Conduit Maximization Solutions - BICSI · • A 500’ reel of Fabric mesh weighs less than 60lbs. MXC / Standard is commonly used for general applications of deploying new or overriding

Conduit Maximization Solutions Lowering the Costs of

OSP/ISP Projects

Infrastructure Considerations

• Future buildings/Work Stations

• Environmental issues

• Potentially hazardous situations

• Road construction

OSP & ISP Choices

• Aerial

• Direct-buried

• Underground (conduit)

• Media

• Pathways and spaces

Why Underground?

• Advantages

– Maintain property’s aesthetic appearance

– Easy to add or remove cables

– Conduit provides physical cable protection

– Easy to locate

• Disadvantages

– High initial installation cost

– Requires detailed planning route

Considerations

• Number of conduits required

– Existing needs

– Spare for maintenance

– Future growth

• Utilities / Right of ways

Maximizing Cable in Conduit

• Pull cable over cable

• Pull cable inside rigid or HDPE innerduct

• Pull cable through mesh innerduct

• Air blow cable (OSP)

• Microduct

• MaxSpace (OSP)

Cable Protection During Installation

• Use innerduct to sectionalize the available duct space

• Without innerduct additional cable pulls may

– Entangle an existing cable

– Cause an interruption in existing service

• As much as possible, ensure that the innerduct is installed without twists, coils, or bunching. (twists increase cable-pulling tension) TDMM 12th ed: 6-43

Fabric Innerduct designed for deploying communication cables.

The flexible nature of Fabric mesh innerduct enables it to take the shape of the cables, allowing more cables to be placed within a conduit.

Fabric Innerduct

Fabric Innerduct

General Product Overview

• Fabric Mesh is available in four standard sizes (4”, 3”, 2”, and 1.25”) • The sizes match the minimum recommended conduit size in a 3-Cell product

• Most styles are available as 3-Cell, 2-Cell or 1-Cell configurations

• Six color of identifying thread are available (black, blue, red, green, white, yellow)

• Pull tapes are pre-installed

• Standard reel sizes are 250’, 500’, 1000’, 2650’, 5300’

• Custom sizes are available over 500’

• Small reel sizes that are easier to work with in restricted space locations • More than 1000’ of Fabric mesh can fit on a 33”x15” reel • A 500’ reel of Fabric mesh weighs less than 60lbs.

MXC / Standard is commonly used for general applications of deploying new or overriding cables. MXD / Detectable is imbedded with a permanent 18 gauge copper wire. It is widely used in longer run green field applications to enable future location of system breaks. MXP / Plenum is used for in building enterprise applications. MXR / Riser is used for vertical applications, either elevator shaft or data communication closet silos in building projects.

General Product Overview

Test 1

Cable on Cable vs. Cable in Fabric

Innerduct

Test 1 – Cable on Cable vs. Cable in Fabric Innerduct

Oct 24, 2011 / Conducted by Milliken USA in Georgia, USA.

Cable Spec 13 mm OD PE Fiber Optic cable

Outer Duct Spec 50 mm ID PE Pipe

MaxCell Spec 4th Generation MaxCell 5222-2

Cable Pulling Tension 140 kg

Cable Pulling Speed 25 meters / min

Cable Pulling Duration 10 minutes (equivalent of 250 meter pull)

20 minutes (equivalent of 500 meter pull

30 minutes (equivalent of 750 meter pull)

Test Conditions & Method

Test Method Test Result

Cable on Cable 250m Pass

Cable on Cable 500m Fail

Cable on Cable 750m Fail

Cable in Fabric Innerduct 750m Pass

Test Results

Pass Fail Criteria : Having no significant external damage on the cable sheath


Control: Cable Observation Before Test

<Cable on Cable > <Cable in Fabric Innerduct>


Cable Observation After Test

<Cable on Cable 250m > < Cable on Cable 500m >



<Cable on Cable 750m > < Cable in Fabric Innerduct 750m >


Cable Sheath Flakes Collected After “Cable on Cable” 750m test


Test 2

Fabric Innerduct vs. PVC Pipe

April 11, 2011 / Conducted by Milliken USA in Georgia, USA.

Cable Spec 13 mm OD PE Fiber Optic cable

Outer Duct Spec 50 mm ID PVC Pipe

MaxCell Spec 4th Generation MaxCell 4418-2

Cable Pulling Tension 125 kg

Cable Pulling Speed 25 meters / min

Cable Pulling Duration 10 minutes (equivalent of 250 meter pull)

Test Conditions & Method

Test 2 – MaxCell vs. PVC Pipe

Test Method Test Result

Cable in PVC pipe only Fail

Cable in Fabric Mesh Pass

Test Results

Pass Fail Criteria : Having no significant external damage on the cable sheath

Cable in PVC pipe only - Significant cable sheath damage was observed. - High amount of cable sheath flaked off the jacket. - Higher pulling tensions and longer pulls may lead to possible signal failure.


Control: Cable Observation Before Test

<Cable in PVC pipe only> <Cable in MaxCell>



<Cable in PVC pipe only> <Cable in MaxCell>


Cable Sheath Flakes Collected After “Cable in PVC Pipe Only” Test


Lower Warehousing Costs

Lower Shipping Costs Fabric mesh is 1/12th the Weight

Fabric mesh is 1/7th the Volume

48,000 Rigid Innerduct Feet

7 Reels

13,700 lbs

224 Sq. feet

48,000 Fabric mesh 3” 3 Cell Feet

3 Reels

1,500 lbs

36 Sq. feet

Value Proposition

Value Proposition

According to NECA’s Manual of Labor Units (MLU) • Shows that the time to place 1000 feet of one three

inch, three cell is 8 hours

• Shows that the time to place 100 feet of one inch innerduct is 3 hours - the equivalent of 30 hours per thousand feet – under normal circumstances according to the report.

• The report also found that, under what NECA defines as “very difficult” conditions, installation of fabric mesh flexible innerduct is even more advantageous than traditional rigid innerduct.

Value Proposition

How much less would a construction project cost if you could reduce the trench size and number of required ducts by up to 66%?

Value Proposition- 300% Greater Cable Density

Enterprise • Less conduit installation

time and expense • Fit more cable in risers • Space for overlaying

migration cable

Outside Plant • Less conduit installation

time and expense • Dig smaller trenches • Faster installation

Fabric Mesh

Mesh

Value Proposition- 3X Faster Installations

Enterprise • Less conduit to install • Can often be installed by hand

reducing set-up & tear-down time • Overlay options can eliminate need

for adding new riser

Outside Plant • Less conduit to install • Higher density equals smaller

trenches to dig • Overlay options can eliminate

trenching all together

Value Proposition- Safely Overlays Existing Cables or Innerduct

• If a contractor using fabric mesh is bidding against a contractor using rigid in an overlay opportunity…Fabric Mesh solution will be lower in cost and could still provide the same amount pathways.

Enterprise • Add cables to existing riser • Overlay fiber to an existing

UTP pathway

Outside Plant • Overlay options can offer a

NO DIG SOLUTION

• For every million feet of single-cell MaxCell brand fabric mesh installed

instead of HDPE Innerduct, the resulting carbon savings are 644 metric

tons CO2 equivalent.

• These Green House Gas (GHG) savings are equal to the annual GHG

emissions from over 126 passenger vehicles on the road or over 72,000

gallons of gasoline consumed.

• MaxCell brand is currently undergoing certification review by the

Carbon Trust.

Green

Performance Advantages

• Fabric Mesh Maintains Low Cable Pulling Tensions

• Coefficient of Friction of fabric mesh is 30%+ lower than HDPE

• Fabric mesh does not possess reel memory; will not spiral like HDPE innerduct

• Fabric mesh will not twist during installation when using swivels

• Fabric mesh will not creep or walk while installing cables

• Fabric mesh can be installed in conduits with many sweeps and bends

• Fabric Mesh Protects the Cable and Conduit

• Pull Tape will NOT burn through fabric mesh

– Melting Point of fabric mesh = 485° F, while HDPE = 220° F

• Separates cables to prevent abrasion

• Fabric mesh is not Affected by Long Term Exposure to Common Ground Chemicals, Petrochemicals, Fresh or Salt Water

Fabric Innerduct Solutions

Curb to Building & Fiber to Cell Sites

Problems

•Place Fabric Mesh in empty duct •Overlay Fabric Mesh in existing congested duct

Fabric Mesh Solution

General Benefits •Avoid construction •Quick deployment – reduced cycle time •No special equipment needed – hand pulls •Less manpower required per installation

•Existing PVC or HDPE – short runs typically less than 500ft •Limited or congested ducts •Patchwork designs with numerous sweeps & bends which

make placing conduit or microduct difficult

Curb to Building

Benefits • Installed Fabric mesh and cable in less than 1 hour

• Set-up time was 15 minutes vs. normal 40 minutes for duct

& cable

•Placed copper cable and fabric mesh at same time – single pull

•Additional pathways available for future changes or adds.

Outer Duct : 100mm PVC Outer Duct – Trenched from pole to building

Existing Cable : None

Pulling Distance : 200 meters with three 90’s

MaxCell : 3” 3-Cell

Number of workers pulling :

4 – two on each end required for safety

Time consumed : 45 minutes for fabric mesh & cable – “piggy-back”

Overbuild

Problems

•Pull fabric mesh over existing cables or innerduct (Overbuild) allowing additional cable(s) to be pulled into dedicated pathway(s)


General Benefits •Avoid new construction of additional outer duct/inner ducts (~$3-200/ft) •Save remaining empty ducts in congested areas for future network

additions/changes •Decrease time required to startup network

•Existing outer ducts occupied with cables and/or PE rigid inner ducts •Desire not to utilize last empty duct •Microducts are difficult to place into occupied ducts •Rigid innerduct may damage existing cables

• The use of fabric mesh Innerduct prevented new construction cost, time, and solved a 5 year plus problem area.

• Have (2) additional raceways for future use.

• New construction costs for a 4”conduit with (3)1 ¼ innerducts were estimated at over $100,000. (This is not including the down cycle time and additional costs for permits from the city)

Section Conduit

ID Existing Cable

Pull Length,

ft

Sweeps / Bends

Fabric mesh Installation Cable Installation

Style Time Crew OD Time Crew

1 4 (2)

1.25” IPP

944 ft. Straight (1) 3x3 20 4 Man -

HP 144

Fiber 15

3 Man - HP

Overbuild

• Section 1 and 2 prevented new construction time and cost.

• Total Cost savings Est. $30,000

Section Conduit

ID Existing Cable

Pull Length

Sweeps / Bends

Fabric mesh Installation Cable Installation

Style Time Crew OD Time Crew

1 4 300 pair

copper 130 Straight 3x3 20

3 Man - HP

144 ct, 0.7

5 2 Man -

HP

2 4 300 pair

copper 550 Straight 3x3 10

2 Man - HP

n/a n/a n/a

Overbuild

Right of Way Obstacles

Problems

•Insert fabric mesh to create more usable space upfront •Overlay fabric mesh and cable in existing conduit •Place fabric mesh & cable at same time to save space


General Benefits •Saves permitting time and cost •Can eliminate need for permitting altogether •Minimizes traffic disruption •Cycle time reduction

•Railroad crossings require significant permitting cost & time (~$5000/permit)

•Inability to obtain digging (boring, trenching, etc.) permits •Construction can inhibit traffic and create safety hazards for crew

Right of Way Obstacles

Benefits • Saved time in placing fabric mesh

• Saved $5000 in permitting costs alone

• No special equipment – standard pulling equipment

Install: Piggyback fabric mesh and copper cable Under Railroad

Outer Duct : 100mm Threaded Steel Pipe – Tack Welded at Joints


Pulling Distance : 122 meters – unknown number of 90s

MaxCell : Two packs 4” 3-Cell

Cables: 600 pair copper and 48 strand armored


4

Time consumed : 1.25 hours

Bridges

•Fabric mesh in overlay or new construction


General Benefits •Fabric mesh optimizes space with the existing conduit structure •Provides future pathways •Lower coefficient of expansion eliminates growth or contraction with

temperature changes •Fabric mesh adds less weight vs. HDPE

•Limited conduit space •Limited space to maneuver equipment •Exposure to elements causes expansion & contraction of HDPE conduit

Problems

Bridges

Benefits • Entire installation time was 8 hours vs. 8 days for innerduct

• Crew of 4 versus crew of 8 to place innerduct

• One single pull each for fabric mesh and cable

Outer Duct : 100mm PVC – Concrete encased


Pulling Distance : 1830 meters - six 45 bends

MaxCell : 4” 3-Cell

Cables: Three 96 ct fibers


4

Time consumed : 8 hours

Fabric Mesh Markets

Universities, Colleges, and K-12 that continue to expand networks to bring services to the classroom, dorm, or desk.

Airports, both internal to terminal/gate service offerings as well as field based communication systems.

Fabric Mesh Markets

Cable TV An historic market for fabric mesh, awaiting the sure-to-come replacement of a coaxial based network with full fiber technologies.

Telecom/RBOCs Current significant market of fabric mesh with VIOS and FTTx network construction combined with Fiber technologies replacing antiquated twisted pair networks.

Fabric Mesh Markets

Enterprise/Fortune 500 Large multiple building corporate campuses as part of large Enterprise market.

Cellular Towers Recent market developed over need of providers to hard wire base stations to near by land lines due to bandwidth limitations

Frequently Asked Questions

• By using Fabric Mesh, aren’t you exceeding the maximum fill ratio for a conduit stated in the BICSI and ANSI documents? – Answer – – There are no fill ratios for Communication wire and cables

• (NEC)NFPA70 2011 Article 800 Section V 800.110

Page 70-675 Part A (2) (B) Raceway Fill for Communications Wires and Cables. " The raceway fill requirements of Chapter 3 and 9 shall not apply to communications wires and cables" Also, the fill ratio table (Table 1 Page 70-711) in the NEC has the word "should" in the requirements. For example, Informational Note No. 1 "a larger size conduit or a lesser conduit fill should be considered"

• Is Mesh Innerduct recognized in the BICSI OSP Manual? In the ANSI OSP 758 Manual? – Answer – Yes it is recognized in both manuals

• Will groundwater, mud, chemicals affect Mesh? – Answer – No.

• Will fabric mesh dry out and stick together? – Answer – No.

• Will the weight of cables in multiple fabric mesh packs make it hard to pull in future cables? – Answer – Not in our experience

Frequently Asked Questions

Don’t Dig –

MaxSpace

Since 1982, rigid innerduct has been used in conduit infrastructure

4” Conduit 3 1/2” Clay Conduit

Rigid innerduct allowed cables to be placed when needed

without having to pull cables over .cables, which can damage both cables.

Rigid innerduct also allowed cables to be placed for longer distances with cable blowing.

After 500m: Cable Jacket Clearly

Damaged

After 250m: Slight Damages

After 750m: Cable Jacket Heavily

Damaged

Cable at Start

Installed rigid innerducts in outer conduits over time eventually fill to capacity with operating cables.

Second cable placed Final cable placed First cable placed

Trenching • New conduits in major cities can

cost $300-$700/ft. Trenching can be as slow as 6” per hour.

• Recovering conduit is a small fraction of the cost and 100 to 1000 times faster – up to 10ft/min removing ducts and placing Fabric Mesh.

Once a conduit is full, operators have to install new conduit to expand services

Utilizing rigid innerducts is an ineffective use of the conduit space – a major reason Fabric Mesh was developed.

Innerducts take up to 80 – 90% of usable conduit space. Three .75” diameter cables use only 10% of the space in a 4” conduit.

Benefits for Your Network

• Recover up to 90% of conduit space

• Add up to 9 new cables

• No disruption of service

• Cables can be placed immediately

• Safer than trenching or boring around current infrastructure

• Service customer needs faster

Benefits for Your Budget

• Save significant costs – SIGNIFICANT

• A NO DIG Solution

• NO engineering costs

• NO new trenches

• NO new conduit

• NO trenching permits required

• NO EPA oversight

• NO Right-of-Way red tape

• NO property restoration costs from trenching or boring

Benefits for Your Construction Project

• Fast Process - A NO DIG Solution

• Remove innerduct in a fraction of time of trenching or boring

• Compact machine for tight vault spaces

• Less than 50 lbs. of tension on cables

• Install Fabric mesh during same service

• Easy Disposal/Recycling of rigid innerduct

• Homeowners and businesses are not inconvenienced

• Safer for pedestrian traffic

Reclaim Your Network

Patents Pending

Renew Remove Recover

Existing conduit completely occupied with conduit with operating cable.

First Innerduct Removed

Second Innerduct Removed

All innerducts removed. Recovered 90% of conduit space.

No

Disruption

of Service

Three Fabric Mesh packs installed in recovered space.

Conduit with nine cables

45% space used

Schematic of Splitter

The cable is protected by Split Metal Protector Sleeve

Downside to Digging

Trenching and

Digging are

expensive, time

consuming and

disruptive.

Easy disposal and recycling of rigid innerduct. As part of the process, extracted innerduct is chipped, bagged, recycled.

Patent Pending

Both the method of removing innerduct over operating cables and recovering space and the specialized equipment used are patent pending and protected.

Blocked Clay Tile conduit before MaxSpace

After MaxSpace 2 active Cables and Fabric Mesh to allow 3 new cables

MaxSpace & Fabric Mesh = Conduit Maximization Solutions

Conduit Maximization Solutions

That lower your bottom line!

Questions?

Conduit Maximization Solutions - BICSI · • A 500’ reel of Fabric mesh weighs less than 60lbs. MXC / Standard is commonly used for general applications of deploying new or overriding

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