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Module Four - Activity 3- Preparing Fibre

Please review the safety section for this module before proceeding with this activity - preparing fibre can be dangerous.

This activity begins with a general overview of fibre preparation, followed by step-by-step instructions.

 



The purpose of preparing fibre-optic cable is to make it ready to be spliced by a fusion splicer, or to have mechanical connectors attached. In the preparation of fibre, the following steps are taken to expose the desired length of fibre optic strand and its buffer tubes:

  • the outer hard jacket and corrugated metal armour are removed
  • unnecessary aramid yarn insulation is cut away to the same length as the outer jackets
  • "filler tubes" which are plastic or foam strands the same diameter as fibre buffer tubes are cut away
  • the strength member is cut to an appropriate length for installation (depending upon the application - strength members are often clamped into place in fixtures to help stabilize and support the fibre,
  • the buffer tubes are carefully handled throughout to ensure that no nicks, scrapes, or damage is inflicted on the tubes, thus protecting the fibre optic strands.

Once these steps are completed, a length of the buffer tube is cut away, exposing the multi-coloured fibre strands. The fibre strands are then carefully and thoroughly cleaned in preparation for either splicing or connectorization.

This summary makes this job sound very simple. However, it does take some time, as fibre optic cable jackets are very difficult to cut through, and the utmost care must be taken in the process. Additionally, the cleaning process must be carried out carefully and thoroughly so that the fibre will be easy to work with during splicing, connectorization, system installation and maintenance.

Although preparing fibre optic cable can be a difficult and somewhat tedious job, there can be enormous cost savings by preparing the cable instead of paying someone else to do this work.

Next are step-by-step instructions on fibre preparation.

 

Strip away the first few inches of outer jacket and armour: First cut away the outer jacket and corrugated aluminum armour, using side-cutters. USE EXTREME CAUTION during this process - the aluminum (or sometimes steel) armour is EXTREMELY SHARP and will cut skin to ribbons.

A carpet knife is also a handy tool to have during this process - it can be used to cut through the outer jacket to give an easier starting point to work with the sidecutters.

     
 

Once the outer casing and armour have been removed, the rip-cords can be exposed. Any of the aramid yarn which is in the way may be cut off using scissors. This will allow a non-slippery spot to hang onto the end of the exposed inner parts of the fibre cable.

As soon as the casing is off, the buffer tubes must be carefully handled. They contain the fibre strands, and must not be poked into anything, or especially anybody.

     

Be careful not to slice yourself on the pliers or on the armour cladding!
 

Once the rip cord(s) is exposed, wrap several turns of it around a pair of needle nose pliers. Grab the head of the pliers firmly, hold the cable firmly with the other hand, and pull very hard to rip the outer jacket open along its length.

This job may be easier with two people, and may take some practice: it is not easy. The outer jacket is VERY hard, and pulling on the ripcord takes a LOT of effort.

     
The amount of fibre that you wish to expose will depend on the activity that is being completed: exterior splice enclosure, interior splice, etc., however a good rule of thumb is that you can never have too much additional fibre slack. Baring a minimum of between four to six feet should be sufficient for most applications.
     

Once the length of fibre has been achieved, cut off the spare filler tubes so that they are flush with the end of the outer casing that remains.

If the fibre being used has a fibreglass or kevlar strength member, determine from the specifications for the specific fibre use what length the strength member should be. Some exterior splice enclosures and some interior fibre mounting racks have special clamps for mounting the fibre strength member so that the fibre will be supported properly. Cut the strength member to length using side cutters.

 
     
 

Next, the majority of the buffer tube will be removed, exposing the fibres. It is VERY CRITICAL during this operation that:

  • the buffer tube be scored all the way around with a knife, but NOT cut through,
  • that BLADES NOT COME NEAR THE FIBRES WITHIN THE BUFFER TUBE - this can not be emphasized enough. DO NOT NICK, scrape, or get blades anywhere near the fibre strands.

     
If individual fibres are left in tact, they are VERY STRONG (see above.) It is possible to put a great deal of pressure on them, and they will not break. A fibre will cut through your hand sooner than it will break. HOWEVER, if the fibre strands are nicked, scratched, or scraped, THEY WILL BREAK EASILY. Therefore, it is critical to the entire fibre optic installation that the fibres be WELL TAKEN CARE OF! Even small fractures will effect acceptance testing readings on an OTDR (Optical Time Domain Reflectometre).
     
Once the buffer tube is scored all the way around, it can be carefully removed, exposing the fibre. The fibre is then carefully cleaned using a special cleaning system. When properly cleaned, the fibre will "squeek" and will easily fall away from the other strands of fibre, not sticking at all. The fibre can then be gently rolled up and is ready to be connectorized or spliced.