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ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Specification for trenching of optic fibre and for the erection of self-supporting optical
fibre cable on traction masts, optical fibre accessories for installations in the PRASA
environment.
NON-DISCLOSURE OF INFORMATION
Information contained in this document is proprietary in nature and/or protected by copyright.
Please obtain written permission from the Author prior to reproducing this document, in
whole or in part.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
TABLE OF CONTENTS Part A: Erection of self-supporting optical fibre cable on traction masts. I ABBREVIATIONS, ACRONYMS AND DEFINITIONS............................................................................................5
II RELEVANT DOCUMENTATION APPLICABLE ....................................................................................................6
III RELEVANT DRAWINGS AND PHOTOS.................................................................................................................7
1. SCOPE AND PURPOSE..................................................................................................................................................8
2. SPECIFICATIONS AND DRAWINGS......................................................................................................................14
3. DESIGN AND APPROVAL..........................................................................................................................................15
4. SURVEY............................................................................................................................................................................19
5. INSTALLATION............................................................................................................................................................21
6. Tensioning......................................................................................................................................................................23
7. Cable Slack......................................................................................................................................................................24
8. Intermediate Poles.....................................................................................................................................................25
9. SAFETY PRECAUTIONS..........................................................................................................................................26
10. SPLICING, TERMINATION AND TESTING......................................................................................................28
11. FINAL ACCEPTANCE..............................................................................................................................................30
12. ANNEXURE 1: SAMPLE OF "AS BUILT" DRAWINGS..................................................................................32
13. ANNEXURE 2: SAMPLE OF "EQUIPMENT" ...................................................................................................33
A. Blocks……………………….…………………………………………………………………………..32
B. Pulling Grips and Devices………………………………………………………………………..34
C. Blocks, Chutes and Brackets……………………………………………………………………35
D. Lashers, Pullers, Positioners and Guides………………………………………………….36
E. Lifting tools and Brakes………………………………………………………………………….38
F. Fibre Preparation and Splicing…………………………………………………..…………..39
14. ANNEXURRE 3: Drawings And Photos………………………………………………….…………………….……40
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
PART B: Optical fibre accessories used in the PRASA environment.
Document Abbreviations Acronyms and Defintions........................................................................47
1. Scope ...............................................................................................................................................................48
2. Introduction …..............................................................................................................................................48
3. Optical fibres.................................................................................................................................................49
4. Ruggedizing………........................................................................................................................................49
5. Outer sheaths ..............................................................................................................................................49 6. Pigtails and patch - lead identification .............................................................................................49 7. Dust caps .......................................................................................................................................................50 8. Mid - coupler (bulkhead) ........................................................................................................................50 9. Connectors.....................................................................................................................................................51
10.Optical distribution frames and racks .............................................................................................52 10.1 ODF's must be available in three different types ......................................................52 10.2 Wall Mount Unit ......................................................................................................................52 10.3 19 inch stackable ODF sub rack ......................................................................................53 10.4 Specialized main ODF Rack or Cabinet..........................................................................53 11. Splice protectors.......................................................................................................................................54 11 1 Heat Crimping Type................................................................................................................54 11.2 Mechanical Crimping Type..................................................................................................54 12. Joint closure with splice organizer……………………………………………...……………….…….54
13. Training........................................................................................................................................................55
14. Manufacturing ………..............................................................................................................................55 15. Extent of testing .......................................................................................................................................56
16. Inspection ……............................................................................................................................................56
17. Samples.........................................................................................................................................................56 18. Packaging.....................................................................................................................................................56 APPENDIX A: Optical performance of connectors …........................................................................57
APPENDIX B: Testing of assemblies .......................................................................................................58 APPENDIX C: mechanical performance of ruggedized assemblies…........................................62
(Un-ruggedized pigtails are excluded from these tests)
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
PART C: Trenching of Optic Fibre Cable
1. INTRODUCTION ………………………………………………………………………………………………..65
2. SCOPE ………………………………………………………………………………………………………………....65
3. TECHNICAL REQUIREMENTS …………………………………………………….………………………...65
3.1 Trenching and Laying of Cables ………………………………………………….........………………...65
3.1.1 Trenching dimensions………………………………………………………..………………...………….65
3.1.2 Bedding and Padding ……………………………………………………...……………………………….65
3.1.3 Back-fill …………………………………………………………………………...……………………………..66
3.1 4 Reinstatement ………………………………………………………………….……………………………..66
3.1.5 Route Layout ……………………………………………………………..…………………………………66
3.1.6 T-Off points from main route ………………………………………………………….………………..66
4. MANHOLE SPECIFICATIONS …………………………………………………………..……………………67
4.1 Dimensions …………………………………………………………………….…………………………67
4.2 Drawings ………………………………………………………………………………………………………….68
4.3 Construction ……………………………………………………………………...………………………………70
4.3.1 Material …………………………………………………………………………………………………………70
4.3.2 Concrete ………………………………………………………………………...……………………………….70
4.3.3 Waterproof material ………………………………………………………….……………………………70
4.3.4 Mixing method and ratio ………………………………………………………………………………..70
4.3.5 Top Surface / Finish ….…………………………………………………………………………………….71
4.3.6 Retainer Walls ………………………………………………………………………………………………..71
4.4 Frames and Covers ……………………………………………………………………………..…………...71
4.5 Frame and Cover Support …………………………………………………………………………………..74
4.6 Slack Management ……………………………………………………………………………..………………74
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
I ABBREVIATIONS, ACRONYMS AND DEFINITIONS
ABBREVIATIONS
AND ACRONYMS
DESCRIPTION
AC Alternating Current
"As-Build" Draw-
ings
Final drawings of a site and/or route installation of trans-
mission infrastructure as presented to the customer at
handover.
BS British Standard
DC Direct Current
GPS Global Positioning Satellite (a system whereby the latitude
and longitude co-ordinates of any site on earth can be de-
termined via a GPS receiver)
HDPE High Density Polyethylene
Kv Kilo-volt
Nm Newton Meters
OFC Optical Fibre Cable
OHTE Overhead Traction Equipment
OTDR Optical Time Domain Reflecto meter
QAD Quality Assurance Department
SOP Standard Operating Procedure
PRASA Passenger Rail Agency of South Africa
UV Ultra Violet
GIS Geographical Information System
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
II RELEVANT DOCUMENTATION APPLICABLE
SPC-00029: Trenching, Laying and Hauling in of Communication Cables
SPC-00033: Optical Fibre Testing Equipment
SPC-00575: Planning and Erection of Self Supporting Optical Fibre Cable on Traction Masts
SPC-00583: Optical Fibre Accessories
SPC-00587: Horizontal Directional Drilling
SPC-00588: Optical Fibre Cable Ducts
SPC-00589: Civil Engineering Works associated with Underground Telecom Plant
SPC-00590: Working to Way leaves, Site Establishment, Safety and Local Authority Re-
quirements
SPC-01242: Wooden Poles for OFC Installations
SPC-01279: Erection of Wooden Pole Routes
PRC-00106: Post installation Test for Optical Fibre Cables
PRC-00107: Pre-testing of Optical Fibre Cables on Drums
PRC-00112: Written Safe Working Procedures for Erection of ADSS OFC on AC OHTE
E7/1: Works on, over, under or adjacent to railway lines and near high voltage equipment.
E.4E: Compliance with the Occupational Health and Safety Act (Act 85 of 1993)
SOP-0H00: Safe Work Procedure for working in confined spaces
BBF1026: Generic Equipment Cabinet
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
I1 RELEVANT DRAWINGS AND PHOTOS
DRAWING NO. DESCRIPTION
Drawing1 PLP Dead End
Photo 5 Method of Application of Dead End
Drawing 2 PLP Fibre Optic Targent Support
Photo 4 Method of Application of PLP Fibre Optic Targent Sup-
port
Drawing 3 Suspension fitting for double boom masts or steel bridges.
Drawing 4 Method of bringing cable down mast and insulating mast
from ground.
Drawing 5 Method of bringing cable down mast and insulating mast
from ground.
Drawing 6 Method of bringing cable down mast and insulating mast
from ground.
Photo1 Approved stringing pulley for fibre optic installation
Photo 2 Cable Suspension Bracket
Photo 3 Termination Bracket
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
1. SCOPE AND PURPOSE
The Scope of work
1.1 Introduction
1.1.1 PRASA requires the installation and commissioning of 96 fibres OFC in various rail-
way corridors. Details of spurs and terminations, specific to each section, will be provided
1.1.2 Emphasis is placed on safety and safe working procedures and Respondents shall ad-
here to all instructions and procedures issued with this tender enquiry, especially the Written
Safe Working Procedure PRC-00112 and all its associated documents as well as provisional
SOP 0H00 for working in confined spaces. If Respondents intend climbing masts, strict ad-
herence to minimum safe clearances must be maintained.
1.1.3 The new 96 fibre OFC must be installed in parallel with an existing working fibre cable,
carrying high bandwidth services, and no interference with this cable will be allowed. The
intention is to install the new cable above the existing cable. The underground cable need to
be installed in the opposite side of the railway. Spare cables are required as indicated in the
BOM.
1.1.4 The work must be planned to ensure minimal interruption to normal train services. Un-
derground track crossings must be executed by means of the “directional drilling” method
specified.
1.1.5 Respondents must note that many of the underground track crossing works may have to
be conducted at off peak hours to reduce disruptions to train services. They must allow for
significant overtime and weekend working.
1.1.6 Maximum benefit must be gained from normal electrical and track occupations request-
ed by other departments. It is therefore imperative that the PRASA regional personnel attend
the regular “occupation” meetings arranged by Train Operations.
1.1.7 Respondents must take specific note of the safety aspects as depicted in Written Safe
Work Procedure PRC-00112 as well as the safety arrangements and instructions attached
thereto and procedural compliance with the Occupational Health and Safety Act; Act 85 of
1993 and regulations. A full Statement of Compliance must be submitted for WSWP PRC-
00112, and this compliance document must be included in the Respondent’s Site Safety File.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
1.1.8 An Occupational Health and Safety Plan and Risk Assessment must be outlined in the
tender document and submitted to the Project Manager by the successful Respondent before
work commences. The Risk Assessment and Safety Plan must also be placed on the Re-
spondent’s Site Safety File.
1.1.9 Safety induction by PRASA electrical officers is required before commencement of
work. Minimum safety clearances from live electrical conductors and Safety Instructions and
Guidelines will be taught and must be observed and exercised at all times.
1.1.10 Sufficient Certificated employees to work on OHTE structures must be in the Re-
spondents employment during construction works. Employee must have “C” certificates, lev-
el 2 first aid, ladder working.
1.1.11 The Respondent must be equipped with all the required plant, tools, safety equipment
and PPE (Personal Protective Equipment) to effectively and safely carry out the Works.
1.1.12 Where electrical and track occupations are required, these must be arranged by the Re-
spondent with the PRASA Supervisor and Electrical Officer.
1.1.13 Respondents must note that PRASA will utilize one PRASA (Telecoms) supervisor /
Project manager/inspector at any time during the contract period to inspect the progress and
quality of the Respondent's work. This person is not available on a full time basis (on site)
and will make scheduled and random site visits.
1.1.14 The successful Respondent must appoint a Site Supervisor for the duration of the con-
tract. The Site Supervisor must be “in charge” on site for the full duration of the contract.
1.1.15 The Respondent's site supervisor must be issued with a site diary and PRASA will
provide a site instruction book. These books must be kept updated at all times and copies
handed over to the PRASA Project Manager at progress meetings.
1.1.16 Respondents must take note that PRASA Perway or OHTE Departments must approve
and supervise all underground and overhead (boom or other) rail (track) crossings.
1.1.17 This specification covers the trenching of optic fibre cable and erection of self-
supporting optical fibre cable on 3 kV DC, 25 kV and 50 kV AC overhead high
tension electrification (OHTE) masts for PRASA.
1.1.17.1 Construction will mostly take place under live traction power conditions
and with the normal operation of train services.
1.1.17.2 Specific attention shall be paid to section 12 of this specification, which
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
covers safety precautions during construction.
1.1.18 The objective is to install the major component of the cable Underground. Overhead
sections should be kept to a minimum. Pipe and chamber systems may be con-
structed or utilized where these exist.
1..1.19 The same optical fibre cable must be utilized for aerial and buried sections.
1.1.20 A clause-by-clause statement of compliance to this specification is required. This
should be done by the contractor on the route surveillance and all points of non-
compliance must be detailed and discussed with the PRASA Project Manager and
singed off before any deviations will be allowed.
1.1.21 Should a tenderer method of construction and cable erection differ from this specifica-
tion, full details thereof must be provided for possible prior approval by the PRA-
SA Project Manager.
Corridor KZN CORRIDORS SUPPLY & INSTALL NEW 96 SM FIBRE OPTIC
NO. STA-TIONS
OVERHEAD FIBRE
UNDERGROUND FIBRE TOTAL
SOUTH COAST
REUNION TO PORT SHEPTON 34
110 110 KM
CLAIRWOOD TO CARTO RIDGE 18
80 80 KM
NORTH COAST
DUFF ROAD TO STANGER 18
70 70 KM
MERBANK TO CROSSMORE 6
15 KM 15 KM
_______________ __________________ _____________________ ______________
TOTALS 76
185 KM 275 KM
Corridor
CAPE TOWN CORRIDORS SUPPLY & INSTALL NEW 96 SM FI-BRE OPTIC
NO. STA-TIONS
OVERHEAD FIBRE
UNDERGROUND FIBRE TOTAL
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
CAPE TOWN TO DIEPRIVIER 16 20 km
20 km
DIEPRIVIER TO MUZERBURG 6
BLOWING FIBRE ONLY 16 KM
MUZERBURG TO SIMONS TOWN 6 8 KM
8 KM
PHILP TO KAPTEINSKLIP 4
BLOWING FIBRE 7 KM
PHILIP TO CHRIS HANI 7
BLOWING FIBRE 15 KM
CAPE TOWN - BELLVILLE- MULDERVLEI 18
48km 48KM
BELLVILLE TO EERSTERIVIER 4
17 KM 17 KM
EERSTERIVIER TO STRAND 5
21KM 21KM
EERSTERIVIER T0 Muldersvlei 5 ________________ 30KM ___________
TOTALS 61 28 KM 116KM 182
Corridor
GAUTENG NORTH & SOUTH CORRIDORS SUPPLY & INSTALL NEW 96 SM FIBRE OPTIC
NO. STA-TIONS
OVERHEAD FIBRE
UNDERGROUND FIBRE TOTAL
Randfo via PARK STATION TO GERMISTON 12 29 KM 30 KM 59 KM
MITCHELL STREET TO SAUSVILLE 12
12km 12 KM
NEW CANADA TO VEREENI-GING 20
60 KM 60 KM
DEWILT TO WINTERSNEST 8 `` 20KM 20 KM
RISSIK TO KOODERSPOORT 3 6 KM
6 KM
NEW CANADA via Nasrec TO GERMISTON 11
25 KM 25 KM
DUNSWART TO SPRING 10
20 KM 20 KM
KAALFONTEIN TO LERALLA 4
10 KM 10 KM
GERMISTON TO KWESINE 7
25 KM 25 KM
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
______________ _________________ _____________________ ___________
TOTALS 87 35KM 202KM 237 KM
The above distances are track distances. The actual cable lengths of sections and spares will
be detailed.
1.2.1 The successful Contractor(s) are required to survey the railway section(s) awarded to
them and produce a revised Bill of Quantities, with reasons for deviation from the original.
1.2.2 The Contractor will test the fibres in the delivered cable drums and send these results to
PRASA Project manager, alerting him if any traces differ from the supplier’s records.
1.2.3 The Contractor must install the OFC according to PRASA specifications and Written
Safe Working Procedures.
1.2.4 The Contractor must test all the fibres of the OFC from ODF to ODF and submit the
fibre traces to PRASA Project Manager/Telecom department.
1.3 The Technical Requirements
1.3.1 The installation works and materials offered must comply with the following specifica-
tions. Any deviations from these specifications must be clearly stated in a clause by clause
statement of compliance to each specification. Failure to do so will result in automatic dis-
qualification.
SPC-00029: Trenching, Laying and Hauling in of Communication Cables
SPC-00033: Optical Fibre Testing Equipment
SPC-00575: Planning and Erection of Self Supporting Optical Fibre Cable on Trac-
tion Masts
SPC-00583: Optical Fibre Accessories
1.3.2 The installation works and materials offered must also comply with the following speci-
fications. Any deviations from these specifications must be stated in a separate document.
SPC-00587: Horizontal Directional Drilling
SPC-00588: Optical Fibre Cable Ducts
SPC-00589: Civil Engineering Works associated with Underground Telecom Plant
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
SPC-00590: Working to Way leaves, Site Establishment, Safety and Local Authority
Requirements
SPC-01242: Wooden Poles for OFC Installations
SPC-01279: Erection of Wooden Pole Routes
PRC-00106: Post installation Test for Optical Fibre Cables
PRC-00107: Pre-testing of Optical Fibre Cables on Drums
PRC-00112: Written Safe Working Procedures for Erection of ADSS OFC on AC
OHTE
E7/1: Works on, over, under or adjacent to railway lines and near high voltage equip-
ment.
E.4E: Compliance with the Occupational Health and Safety Act (Act 85 of 1993)
2. SPECIFICATIONS AND DRAWINGS
2.1 This specification sets the standards for the materials and techniques to be used in under-
ground optical fibre cable installation and aerial optical fibre cable installations,
and may not be deviated from without the permission of the PRASA Project Man-
ager at all times.
2.2 Where reference is made to approved materials or techniques, this approval must be ob-
tained from the PRASA Project Manager, who must co-ordinate any necessary in-
terfacing with the relevant authorities.
2.3 This specification shall be read in conjunction with the Main Specification describing the
project requirements. Should discrepancies arise between the Main Specification
and this specification the requirements of the Main Specification shall prevail?
2.4 The following documentation should be read in conjunction with this specification :
2.4.1 Specification for works on, over, under or adjacent to railway lines and near
high voltage equipment. (SPK7/1)
2.4.2 E.4E: Safety arrangements and procedural compliance with the occupational
health and safety Act; Act 85 of 1983 and regulations.
2.4.3 Guideline for approval of OFC Suspensions on OHTE Masts.
2.4.4 SPK7: Protection of construction workers on or near railway lines.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
3. DESIGN AND APPROVAL
3.1 Installation shall consist of a bracket clamped to the traction mast supporting a
cable suspension fitting and the cable. No drilling or welding will be allowed
on traction masts for the fixture of support brackets of any kind.
3.2 The design of the suspension hook shall be such as to prevent the cable touch-
ing or chafing against the suspension bracket or other infrastructure under the
various load conditions that the OFC will be subjected to.
3.3 All fittings and brackets installed must be galvanized in accordance with SABS
specification 763 or manufactured from approved corrosion resistant materi-
als. Where the installation is within 30 kilometers from the coast, fittings
and brackets must be stainless steel 304 as per BS (British standard)
1449/2. Tenderers must comment on the likelihood of galvanic corrosion be-
tween the stainless steel bracket and the galvanized mast and propose
measures to avoid this possibility.
3.4 An approved range of fittings and brackets, strain grips; suspenders etc. must
be used (Approval by PRASA Project Manager).Should alternative brackets
and fittings be offered then the tenderer must submit a drawing and sample of
each type of bracket and fitting for approval. Design specifications of the
brackets and fittings are required.
3.5 The design of each bracket and fitting must be sufficient to support one span of
cable load under installation and worst load conditions.
3.6 Tenderers must note that PRASA reserves the right to free issue all or part of
the necessary fittings and brackets as well as other materials including cable
should this option be exercised.
3.7 At termination points (dead ends) the cable tension shall be aligned with the
mast to avoid bending moments that cantilever fittings would cause. The ten-
sion on any mast, in any direction and under maximum load condition, must
not exceed 2000 Newton’s.
3.8 On an A frame structure, only one suspension arm must be fitted on one leg of
the A frame.
3.9 Installation of the optical fibre cable must comply with the Guideline for Ap-
proval of OFC Suspensions on OHTE Masts (as per Spoornet's letter reference
S.PL&T/I/CAO/13/3/1/6). The location of the OFC cable must not obstruct
access to the OHTE conductors for maintenance purposes at any point.
3.10 NOTE: Where this specification refers to HDPE conduit it must comply with
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
SABS specification 533 Part 2/1982.
3.11 Where a signal gantry structure is utilized to cross the tracks, the optical fibre
cable must be installed in 50 mm diameter HDPE conduit or galvanized
trunking secured to the channeling of the handrail. The HDPE conduit or
trunking must be properly secured to prevent sagging.
3.12 Where a boom structure is utilized to cross the tracks, the optical fibre cable
must be installed in 50 mm diameter HDPE or galvanized trunking secured in
the web of the boom. or in the channel of the I beam so that overhead person-
nel can walk on top of the beam
The HDPE conduit or trunking must be properly secured to prevent sagging.
When galvanized trunking is used, an electrical occupation must be arranged with
the relevant operational department to cross tracks.
3.13 Alternative methods or material such as fibre glass, PVC or poly carbon may
be used to cross the tracks where a boom structure is utilized, but will re-
quire prior approval from the PRASA Project Manager.
3.14 No suspension must be made on masts carrying track switches, transmission
line switches, make-off arrangements (except on A-frame structures) and
transformers. The installer will use alternative structures. Optical fibre ca-
ble deviating onto such alternative structures must clear this equipment by 2
meters in the horizontal. This alternative structure must either be a galva-
nized pole, treated wooden pole or a concrete telephone pole of the right
height and thickness to support the cable approved by the PRASA Project
Manager.
3.15. The height of the cable must be so that it will not interfere with the
normal day to day activities of the maintenance personnel and their vehicles
and ladders. This height to the bottom of the cable should be in excess of 5
meters minimum.
3.16 Where existing optical fibre is suspended on traction infrastructure, new in-
stallations must be positioned as close as possible to the existing cable, in
order to minimize possible obstruction, or be installed on the opposite side
of the rails in compliance with the revised requirements which will be ap-
proved by Prasa rail and the PRASA Project Manager.
3.17 The design must be such that at any point the bending radius of the cable must
not be less than 20 times the outside diameter of the cable.
3.18 At anchor and intermediate positions, there shall be no slippage of the cable
under any condition.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
3.19 No fitting or clamp shall exert a crushing force on the cable of more than 1
000 N.
3.20 The cable shall be tensioned so that under normal conditions, i.e. when no
wind is blowing, a cable temperature of 25 °C, the maximum sag per 70 me-
ter span length must be 500 mm. Under the worst conditions, i.e. when the
wind is blowing cross-sectional at a speed of 100 km/hour, at a cable tem-
perature of 65°C, the maximum sideways deviation (sag) shall not exceed 2
meters.
3.21 The cable parameters will be provided in the Main Specification as supplied
by the cable manufacturer.
3.22 To avoid Point Loads being applied to the cable, the following guidelines in
this regard shall apply :
3.22.1 0 — 15° deviation from the straight run - standard suspension method, pre-
formed fibre optic suspension type unit or other approved fitting.
3.22.2 15° and greater deviation from straight run - false termination or similar
method.
3.23 Excessive lengths of non-terminated cable shall be avoided. On straight runs,
false terminations must be installed at intervals not exceeding 500 meters.
3.24 The position and types of brackets to be mounted on bridges and tunnels must
be clearly indicated on the bridge plans. The OFC position must be selected
to protect the cable against objects protruding from train wagons and wind
lashing. The cable may also be protected by means of an approved conduit.
The PRASA Project Manager, together with the relevant authorities, must
then approve these fittings and plans.
3.25 Clearance must be obtained from the PRASA Project Manager and other de-
partments for each bridge, tunnel and retaining wall where brackets must be
mounted. These brackets must be fixed against the wall by means of a stain-
less steel stud grouted into a hole and sealed. Rawl bolts are acceptable if the
sheath is made with an aluminum bronze finish. Chemical fixers are also ac-
ceptable. Unsuccessful holes must be closed in an approved manner.
3.26 Optic Fibre Aerial Cable Pulley or Sling :
3.26.1 A specially designed pulley or sling for the erection of optical fibre aerial
cable should be obtained for the installation and regulation of the cable.
3.26.2 The pulley/sling shall be of a suitable size to accommodate the minimum-
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
bending radius of the cable, of low friction and should be able to accom-
modate an installation tension in all four directions (i.e. down, up, left and
right).
3.26.3 The design of the installation pulley shall be such as to prevent touching or
chafing against any infrastructure under the various load conditions that
the pulley and OFC will be subjected to during installation.
3.26.4 After regulation it should be possible to remove the cable from the pulley or
sling and attach the cable to the suspension fitting.
3.26.5 A sufficient number of pulleys shall be available to install a cable length of
2 000 - 4 000 meters at every suspension point.
3.26.6 The PRASA Project Manager must approve the design of the pulley or
sling.
NOTE: Photo 1 indicates an approved stringing pulley for fibre optic installation.
Alternative designs will be considered, but full technical details and a
sample shall be provided for evaluation and approval.
4. SURVEY
4.1 Aerial optical fibre cable should normally be ordered in lengths of 2 000 or 4 000 meters.
Shorter lengths can be provided on request. It is however advisable not to exceed
4 000 meters due to excessive drag under installation conditions.
4.2 When a route is to be measured for the purpose of erecting an aerial optic fibre cable, a
measuring wheel should be used for accuracy. It should therefore be determined in
advance on which mast a joint/splice will be required.
4.3 Specific lengths should be determined as follows :
4.3.1 Start measuring at the termination cabinet up to the 2 000 / 4 000 meter mark.
At the 2 000 / 4 000 meter mark, a suitable mast should be selected at
which a joint could be made without any obstructions. The selected
mast must be situated in a position where it accessible for splicing. A
standard length of slack on either end must be allowed for termination
and splicing of the fibers at ground level.
4.3.2 Add at least 35meters to every length of cable to allow for splicing and add
additional for the sag of the cable per span.
4.4 False terminations must be placed at intervals of less than 500 meters.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
4.5 The mast must also be identified for the construction team exactly where the first length
of cable ends and the second length starts. These masts are to be indicated on the
survey sheets. The whole route must be measured and marked in this way. Masts
where joints are to be made must not have any other traction equipment on it.
4.6 It should be noted that no additional splices, without the approval of the Project Manager
would be allowed. That means that the cable shall be fed through any obstacle that
may occur.
4.7 Care should also be taken, when measuring, to avoid short lengths of cable at the end of
the routes, thus eliminating extra splices in the cable. Transmission losses must be
reduced to a minimum.
4.8 The final route selected must avoid an excessive number of track crossings. It is im-
portant that the correct side of the track be selected beforehand. This should nor-
mally be where the service road runs, for ease of access and added fire protection.
4.9 Care must be taken at platforms, bridges and footbridges to keep the cable clear from pe-
destrians in order to avoid tampering and malicious damage to the cable.
4.10 The positioning of the optical fibre cable on 3 kV DC, 25 kV and 50 kV AC electrified
structures must be selected to avoid placing the cable in strong electric fields. Sur-
veyors must specifically adhere to the minimum clearances required.
4.11 Possible damage by grass and bush fires, e.g. on the embankments of cuttings, must be
taken into account during the survey. All potential grass and bush fire hazards
must be indicated on the survey. An alternative route must be indicated on the
survey on how to avoid these potential fire hazards.
4.12 All positions where intermediate poles are required must be indicated on the survey
drawings.
4.13 A complete set of survey sheets must be submitted before installation commences. The-
se survey sheets must indicate the start and finish of cable sections, types of brack-
ets and fittings, joints, track crossings, obstacles, etc. The cable route must be dis-
tinguished by the international symbol for optic fibre cable.
4.14 The survey sheets must be A4 pages in portrait, and each page shall cover 1 km. The
start of the cable shall be on the top of the first page, and each page will follow in
logical order. Refer to Annexure 1.
4.15 The contractor will survey the route of optical fibre cable and will provide drawings and
positions for the suspension on each mast to the Project Manager for approval by
the Regional Prasa rail Maintenance Manager at each Infrastructure Depot or local
authorities.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
4.16 On completion of the work, "As Build" route drawings must be submitted, as per the
survey sheets and as stipulated in the Main Specification, which must indicate the
following :
4.16.1 Requirements as per sub clause 4.12.
4.16.2 Joint numbers and traction mast numbers.
4.16.3 Amount of cable slack at joints, underground deviations and at other inter-
mediate points.
4.16.4 All cable and drum numbers must be recorded on the survey sheets.
4.17 The co-ordinates of all joints, terminations and significant changes in direction must be
recorded via GPS. These co-ordinates must be shown on the "As Built" drawings,
and must be provided in electronic format (Auto Cad or Micro stations) in order
for it to be loaded into PRASA G.I.S Database.
5. INSTALLATION
5.1 On receipt of the cable, the following steps must be taken :
5.1.1 Ensure that the cable delivered is of the correct type and fibre count e.g. anti-
tracking cable for AC electrified sections.
5.1.2 Ensure that the cable or drums are not damaged.
5.1.3 Record drum numbers and lengths, and verify cable lengths.
5.1.4 Arrange drums according to the survey to ensure that the relative lengths are
erected in the correct order.
5.2 Ensure that all pre–testing has been completed and approved.
5.3 Preparation must be carried out on the route on which the cable is to be erected. Trees,
bushes and grass must be cut so that work can be carried out without any obstacles by the
contractor. The aerial route must be at least 3 meters clear of bush and trees within the
Prasa rail reserve. Where excessive trees or bush, which could become a fire hazard are
encountered, an alternative route must be chosen in accordance with the PRASA Project
Manager’s approval and the availability of alternative land within the Prasa rail reserve.
Tree branches overhanging the cable must be removed.
5.4 It is recommended that a 7 mm nylon ski-rope of ±2 000 meters shall be obtained to haul
the cable through the special manufactured pulleys.
5.5 The rope must be fed through the pulleys before hauling commences. Equipment such as
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
a mechanical fuse and swivel must be inserted between the end of the cable and the haul-
ing rope to prevent the cable from twisting during installation. A grip on or Kellems Grip
must be used to pull the fibre optic cable. The correct size grip for the particular cable
must be used. If aramid yarn is a part of the cable structure, it must be tied to the grip to
further distribute the pulling force between the hauling rope and the cable.
5.5a.The mechanical fuse must be examined after every few hauls. If the fuse has worn more
than half way it must be replaced with special copper fuse wire.
5.6 Erection of Cable on AC/DC Traction Masts :
5.6.1 Fit the universal multipurpose bracket at ±1, 5 meters above ground level.
5.6.2 Fit a pulley or sling on every suspension bracket for a distance equivalent to
the length of the cable to be hauled in.
5.6.3 Feed the hauling rope through the pulleys or slings. Two hauling ropes may
be used to expedite the hauling i.e. while the one is used for hauling, the oth-
er can be fed through the pulleys of the next section.
5.6.4 Place the drum with cable at least one span length of 70 meters away from
the mast where the cable will pass through the first pulley. This would pre-
vent the cable from bending too much while being hauled. Under no circum-
stances should the cable be bent excessively. This drum should be placed on
cable jacks with an axle. The rate of the hauling should be controlled from
this point.
5.6.5 The cable must be fed off the drum according to the speed with which the
cable is hauled. Care must be taken that the cable is not tightening between
the drum and the first pulley. A constant tension must be maintained on the
cable by braking of the cable drum when necessary. Tension must be main-
tained to avoid contact with trains. Hauling should be avoided on very windy
days.
5.6.6 The hauling team must haul the cable evenly and slowly to prevent the cable
from jerking which can result in broken fibers.
5.6.7 Good communication between persons at the drum, alongside the cable end
and the hauling team, is absolutely essential and must be available at all
times. If the communication breaks down, the hauling must be stopped
immediately until such time that communication had been re-established.
5.6.8 When hauling the cable, a person with a two-way radio must walk alongside
the cable-end to ensure that the cable is not twisting with the rope, especial-
ly at angle-masts where the possibility of twisting is great. When the cable
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
starts twisting, hauling must be stopped immediately. The cause of the
problem must then be pinpointed and rectified.
5.6.9 The person walking at the hauling end must ensure the best route for the ca-
ble, avoiding the cable chafing against stays or other obstacles.
5.6.10 Tensioning shall be as per sub clause 5.7.
5.6.11. Less cable slack is required for AC-type installations but sufficient slack
must be left for splicing purposes.
5.6.12. Once tensioning and splicing of the cable is completed, the suspension
bracket shall be moved up the mast in at least three steps with various
lengths of installation tools to the correct position on the mast. Note that
approved non-conductive tools must be used and installation teams must
avoid touching any high voltage carrying infrastructure at all times.
5.6.13. The splicing team must strive to keep-up with the hauling team. If this is
not the case, additional labor will be required to lower and raise the cable
for splicing purposes.
6 Tensioning
The pulling tension for the particular type of cable used is specified in kg/N.
6.1 A termination bracket and fitting (dead end) must be installed at the beginning of
each length. Where only false terminations occur in a cable section the cable
must be tensioned sequentially for every false termination section.
6. 2 The cable sag and tension under normal installation conditions may vary around
bends. Special care must be taken when the cable is removed from the pulley
and placed onto the termination fitting so that the cable does not exceed the
prescribed tension.
6. 3 The cable shall be tensioned by means of an approved device and the tension
shall be continually monitored not to exceed the parameters provided by the
cable manufacturer.
6. 4 On sections with a number of angle masts, it may be required to tension the cable
over shorter distances. In this case care should be taken not to damage the ca-
ble at the intermediate tensioning points.
6.5 Sufficient time shall be allowed for the tensioned cable to settle. This time is
when there is no longer a movement on the tensioning scale. When the correct
tension has been achieved, the suspension and termination fittings shall be fit-
ted.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
6.6 The cable must be marked at all anchor points in an approved manner to indicate
possible slippage.
6.7 The site supervisor must record the final stringing tensions and terminated span
lengths on a control sheet. The site supervisor must submit these sheets with
the site diaries for scrutiny and retention.
NNEEVVEERR EEXXCCEEEEDD TTHHEE MMAAXXIIMMUUMM PPUULLLLIINNGG TTEENNSSIIOONN!!
Excessive pulling force will cause the cable to permanently elongate. Elongation may cause
the optical fibre to fail by fracturing. Good construction techniques and proper tension moni-
toring equipment are essential.
7 Cable Slack
7.1 At positions where it may be required to accumulate cable slack due to the nature
of the route, this slack must always be coiled in a figure of eight to avoid
twisting of the cable. In muddy conditions the figure of eight must be done
on a ground sheet to avoid soiling of the cable.
7.2 After the hauling process, sufficient slack must be left for splicing purposes. The
cable must reach ground level plus 15 meters plus another 15 meters on the
hauling end, which must be cut off by the installation team. The installer
must ensure that this length is cut off during the installation process.
7.3 The slack shall be coiled in two separate coils of minimum 500 mm diameter, tied
with UV stabilized cable ties at four positions and secured at the top of the
mast.
7.4 If slack boxes are specified in the main specification, these must be of sufficient
size to accommodate the cable minimum bending radius. The contractor
will supply these items according to the project specifications and the ap-
proval of the PRASA Project Manager.
7.5 Care shall be taken not to twist the cable when coiling the cable slack.
7.6 A small amount of slack, between 250 and 300 mm (sag) must be allowed at false
terminations.
7.7 In order to avoid sharp angles in the vertical plane when going over or under bridges a
gradual increase or decrease of the route shall be obtained by adjusting the suspen-
sion brackets upwards or downwards on the masts.
8. Intermediate Poles
8. 1 Intermediate poles (where required) must be installed where span lengths ex-
ceed 70 meters or where the cable veers away from the track for any
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
reason. Intermediate poles must be of the wooden, steel or concrete tel-
ephone type. The ground clearance of the suspended cable must not be
less than 7, 0 meters. Where the intermediate wooden pole is in the
danger of burning, a 2 meter high galvanized metal sleeve must be fitted
around the base of the pole.
8.2 The Project Manager will obtain approval for the erection of intermediate
wooden, steel or concrete poles in the vicinity of electrified tracks.
8.3 Similar cable support fittings must be utilized for the suspension of the cable
on poles as that used for the electrification masts.
8.4 The contractor will supply intermediate poles. These poles will be approved by
the PRASA Project Manager.
8.5 Stays or struts must be fitted as required or as directed by the Project Manager.
Critical poles must be concreted in position.
8.6 To make the poles more visible at night, a reflective band of UV resistant ma-
terial must be fixed to the pole next to service or other roads at a height
of 1, 5 meters above ground level.
9. SAFETY PRECAUTIONS
9.1 Due to the proximity of live wires the installer must ensure that his employees installing
the cable on the masts obtain a Category C certificate from the PRASA Project
Manager in conjunction with Esselen Park training center or any PRASA accredit-
ed institute before any work can be carried out on the masts.
9.2 The contractor's employees must be trained for competence and understanding of the
basic electrical safety requirements. The certificate obtained will not be transfera-
ble. The cost of the training will be borne by the Installer or as stipulated in the
contract document.
9.3 The installer and his employees installing the cable must be fully conversant with the
Electrical Safety Instructions and the Transnet specification E.7/1 and E.4E.
9.4 No work within 900 mm from live. DC equipment and transmission lines, and 1200 mm
from 11 kV AC live equipment. Preferably this clearance should be as great as
possible.
9.5 In all instances where the safety of workmen is jeopardized, electrical and/or track occu-
pations must be requested. The Prasa rail representative in accordance with the PRASA
Project Manager will arrange these occupations. Notification is however required
Twelve (12) weeks in advance.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
9.6 Under bridges where live cross span wires are involved, at make off masts and where the
live conductors approach the optical fibre cable very closely, a standard warning board
must be fitted. Electrical personnel must be approached to arrange for a work permit to
fit the cable and warning boards.
9.7 No attempt must be made to install the cable in windy conditions, especially when the sag
(before tensioning) is blown in the direction of the track. Supervisors must use their dis-
cretion in this regard.
9.8 Tenderers must note that no metal ladders will be allowed but only wooden or fiberglass
ladders.
9.9 Tenderers must note that the AC bracket installation tool (stick) may not be used in wet or
rainy conditions.
9.10 Hard hats, protective clothing and safety belts must be worn whilst working on masts
and other structures.
9.11 Optical fibers are extremely thin and can easily penetrate skin and eyes. Any off cuts or
bare pieces of fibre must be properly disposed of. Optical fibers are categorized as
hazardous materials and require special disposal measures.
9.12 Care must be taken when testing as the laser in test equipment produces an invisible
light, which can cause permanent eye damage. All fibers should be treated as "live".
9.13 All personnel involved in the installation and testing must be made aware of the above
safety aspects.
9.14 A Health and Safety Agreement shall be entered into between PRASA and the success-
ful tenderer. The contractor will also comply with the Prasa rail regions Health and
Safety standards and will be represented on the Prasa rail regions Health and Safety
meeting.
9.15 The contractor must comply with the "Standard Safety Work Procedures for the Installa-
tion of Optical Fibre Cable" SANS 10340 (latest version). This document must also be
attached to the Health and Safety Agreement.
9.16 The Contractor must comply with the "Protection of Construction Workers on or near
Railway Lines". This document must be read in conjunction with this specifica-
tion.(SPK7/1)
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
10. SPLICING, TERMINATION AND TESTING
10.1 Splicing can commence after approval is obtained from the PRASA Project Manager.
10.2 All splicing and testing must be done inside a vehicle or a dust free shelter. Cleanliness
is absolutely essential to make satisfactory splices.
10.3 A competent team using an optical fibre fusion splicer in compliance with the manufac-
turer of the said device (with the stipulated software) must carry out fusion splicing and
terminations. Tenderers must state the competence and experience of the personnel en-
visaged to do the fusion splicing. Splicing must be carried out in accordance with proce-
dures and instructions as stipulated by the cable and splice housing manufacturers.
10.4 The splicing team must be suitably equipped with all the necessary materials, accesso-
ries and equipment to carry out the fusion splicing. The splice losses expected during in-
stallation must be similar to those obtained during the drum tests which should be record-
ed on a spreadsheet for reference purposes. This spreadsheet should be attached to the test
certificate when handed to the Project Manager.
10.5 Splicing must comply with the splice housing manufacturer's specifications i.e. securing
of the strength member and Kevlar, slack inside the splice closure and protection of the
individual splices.
10.6 The individual fibers must be numbered or easily identified inside the splice organizer.
The up and down ends of the cable and loose tubes must be identified.
10.7 On completion of the individual splices the organizer must be placed in approved her-
metically sealed splice housing. The contractor will supply these splice housings with
an approved manufacturer as specified in the main specification. And with the approval
of the PRASA Project Manager.
10.8 The splicer must ensure that the silica-gel packet, supplied with the dome closure, be
opened and inserted in the dome closure before closure of the dome.
10.9 The splice housing must be fixed to the mast and numbered in an approved manner with
sufficient cable slack as specified in sub clause 7.11.7.
10.10 Termination of the fibers must be carried out on approved connector’s pigtails and ter-
mination cabinets as specified in the Main Specification. The contractor will supply
these items with an approved manufacturer specified in the main specification. And
with the approval of the PRASA Project Manager.
10.11 After the complete installation each individual fibre must be tested from both fibre
ends Testing must be carried out in conjunction with Projects personnel from PRASA.
The test to be conducted shall be :
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
10.11.1 Fibre continuity.
10.11.2 Overall attenuation (loss) - tested by means of optical power source and
power meter.
10.11.3 Splice Loss - for each individual splice.
10.11.4 Attenuation profile - tested by means of OTDR.
10.11.5 The Project Manager reserves the right to carry out individual tests should
this be required on any length of installed fibre during any phase of the
construction. The installer shall be required to witness these tests.
10.11.6 Graphic print outs or software files must be submitted to the Project Man-
ager for his scrutiny and forwarded for approval by the Chief Signal Engi-
neer.
10.11.7a.When a splice is completed and fitted into a joint enclosure, the cable
slack (30 meters in total) must be coiled into a suitable slack box, which is
fitted to an arm on the pole or coiled around suitable brackets fitted on the
pole.
10.11.7b.When coiling the slack after the joint has been completed; it must be
coiled before the joint is secured to the pole/arm. Start coiling by rolling
the slack with the joint as the leading end (roll cable like a wheel). This
will ensure that no twists are put in the cable which will result in the fibers
being damaged.
10.11.7c.When completed place the coil into the slack box and secure the joint clo-
sure at a suitable position on the arm/pole.
11. FINAL ACCEPTANCE
11.1 Each fibre must be tested before it is introduced as directed in clause 7.11and with the
approval of the PRASA Project Manager. The purpose of these tests is to ensure that the
fibers are acceptable for use in the PRASA network.
11.2 An approved OPTICAL TIME DOMAIN REFLECTOMETER (OTDR) in compliance
with the cable manufacturer with the stipulated software must be used for the testing and
measuring of the fibers. Records of all the results must be kept for reference purposes.
11.3 Tests must be carried out at both 1310 nm and 1550 nm wavelengths. These test results
must be forwarded to The PRASA Project Manager for scrutiny and approval.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
SAMPLE OF "AS BUILT" DRAWINGS
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
A Equipment: Blocks
Multiple Cable Block
Used for supporting multiple cables in independent rollers. Multiple cable
blocks make a cable positioner unnecessary when lashing multiple cables.
Single Roller Block
Typically used to support a single cable prior to lashing and may be used
when cables are lashed directly to strand or in over-lash applications. In
new strand situations, single roller blocks may be locked onto the strand.
In over-lash applications, this block should not be pushed in front of the
lasher.
Economy Block
Used to support a single cable prior to lashing and, depending on the ac-
tual block, may be used when cables are lashed directly to
Strand or in over-lash applications.
Pole Mount Cable Block
Used to install self-support cable and is attached to the pole hardware to sup-
port the cable as it is pulled out.
Take care that cable slack does not exceed the minimum bend radius
over blocks.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
B Equipment: Pulling Grips and Devices
Kellems® Grip
This reusable grip is woven from strands of stainless steel, acts
like ‘Chinese finger cuffs’ and compresses upon being relaxed. It
provides an evenly distributed hold on the jacket of the cable.
Dynamometer
Used in monitoring the pulling tension applied to
Fibre optic cables
Breakaway Swivel
Used for preventing excessive pulling tension. It is designed to break
should it exceed a pre-set tension limit.
C Equipment > Blocks, Chutes and Brackets
90° Corner Block
Used to route cables through inside or outside corners
up to 90°. It minimizes drag on the cable in corners and
ensures that the minimum bending radius of the cable is
not exceeded. It requires specialized mounting hardware
depending on the specific use of the equipment
45° Corner Block
Used to route cables through inside or outside corner up
To 45° it minimizes drag on the cable in corners and
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Ensures that the minimum bending radius of the
cable is
Not exceeded.45° corner blocks may be used as a
set-
Up chute to guide Cables from the cable trailer or
a reel stand. It requires specialized mounting hardware
depending on the specific usage of the equipment
Set-Up Chute
A set-up chute is used to guide cables from the cable trailer or reel stand.
This equipment requires specialized mounting hardware depending on the
specific use of the equipment.
Set-Up Bracket
This bracket is used to support 45° and 90° corner blocks or set-up chutes
at mid-span.
D Equipment > Lashers, Pullers, Positioner’s and Guides
Cable Positioned (or Magic Box)
This is pushed in front of a lasher by a cable block pusher to uniformly
position multiple cables that are being lashed.
Cable Guide
Used for guiding the cable into the lasher in drive-off applications. It can
be used for new strand or over-lash applications. The guide may be
pushed in front of the lasher with a cable block pusher, pulled in front of
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
the lasher or physically attached to the lasher, dependent on the cable guide type.
Cable Lasher
Used for lashing cable directly to installed strand or cable bundles. Lash-
ers are somewhat specific to cable and strand size – improper lasher size
or adjustment may damage cables.
Multiple Cable Pullers
This allows for multiple cables to be pulled into place when lashing
cables directly to the strand. It’s equipped with a strand brake to pre-
vent sagging of cables as the pulling tension is released. Allows pulled
cables to independently swivel.
Over-lash Cable Puller This allows multiple cables to be pulled into place in over-lash appli-
cations. Allows pulled cables to independently swivel.
Cable Block Pusher (Shotgun / Shuttle)
Used for pushing equipment ahead of a pulled lasher.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
E Equipment: Lifting Tools and Brakes
Lay-Up Stick
A fibreglass stick used to lift cable blocks and cables into place utilizing
appropriate lay-up stick heads.
Cable Lifter (or Lay-up Stick Head)
This is used in conjunction with a lay-up stick to lift cables into place. The
lifter ensures that the cables being lifted are not damaged by exceeding
the minimum bending radius.
Cable Block Lifter
Used in conjunction with a lay-up stick to place assorted cable blocks
mid-span.
Wire Raising Tool
This is used in conjunction with a lay-up stick to lift cable blocks and
strand.
Strand Brake
This device is selectively placed at pole hardware locations to prevent dangerous strand sag
while strand is being installed. The strand brake allows the strand that is being pulled into
place to move in only one direction, which is the direction of the strand pull. Use of strand
brakes in conjunction with reel brakes effectively limits the amounts of strand sag between
poles during strand installation.
F Equipment > Fibre Preparation and Splicing
Buffer Tube Cutter
These are used to score drop armoured, central tube and stranded
loose tube buffers to facilitate exposing the fibbers.
Coating Stripper
This device mechanically strips fibre coating using precision blades
and preset openings in much the same way as a wire stripper takes in-
sulation off a copper wire. After the coating has been stripped, the fi-
bre is cleaned with a solution of 95% or higher isopropyl alcohol.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Fibre Cleaver (Hand Held)
Fibre cleavers score and then trim the fibre. Price and complexity of
cleavers vary widely - generally, the more you spend, the greater the
consistency of cleave. The beaver tail cleaver shown is a lower cost
model.
Fibre Cleaver (Free Standing)
This is a larger and more expensive version of a cleaver. Its main
advantage is that it performs accurate cleaves more consistently than
the hand-held models.
Fusion Splicer
Most low-loss splices are made with fusion splices, which use an electric
arc to fuse together the cleaved ends of fibbers. Splicers vary widely in
complexity, features and price. Some automate the entire splicing pro-
cess. An applicable splicer for fibre optic cables would have:
1. A fusion heat source, usually an electric arc
2. V-groove clamps for holding the fibbers
3. A way of positioning the fibbers for optimum splicing
4. A way of viewing the fibbers (microscope, display screen)
So they can be accurately positioned.
5. LID (Local Injection and Detection) and/or PAS (Profile
6. Alignment System) to aid with fibre alignment
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Drawings and photos
Photo 1 Cable pulley
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Photo 2
Photo 3 Termination bracket
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Drawing 1
Drawing 2
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Drawing 3
Drawing 4
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Drawing 5
Drawing 6
End- Part A
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
PART B: Optical fibre accessories used in the PRASA environment
Abbreviations, Acronyms and Definitions’
Abbreviation and Acronyms Description
PVC Polyvinyl Chloride
ODF Optic Distribution Frame
LSZH Low Smoke Zero Halogen
PABX Private Automatic Branch Exchange
DEFENITION DESCRIPTION
Assembly Consist of a terminated cable in a pigtail or patch-lead configuration
Pigtail - Unrug-
gedised
Secondary coated fibre connectorised at one end (of specified length)
Pigtail - Rugged-
ised
Secondary coated fibre with aramid polymer fibers in a 1,6mm PVC sheath con-
nectorised at one end (of specified length)
Patch lead -
Ruggedised
Secondary coated fibre with aramid polymer fibers in a 1,6mm PVC sheath con-
nectorised at both ends (of specified length)
Duplex Patch
lead - Rugged-
ised
Two of secondary coated fibre with aramid polymer fibers in a figure 8 PVC sheath
with nominal thickness of 1,6mm each (of specified length)
Overall Rugged-
ised
Two of secondary coated fibre with aramid polymer fibers in a figure 8 (zip
cord)PVC sheath with nominal thickness of 1,6mm each (of specified length) with
an additional overall protective sleeve
Connector Coupling device attached to pigtail or patch – lead (of specified type)
Mid – Coupler Receptacle to fit in a cabinet to join two connectors together, also known as a mid-
dle alignment sleeve.
Flat twin cable Two simplex cables (see Duplex Patch- Lead Ruggedised) with a PVC outer pro-
tective sheath.
Strain relief boot Mechanical device that ensures that additional strain on the cable will not be trans-
ferred to the ferrule or fibre.
Organizer A unit that can accommodate fibre slack coils and splice protectors
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
1. SCOPE
This specification covers the supply of optical fibre accessories to supplement single
mode optical fibre cables.
2. INTRODUCTION
This specification covers the requirements for the supply of the following optical fibre
accessories and services to Prasa rail and the PRASA:
2.1 Pigtails (ruggedized and unruggedised).
2.2 Mid-Coupler (Mid alignment sleeves).
2.3 Patch cords with Connectors.
2.4 ODF's (Optical distribution sub racks)
2.5 ODF's (Optical distribution Main Frames)
2.6 Splice protectors.
2.7 Joint closures with splice organizers.
2.8 Training on installation practices.
This specification also covers the quality requirements and testing of the completed
patch-leads and pigtails as per Appendixes A, B and C.
The tenderer must indicate, clause-by-clause, in a separate statement of compliance
whether optical fibre accessories offered comply or do not comply with this specification.
If the tenderer submit ANY alternative offer, all deviations from this specification must
be clearly stated and explained. The alternative will have a test sheet and must be ap-
proved by the PRASA project manager.
The Tenderer must note that the standard connector requirement is the E-2000 APC type.
Various combinations of connectors may be a requirement in specific cases.
All units must be able to accommodate and organize cable, fibre and patch-lead slack.
Tenderers will be required to demonstrate all units offered when requested.
All ODF's must be manufactured from durable materials suitable for use in coastal areas.
All units must be completely dust proof. Tenderers are requested to specifically comment
on this requirement.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
3. OPTICAL FIBRES
Only 9/125/250 pm coated optical fibers must be used to ITU G.652.D recommendations.
The fibre types used must be easily strippable and comply with customer specifications
for single mode optical fibre.
4. RUGGEDIZING
When specified, aramid-polymer fibers must be stranded longitudinally around the buff-
ered secondary coating.
The aramid-polymer fibre must be stranded with evenly thick bundles around the second-
ary sheath.
Duplex patch-leads must be offered.
All finished assemblies must be tested as specified in Appendix B of this specification.
The mechanical performance required from ruggedised assemblies is specified in Appen-
dix C.
5. OUTER SHEATH
The outer jacket material must be uniformly sheathed with PVC Type TM1 or alternative-
ly with LSZH (when specified).
The sheath must have a minimum thickness of 0; 5 mm and the overall diameter
must be 1, 6 mm +0, 2 mm.
The sheath must be yellow for single mode (SM) and orange for multi-mode (MM).
The sheath must be easily strippable from the cable.
6. PIGTAIL AND PATCH-LEAD IDENTIFICATION
A unique serial number must be printed on a permanent affixed label and attached to each
unit between 10 -20 cm from the boot of each connector. This label can also serve as
proof of testing/QA.
Labelling must be done at both ends in the case of a duplex patch-lead.
The following information must accompany each assembly:
6.1 Insertion loss @ 13 10 nm and 1550 nm (Single mode).
6.2 Return loss @ 13 10 nm and 1550 nm (Single mode).
6.3 Unique serial number.
6.4 Product description.
6.5 Order number.
6.6 Date tested.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
6.7 Length of tail or patch-lead.
6.8 Type of connector.
6.9 Type of fibre (e.g. 13101 1550 nm single modes).
The rubber boot of the connector can be blue for 0" flush-polished connectors and green
for 8" angle polished connectors.
A unique identification mark (color or number) must be applied to either end of patched-
leads to assist with identification of patched-leads in densely populated ODF's or termina-
tion cabinet.
The A and B leg of Duplex Patch lead must be identified.
7. DUST CAPS
Each E-2000 (or otherwise specified) connector or mid-coupler supplied must be fitted
with an integrated dust cap to protect the end face from dust and scratches.
The E-2000 (or otherwise specified) dust cap must be spring loaded to ensure positive
closure when not mated and constructed of a material to protect users from laser radia-
tion.
Dust caps for other connectors and mid-couplers must comply with the requirements of
this specification.
Dust caps must be color coded to differentiate between single mode and multi- mode
units as well as angle and flush polished (refer to sub clause 8.3).
8. MID-COUPLER (BULKHEAD)
Single mode mid-couplers must have a ceramic alignment sleeve with a yellow insert for
identification purposes. Mid-coupler offered must have a self-secured clip that can easily
connect onto the coupling plate supplied by the optical distribution frame or rack.
The color coding must be blue for 0" flush polished and green for 8" angle polished mid-
couplers.
9. CONNECTORS
This specification generally specifies the (angle polished connector) APC E2000 con-
nectors unless otherwise specified.
Other types of connector’s angle or flush polished may be required and the minimum re-
quirement is conformance to this specification.
All connectors must consist of a ceramic ferrule and strain relief boot. Other materials
will be considered but comprehensive technical information and test results will be re-
quired.
All connectors must withstand the mechanical tests covered in this specification.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
A heat-cured epoxy must be used on all connectors.
Isopropyl alcohol together with lint free tissue will be used for cleaning connectors. As-
semblies must be inert to cleaning with this fluid.
The customer reserves the right to request specialized connector materials.
The optical performance of the required connector is specified in Appendix A of this
specification.
The colour coding must be in accordance with Heading 8. MID-COUPLER (BULK-
HEAD) sentence 3
10. OPTICAL DISTRIBUTION FRAMES AND RACKS
10.1. ODF's must be available in three different types
10.1.1. A wall mount unit for small communication or PABX rooms.
10.1.2. A 19 - inch stackable ODF rack for terminating and patching fibers for small to
large communications room.
10.1.3. Specialized ODF (Main frame) for large distribution site.
10.2. Wall Mount Unit
10.2.1. The wall mount unit must have a minimum capacity for the termination of 48 Fi-
bre.
10.2.2. The unit must be easily accessible and easy to terminate and patch fibers.
10.2.3. The unit must be supplied with a removable panel to accommodate dif-
ferent types of connectors and mid-couplers.
10.2.4. The unit must be tamper proof and lockable. Two separated areas will be re-
quired:
(I) Cable entry and termination of fibers; and
(II) Distribution and patching of fibers.
10.2.5. The unit must provide cable entries for terminating and distribution to other
equipment.
10.2.6. The unit must be supplied with all cable glands, screws, nuts and bolts to secure to
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
a concrete or brick surface.
10.2.7. The unit must be supplied with standard accessories -splice organizers,
connector plate, cable clamps, fan-out devices and transportation
tubes.
10.3. 19 inch stackable ODF sub rack
The 19-inch stackable ODF sub-rack must have a combined splicing, termination
and storage function with a capacity for the termination, cross-connecting, store ex-
cess fibre and patching of minimum 24 fibers.
Each unit must be easily accessible and easy to terminate and patch fi-
bers.
Each unit must have a maximum height of 3U and must include a patch- lead routing
scheme.
The unit must be designed to optimize accessibility allowing minimum movement of
pigtails and fibers when the unit is opened and closed while connected systems re-
main fully operational.
The unit must be designed with a front panel for the protection of optical fibre patch-
leads.
The unit must be designed to organize excess patching cords with the option for dis-
tribution via the front or rear of the rack.
The unit must be supplied with standard accessories -splice organizers, connector
plate, cable clamp, fan-out device and transportation tubes.
10.4 Specialized main ODF Rack or Cabinet
The main ODF cabinet must have a maximum height of 47U, free standing and be
able to accommodate standard 19-inch sub-racks.
Each cabinet must be designed to facilitate various configurations based on opti-
mized modular units and to enable a variety of cabling requirements.
The cabinet must be designed to provide a complete management and storage system
for the cabling of long optical patch-leads and pigtails.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
11. SPLICE PROTECTORS
11.1. Heat crimping type
A. Splice protectors must be manufactured from a durable crimping material.
B. It must have a non-corrosive material insert for strengthening purposes.
C. The length of splice protectors offered must be 60 mm.
D. All splice protectors offered must have a crimping temperature range of 210 "C
±10 "C.
11.2. Mechanical Crimping Type
Tenderers may offer mechanical splice protectors, which must comply with the re-
quirements of this specification. Comprehensive technical application and testing in-
formation must be provided to the PRASA Project Manager for approval before me-
chanical splice protectors will be used.
12. JOINT CLOSURE WITH SPLICE ORGANISER All closures must be re-enterable designed to protect splices and bare fibre from en-
vironmental and mechanical damage.
Closures must be available in various sizes and designed to accommodate splice or-
ganizers for a minimum of 48, 96, 144 and 288 splices.
All closures must be designed with a minimum of 6 cable entry ports. At least one
entry port must be oval or be able to do a "loop through" facility with minimal fibre
splices.
All cable entry ports must normally be sealed off and will only be opened when re-
quired.
The closure must be suitable to simultaneously accommodate conventional cables as
well as micro-tubes and micro cables. On the large type closures, multiple entry
ports will be preferred as well as ports that can accommodate multiple micro tubes or
micro cables.
Every component of the closure and organizer must be corrosion proof.
All closures must be UV stabilized for outdoor installation.
All closures must be water tight and suitable for direct buried applications suitable
for any environment -aerial, pedestal, and direct buried and underground applica-
tions.
All closures must be designed for numerous splice applications; expressed, tap-off,
branch and repair.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
All closures must accommodate a mounting bracket for wall or aerial mounting.
The mounting type will be specified during ordering for 6, 12, and multiple fibers
per tube.
The Splice Closure Organizer must provide proper fibre management.
13. TRAINING
Training on all equipment may be required and may be ordered.
Should the Tenderer have training to offer, he/she is encouraged to do so.
Training when ordered must comply with the customer specifications.
14. MANUFACTURING
The customer reserves the right to inspect and approve the Contractors production
facility.
The preferred requirements for such a production facility are:
1. Approved termination, inspection and test equipment which will guarantee a
final product that will conform to customer specifications.
2."On site" customer audits may be conducted prior and during tenders for new
contracts.
15. EXTENT OF TESTING
Optical tests must be done on each assembly, and must comply with specification
IEC 60874, as per Appendix A and B.
Mechanical tests required for ruggedised tails or patch leads only, must be consid-
ered type approval tests as per Appendix C, and may be at the discretion of the cus-
tomer.
The tenderer must have equipment to do the tests called for in this specification.
16. INSPECTION
The customer reserves the right to call for the inspection of goods on any contract or
order, at any stage before final acceptance. When such inspection is required, the
relevant contracts and orders will be endorsed accordingly.
The Contractor must prepare, without charge to the customer, samples and speci-
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
mens for testing at any laborite or testing agent under supervision of the customer
17. SAMPLES
A sample of any item covered by this specification must be submitted within four-
teen (14) days if called for. The sample will be regarded as being identical with the
items for which this tenders are submitted.
The sample will be non – returnable unless specifically qualified by Tenderers.
Some items may be tested to destruction.
18. PACKAGING
Pigtails, patch-leads and components must be dispatched as per order.
Each assembly must be individually coiled with a minimum diameter of160mm.
Each item must be individually wrapped in a suitable plastic packet.
All items must be dispatched in suitable packaging to prevent damage during normal
handling. Rigid packaging is required
APPENDIX A:
OPTICAL PERFORMANCE OF CONNECTORS
OPTIMISATION The positioning of the connector key-way must be as indicated in Appendix B, test
method A.
INSERTION LOSS
The insertion loss throughout the range 1260 nm and 1558 nm must not be greater
than:
Type connector 1 Specification
Single mode 00 PC 0.3dB
Single mode 80 PC 0.3dB
The test method is shown in Appendix B test method B. Insertion loss is defined as:
Where P1 is referred optical power P2 is transmitted optical power
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
RETURN LOSS The return loss throughout the range 1260 nm and 1580 nm must not be greater than
or equal to:
Type connector Specification
Single mode 00 FC-PC 45dB
Single mode 80
APC 70dB
The test method is shown in Appendix B test method C.
Return loss is defined as: 101oglO (P 1 / P3) dB
Where P1 is reference optical power and P3 is reflected optical power
A4 E-2000APC Specification
Item Parameter
Strain Relief 100N
Operating Temperature -250 to 70
0 Celsius conditioned by the table
Durability Min 1000 cycles
Assembly procedure Epoxy and polished
Connection Physical contact
Lock mechanism Snap-on
Standard En186-27/cecc86 275-801/802/IEC 61 754-
15
Ferrule Materials Full ceramic zirconia
Connector Material UL 94-VO
APPENDIX B: TESTING OF ASSEMBLIES
GENERAL
All tests must be conducted between 20 "C and 25 "C.
For convenience, the optical measurements are performed on cable terminated at both
ends. On completion of the measurements, the cable may be cut to provide two optical
terminations (pigtail).
If equipment or test methods used are other than those specified below, prior permis-
sion must be obtained from Customer
Test methods must comply with specification IEC 60874.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
MEASUREMENT SYSTEM
The source and power meter combination must be stable to within +0, 05 dB over a
period sufficiently long to enable to measurement to be completed. The source must
consist of a 1310 nm and 1550 nm laser (+20 nm) for Single mode and at 850 nm and
1300 nm LED for Multi-mode testing.
MASTER CORD
A master cord must be used specifically for the purpose of measuring insertion loss
and return loss. It must employ the same connector as the one to be tested and must
have a core eccentricity of less than 0, 5 pm. The error vector must be within 1130
degrees from the alignment key vector. The ferrule end face must be of the APC/PC
type. The master cord must effectively remove cladding modes within its length.
TERMINATOR
An optical terminator must be employed such that the reflected power from the end of
the fibre is reduced to a negligible value.
TEST METHODS
Optimization An example of the test configuration required is shown in figure 2
NOTE: Optimization has to occur before angle polishing because the angle has a specific
relation to the key which cannot be changed.
FIGURE 2
After the optical transmission of the connector is optimized, the key-way must be fit-
ted.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Insertion Loss using the configuration shown in Figure 3, the reference power P1
must be measured.
The connectorised cord under test must then be inserted into the system as shown in
Figure 4, and the transmitted power P2 must be measured. The insertion loss of the
mated connector id defined as Insertion loss = lOLog10 (Pl/ P2) dB
FIGURE 3 (Reference Power, PI)
FIGURE 4 (Transmitted Power P2)
Return Loss
Return loss unit
FIGURE 5 (Reference Power P 1)
Using the configuration in Figure 5, the reference power P1 must be measured.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Return loss unit
Connector under test FIGURE 6 (Reflected Power, P3)
The cord under test is then inserted into the system, and a connectorised fibre tail is connect-
ed to the cord under test as shown in Figure 6. The fibre tail must be terminated in such a
manner that the reflected power from the fibre end is negligible.
Using the configuration shown in Figure 6, the reflected power P3 must be measured.
The return loss of the two connectors under test is defined as:
Return loss = 10Log10 (P 1 / P3) -X dB
Where X = insertion loss of the directional coupler from port C to port B.
Note: This method of measuring return loss ignores the fibre loss, and also the far end con-
nector contributes to the reflected power measured.
Quality of Polish When the ferrule end face is examined with microscope at X 300 magnification, there must
be no visible cracks, scratches or other marks over the surface of the end face.
Interferometer testing Interferometer testing is required to check radius of curvature, fibre height, and apex offset,
fibre angle, and fibre and ferrule roughness. Interferometer reports must be available when
required by the customer.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
APPENDIX C: MECHANICAL PERFORMANCE OF RUGGEDIZED ASSEMBLIES
(Unruggedised pigtails are excluded from these tests)
FLEXIBILITY
The fibre or any other component part of the cable must not suffer permanent damage when
the cable is repeatedly wrapped and unwrapped 4 complete turns for 10 complete cycles
around a mandrel 20 mm in diameter. The cable must be coiled with sufficient tension to
maintain continuous contact with the mandrel.
COMPRESSIVE STRESS
The fibre and component parts of the cable must not suffer damage when subjected to a com-
pressive load of 1000 N applied between two rigid and parallel plates of dimensions 50 mm
by 50 mm. The load must be applied for 60 seconds.
Tensile Test
The connector under test must be mated via a bulkhead to the optical test equipment. At a
maximum point of 300 mm from the boot, the cable must be anchored on a mandrel, without
detriment to its optical performance. The free end of the cable must be connected and routed
via a bulkhead to the optical test equipment.
A load of 100 N must be applied at a rate of 5 mm/min and held for 10 minutes. The load
must then be increased to 150 N and held for 5 minutes.
The insertion loss must be measured and recorded through the duration of the test.
The test must then be repeated for return loss measurements.
At the 100 N / 10 min stage the insertion loss must be less than 0, 6 dB and the return loss as
per Appendix A specification.
At the 150 N / 5 min stage the insertion loss must be less than 0, 7 dB and the return loss as
per Appendix A specification.
After the completion of the test the cable must be removed from the assembly and allowed to
relax for 5 minutes. Insertion loss and return loss must be measured and recorded. The inser-
tion loss must be as per Appendix a specification.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
TORSION TEST
The connector under test must be mated via a bulkhead to the optical equipment. At a point
1000 mm from the rear of the boot, a force of 5 N must be applied. The weight must then be
rotated through the range 0 + 180" for a total of 10 cycles. See figure 1
The insertion loss must be continuously, recorded throughout the duration of the test. The test
must then be repeated while the return loss is measured.
During the duration of the tests, insertion loss must be less than 0, 6 dB and the return loss.
The return loss must be as per Appendix a specification. There must be no failure of the boot
bonding materials.
On completion of the test the insertion loss and return loss must be as per Appendix a
specification.
TEMPERATURE CYCLING
The optical tails under test must be connected together using bulkheads and then be connect-
ed to the test equipment.
The optical tails under test must then be subjected to ten complete cycles of four hour dura-
tion's each cycle commencing at 20 "C rising to 70 "C, falling to 15 "C and ending at 20 "C to
permit a dwell time of 1 hour at both 70°C and a transition time between temperature ex-
tremes of one hour.
For the duration of the test, the tails must be monitored for insertion loss. The insertion loss
must be equal to or less than 0, 4 dB.
The test must be repeated while the return loss is monitored. The return loss must be as per
Appendix a specification.
REPEATABILITY
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
Two pairs of connectors must be tested for endurance and repeatability of performance. A
pair of connectors must be mated by hand via a bulkhead and the insertion loss and return
loss be measured and recorded.
The pair must be removed from the bulkhead and mated 1000 times with the insertion loss
and return loss being measured after every 10 parting / mating cycles. The connector must be
cleaned with Isopropyl alcohol after every 10 cycles and the relevant measurements have
been completed.
The insertion loss must not increase by more than 0, 2 dB from start value or exceed 0, 4 dB
the return loss must be as per Appendix A specification.
END OF APPENDIX C
PART C: Trenching of Optic Fibre Cable
1. INTRODUCTION
This specification has been compiled for the purpose of providing guidelines, alternatives or
solutions to such situations where built manholes may be required.
2. SCOPE
This specification covers the methodology that shall be applied when constructing an under-
ground route for Telecommunication cables as well as built manholes and access termination
points (buildings)
3. TECHNICAL REQUIREMENTS
3.1 Trenching and Laying of Cables
The Trenching/pipe and chamber system must be installed on the property of PRASA be-
tween the fence line and the track formation, 3.0 meters from the center line of the nearest
track. The exact location will be decided at the site inspection and/or as shown on the at-
tached line or trench route plans.
3.1.1 Trench dimensions
a) All trenching shall be a depth of 900mm and 400mm wide
b) In difficult rock conditions i.e. shale, sandstone, late rite (ouklip), calcrete (limestone)
a trench of 500 mm is required. Sharp edges in the trench must be removed. Concrete
slabs must be laid on the padding and backfilled should the trench be at this depth.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
3.1.2 Bedding and Padding
a) The trench must be laid with padding of 150 mm of approved material before cable
laying is commenced. The soft material must past thru a 12 mm riddle, before the ducting
(3 x 32 mm direct berried duct) is installed.
b) Padding can only be pleased in the trench once the Site Manager is satisfied that the 32
mm duct is installed properly. The padding material will consist of the same material as
the Bedding used before. A layer of 150 mm of Padding must be placed on the installed
ducts, and tampered by hand. No mechanical device is allowed at this stage. The force of
these types of machines can deform and damage the ducts.
3.1.3 Back-fill
a) Once the Padding is installed properly, the trench can be backfilled with the remain-
ing material that was excavated from the trench. No large rock must be used as backfill
material; the Site Manager must ensure that any material that can potentially damage the
ducts must not be allowed as backfill material.
b) A layer of 250 mm of backfill material must be installed first. A mechanical tamper
(Petrol Rammer) must be used to ensure that the compaction is done properly. Water can
be added in very dry condition; to ensure better compaction. The last layer of 250 mm of
material can now be added. Again it must be tampered as before.
3.1.4 Reinstatement
a) The compacted surface must be cleaned of any remaining material. The surface
should be raked; and all additional material must be removed from site.
3.1.5 Route layout
a) The route should be laid out in such a matter that the standard duct length (1000 me-
ters) can be used with minimal wastage. Manholes should therefore not be placed more
than 950 meters apart. At least 3 meters of duct slag should be left at the position where
the manhole will be built; only after this construction is done can it be cut to length. All
un-used ducts must over lap inside the manhole; to be jointed at a latter stage.
3.1.6 T-Off point from main route
a) Under no circumstance must this route be deviated above ground. The same trenching
methods must be adhere to up to the first line (track), only then must the crossing under
the rail comply with the stander under rail crossing specification. Only certified contrac-
tors with the necessary permission from the local Per-way office will be allowed to do
the construction under the rail.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
b) All routes must enter the building underground. If not possible due to construction re-
straints (possible damage to foundation est.) can the contractor apply to secure the final
entry on the outside of the building.
c) Should this route be used as a redundant route, must the contractor ensure that the entry
point to the building of two routs be kept apart as far as possible.
4. MANHOLE SPECIFICATIONS
4.1 Dimensions
a) Manholes shall be designed and built as per site conditions.
b) Where deeper, larger or smaller (than the standard manhole) size manholes are consid-
ered, it would be preferable if one dimension (height, length, width) can be reduced one at
a time.
c) Larger manholes are used to a limited extent and shall depend on the types of services
on that particular site.
The following dimensions shall apply:
Dimension Ideal / Standard Reduced Size Manholes
Minimum Maximum*
Length (mm) – excl walls 1000 600 1000*
Width (mm) – excl walls 1000 600 1000*
Depth (mm) – excl base and
cover
800 400 800*
Wall Thickness (mm) Double brick approx. 220 mm
Base Thickness (mm) 150 145 155
Roof Thickness (mm) See Clause 4.3 frames and covers
*Maximums on all dimensions may be exceeded based on specific requirements such as:
Trench depth variations i.e. moving from a shallower trench to a deeper trench such as
sections on slopes
Nodal points require several splice closures
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
4.2 Drawings
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
4.3 Construction
4.3.1 Material
a) All manholes shall be built on site using semi-face clay bricks. Cement bricks are not
acceptable.
b) All manholes shall have double brick layers.
4.3.2 Concrete
a) Concrete strength shall be at least 25 Mpa and shall be certified.
4.3.3 Waterproof material
b) Cemflex® sealant shall be used in all cement mixes to ensure that the walls are water-
proof but vapor permeable.
4.3.4 Mixing method and ratio
a) Ensure that Cemflex® is thoroughly mixed prior to use.
b) Dilute one part by volume of Cemflex® with 10 parts by volume of clean water in a
suitable container (bucket) and mix thoroughly.
c) The best results are achieved by first mixing equal volumes of Cemflex® and water,
and then adding remainder of the water slowly whilst stirring.
d) The diluted Cemflex® is added to the appropriate dry cement/sand mixture as detailed
in the table below
Application Mix Ratio by Volume (Parts)
Cement Sand
Walls 1 3-5
Floor 1 2-3
e) If required, additional water may be added to achieve the desired consistency.
f) The mortar shall be applied with a steel trowel
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
4.3.5 Top surface / Finish
a) Any completed manhole shall have the top surface leveled with the adjacent ground
more especially for manholes on walkways.
b) A corrugated sheet cut out made to cover manhole shall be placed for mortar fill.
c) Wire mesh shall be placed 30 mm above the corrugated sheet in between the mortar for
the purposes of re-enforcement.
d) The wire mesh shall be cut out to the size of the coping and to the manhole lid opening.
4.3.6 Retaining walls
a) A retaining wall shall be built for manholes situated on sloping areas.
b) The retaining wall shall have double brick layer with semi-face clay bricks.
4.4 Frames and covers
a) Type 4 Manhole cover and frames shall be used with the dimensions as shown in the
pictures 1 below and the related specifications.
b) Covers and frames shall be made of conventional Cast-iron or Concrete
c) Covers and frames shall be load tested to specifications as set by the SABS. This test
shall be done by the supplier / manufacturer and a test report shall be provided.
d) Cover shall have a secure lucking system with a key system dedicated to PRASA.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
e) Specifications on lid and frame.
ANNEXURE 4 - SPECIFICATION
Specification for the trenching of optical fibre cable,
erection of self-supporting optical fibre cable on trac-
tion masts, optical fibre accessories, for installations in
the PRASA environment.
4.5 Frame and Cover Support
a) I –beams shall be mounted as support structures for the manhole frame and cover
b) The I-beam shall be located over the manhole in such a way that it offers maximum
support and without interfering with the opening of the manhole lid and or reducing the
circumference of the manhole entry.
c) The dimensions of the I-Beam shall be 100 x 55 with a wall thickness of +/- 5mm.
d) The I-beam shall be strong enough to handle weights of about 6 tons for manholes on
driveways.
4.6 Slack Management
The built manhole shall be equipped with a slack management facility that has the follow-
ing characteristics:
a) A Cable Slack Storage device shall be mounted 90° from the Splice Closure Mount-
ing.
b) The Cable Slack Storage shall be a third of a circle. The bed shall have a radius of
180mm with a lip of 60mm.
c) The Cable Slack Storage shall be hot dipped galvanized.