or banded to the tower leg approximately eighteen (18) feet (5.5 m) above
the ground line.

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 Vibration dampers are installed to suppress aeolian vibration that can be induced on the
installed Slotted Core by local environmental conditions. The number of vibration dampers
to be installed is dependent on several factors including ruling span, tensions, and loading
conditions. Recommendations for vibration dampers are available from the AFL
Engineering Department or from the vibration damper manufacturer.

Vibration dampers are manufactured in three basic designs. They are the Stockbridge, dog-
bone, and spiral type. Other designs are being investigated including mid-span dampers.

Stockbridge and dog-bone type vibration dampers are mounted on the Slotted Core with
bolted clamps and may be installed over armor rods or directly over the OPT-GW. These
clamps must be tightened to a specified torque using calibrated torque wrenches. Torque
specifications are recommended by the manufacturers of vibration dampers. Spiral
vibration dampers are not location dependent but are typically installed about 6 inches (150
mm)(one hand’s width) from the adjacent hardware armor rods directly on the OPT-GW.
Ensure the gripping section of the spiral damper is nearest the support structure with the
large end of the spiral damper opening towards the span.

3.0 Splicing Procedures

The fibers of consecutive stringing sections must be spliced together to form a continuous
optical path. Completed splices are housed in a splice enclosure for protection. Several
methods are available to splice the fibers but fusion splicing is by far the most popular.

Cable reel length determination must provide adequate excess to allow the Slotted Core to
pass down the tower to ground level and provide additional cable length for splicing.
Splicing is typically performed in climate controlled vehicles or tents and at ground level.
Splicing procedures are maintained by the splicing contractor. Consult your splicing
contractor for splicing procedures. See section 3.2 for a description on cable preparation for
splicing.

3.1 Splice Enclosure

The splice enclosure is typically mounted on the side of the tower approximately eighteen
(18) feet (5.5 m) above the ground. This height above ground is usually adequate to keep
the splice enclosure out of reach of vandals, children etc. Once the fibers are spliced
together and the splices are mounted on splice trays, the trays are inserted into the splice
enclosure which is then attached to the tower. The splice enclosure can be attached to the
structure by any of several methods, or inserted into a bullet-resistant canister. Consult the
splice enclosure manufacturer for details. Excess Slotted Core is coiled up and attached to
the tower under, around or beside the splice enclosure. The cable coil can be attached to the
structure by the use of modified down-lead cushions or stainless steel banding. This will
allow the enclosure to be easily accessed for future maintenance if required.

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 The coil should be at least three (3) feet (0.91 m) in diameter to avoid excessive bending and
damage to the cable and fibers.

3.2 Cable Preparation

Refer to Figure 4 for description of cable preparation for splicing.

Cable preparation for splicing to be performed by fiber splice crew.
a) Determine location on cable where splice point is to be located.

b) Measure and mark ten (10) feet (3 m) of cable for splice preparation. Attach a hose
clamp at the ten (10) feet (3 m) mark. This will keep the outer strands in place while
the strands are cut.

c) Use a hacksaw to cut the strands six (6) inches (15 cm) from the clamp. Only cut
strands approximately ¾ through the diameter - not completely through in order to
prevent damaging the central channeled core and fiber.

d) Remove the strands (and aluminum tape if present) from the cable, exposing the
aluminum core with the buffer tubes. Unwrap the additional six (6) inches (15 cm) of
strands (and remove additional aluminum tape if present) so that it will be possible to
apply sealing tape around the core underneath the ends of the wires. Sealing tape is
available from Preformed Line Products part #80801796 and General Sealant Co. part
#GS-37.

e) Clean the surface area only under the wires and around the channel core so that tape will
adhere to the core. Apply one (1) or two (2) half lapped layers of tape around the
channel core so that when the wires are again wrapped around the core, the excess tape
will fill the interstices between the wires. Rewrap the wires around the core and the
sealing tape. The sealing tape should only be located under the last six (6) inches (15
cm) of wire.

f) Prepare the outside of the wires in a similar fashion applying sealing tape to the last six
(6) inches (15 cm) of stranding.

g) Install the cable in the splice enclosure end cap per manufacturer's instructions.

h) Carefully remove the buffer tubes from the exposed core one at a time. Be careful not to
kink the tubes during handling.

i) Cut the core so that two (2) inches (5 cm) will extend from the ends of the stranded wire.
Remove any burrs or sharp edges from the central core slots so the tubes will fit easily
back in place.

j) Replace tubes in the slots and wrap electrical tape around the remaining two (2) inches
(5 cm) of core over lapping one half (½) inch (1.2 cm) beyond the core. This will
secure the tubes and help prevent kinking the tubes during handling.
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 k) Secure the buffer tubes in the splice tray per the manufacturer's instructions.

l) Fiber breakout of Slotted Core is based on fiber color coding and fiber bundle color
coding. Color sequencing is based on TIA/EIA Std 598. For buffer tubes of 12 fibers or
less, standard BLUE – AQUA fiber coloring is applied. For buffer tubes containing
more than 12 fibers, fiber bundles are created using colored identification thread. Each
colored thread contains up to 12
colored fibers. Identification thread is also applied in the standard BLUE – AQUA color
sequence. Bundle separation is performed in the following manner:
(1) remove approximately 1 meter of buffer tube,
(2) hold with one hand the end of the exposed total group of fibers to prevent the
identification threads from unwinding,
(3) where the fibers exit the buffer tube - gently work the fibers to grasp one
identification thread then work that thread up the 1 meter to the hand held end in
order for the thread to separate its fiber bundle from the others (ensure hand held end
remains grasped),
(4) repeat steps for remaining fiber bundles.

m) After completion of the splicing operation, assemble the splice enclosure in accordance
with the manufacturer's recommendations. Repeat the above procedure for each cable
end that will need splicing.

Clamp

Stranding

Core Fiber
Buffer Tube

2"
6"

10 '

Figure 4. Slotted Core Prepared for Splicing

Page 11 of 12 2000 Edition, Issue 1

 REFERENCE A

STRINGING AND HANDLING OPT-GW DIAMETERS

AND

BENDING RADIUS

The following guides apply to Alcoa Fujikura Ltd. OPT-GW Optical Groundwire
with a central pipe/slotted core configuration:

1. Maximum OPT-GW recommended stringing tension is 20% of the rated

breaking strength.

2. The minimum bull wheel diameter for tensioners is 70 x D (where D

represents the nominal diameter of the OPT-GW).

3. The recommended stringing sheave (root) diameter is 40 x D (Based on 30°

through angle and maximum stringing tension of 20% of the rated strength
of the OPT-GW).

NOTE: Refer to next page for additional information on minimum

diameters of the stringing blocks for other conditions.

4. The minimum permanent bending radius for the OPT-GW is 20 x D.

NOTE: Based on actual OPT-GW size, etc., care must be taken when
bending the OPT-GW to avoid kinking the strands and, therefore, damaging
the optical fibers contained therein.

5. The minimum permanent bending radius for the OPT-GW aluminum pipe is
15 x d (where “d” represents the diameter of the aluminum pipe/slotted core).

6. The minimum permanent bending radius for the optical cable unit is 3
inches.

7. The minimum permanent bending radius for the optical fibers is 1.5 inches.

Page 12 of 12 2000 Edition, Issue 1

 REFERENCE A (Continued)

The following are minimum diameters of stringing blocks at:

1. First Structure

The minimum stringing (sheave) block diameter (root) of 40 x D (where

“D” represents the diameter of the OPT-GW) is considered satisfactory if
the pulling line slope is at least three horizontal to one vertical from the
traveler to the site and the stringing tension does not exceed 20% of the
OPT-GW’s rated breaking strength.

2. Intermediate Structures

The minimum stringing (sheave) block diameter (root) for various stringing
tensions and sheave thru angles are shown on the attached graph entitled:

“Minimum Sheave Diameters for Stringing Tensions versus Thru Angle for
AFL OPT-GW Installation Through Tangent Structures only.”

The minimum recommended sheave diameter is 8 inches independent

of the tension or angle.

3. Angle Structures

For stringing angles greater than 60°, a minimum sheave root diameter of 60
x D is recommended.

For stringing angles greater than 20°, a minimum sheave root diameter of 40
x D is recommended.

For stringing angles of 20° or less, a minimum sheave root diameter

of 30 x D is recommended.

Page 12 of 12 2000 Edition, Issue 1

 REFERENCE A (Continued)

Page 12 of 12 2000 Edition, Issue 1

 B

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