2004 Specifications CSJ 0914-00-307 & CSJ 0914-25-003 SPECIAL SPECIFICATION 8540 Telecommunication Cable 1. Description. This specification governs the materials, installation, termination, splicing, testing, training, documentation, warranty, and maintenance for telecommunication conductors, in a cable, used between elements of a traffic management system. Place cable in material described in Item 618, Conduit, Item 624, Ground Box, Special Specification Item, Duct Bank, Underground Cable Vault, ITS Equipment Cabinet, and Communication Hub Enclosure when shown on the plans. Prevent damage to cable at all times. 2. Materials. A. General. Furnish, assemble, fabricate, install, terminate, splice, and test new, corrosion resistant materials in strict accordance with the details shown on the plans and in the Specifications and listed in United States Department of Agriculture (USDA), Rural Utilities Service (RUS), List of Materials, Informational Publication 344-2. All splicing kits, caps, sealants, terminators, splice trays, and accessories to complete the communication network shall be provided as incidentals. Provide all equipment for assembly, fabrication, installation, terminating, splicing, testing, training, documentation, and warranty. Primary communications for voice, data and video are the conductors furnished under this Item. Furnish conductors suitable for installation in an underground conduit environment including constant immersion in water. Provide stainless steel external screws, nuts, and locking washers. Do not provide selftapping screws unless specifically approved by the Engineer. Provide corrosion resistant material, such as plastic, anodized aluminum or brass. Protect all materials used in construction from fungus growth and moisture deterioration. Separate dissimilar metals by an inert dielectric material. B. Field Telephone Units and Modular Jack Equipment. Provide field telephone units described in Special Specification Voice Communication Equipment in all enclosures terminating telecommunication conductors. Provide modular jacks for field telephone unit in all enclosures terminating telecommunication conductors. This equipment is considered incidental to enclosures terminating telecommunication conductors and is not paid for directly. 1-8 8540
C. Metallic Conductor Cables. Furnish low density, high molecular weight polyethylene, aluminum shielded, multiconductor telecommunication cable with standard twisted pairings of copper conductors. Furnish the number and gauge of installed working pairs as shown on the plans. Furnish cable of the same type from the same manufacturer. Comply with the following requirements for underground and aerial cable: 1. Underground. Furnish gopher-resistant cable with a 0.008 in. aluminum shield, single-jacketed, and a filled core (for moisture resistance). Furnish cable conforming to the latest revision of the United States Department of Agriculture (USDA), Rural Utilities Service (RUS) Bulletin 1753F-205 (PE-39), "REA Specification for Filled Telephone Cables". 2. Aerial. a. For aerial installations, furnish one of the following 2 types of cable as shown on the plans. Furnish cable with a 0.008 in. aluminum shield and single jacketed including an integral messenger strand. Furnish cable conforming to the latest revision of United States Department of Agriculture (USDA), Rural Utilities Service (RUS), REA Specification for Self Supporting Cable", No. PE-38. b. Furnish cable with a 0.008 in. aluminum shield and single jacketed supported by an external messenger strand conforming to Item 625, "Zinc-Coated Steel Wire Strand", except for Measurement and Payment. Furnish cable conforming to the latest revision of the United States Department of Agriculture (USDA), Rural Utilities Service (RUS), REA Specification for Aerial Telephone Cable", No. PE-22. Use the cable with the integral messenger strand, if the type of aerial cable to be used is not shown on the plans. D. Optical Conductor Cable. Furnish fiber optic cable of the various types and sizes shown on the plans conforming to the latest revision of the United States Department of Agriculture (USDA), Rural Utilities Service (RUS) Bulletin 1753F-601 (PE-90), "REA Specification for Filled Fiber Optic Cables". Furnish cable of the same type from the same manufacturer. 3. Construction. A. Installation. 1. General. Provide installation personnel resumes indicating personnel involved in the installation, splicing and testing of telecommunication cable meet the requirements of the Special Provisions Item 2, "Instructions to Bidders" concerning cable installation, splicing, and testing. The referenced experience requirements apply to metallic and optical cables. Provide Engineer with copies of the Contractor s Installation Practices for approval. Include practices, list of installation equipment, and splicing and test 2-8 8540
equipment. Detail field quality control procedures as well as procedures for corrective action. Install communication cable in accordance with the latest revision of RUS Bulletin 1751F-644, Underground Plant Construction and the following RUS bulletins: a. RUS Bulletin 1753F-151, RUS Form 515b, Specifications and Drawings for Construction of Underground Plant. b. RUS Bulletin 1753F-152, RUS Form 515c, Specifications and Drawings for Construction of Aerial Plant. Resolve any question concerning applicability in accordance with Standard Specification Item 5, Control of the Work. Terminate every conductor which enters an above grade enclosure as shown in the plans, and leave one turn coiled in the enclosure. Seal the ends of the telecommunication conductor to prevent moisture from entering the cable. 2. Optical Conductor Cable. Terminate or splice all fibers within fiber optic cable enclosures. Use rack mounted organizer trays to hold the spliced fibers, with each fiber neatly secured to the tray. Use fully enclosed in 19 in. rack mounted units, or other material as shown on the plans, for fiber optic termination enclosures. Provide mounting brackets that provide cable clamps for strain relief of up to 4 incoming cables on the enclosure. Install the fiber optic cable according to the manufacturer's recommended standards for the cable distribution panel used. Size fiber optic termination enclosures according to the fiber count shown on the plans. Provide each enclosure capable of holding at least the number of connector bulkheads to support the total number of fibers in the incoming cables. Provide each enclosure capable of holding at least the number of splice trays to support splicing the total number of fibers in the incoming cables. In enclosures where the optical fibers have to be connected to terminal equipment, provide matching connectors with fiber pigtails of sufficient length and splice them to the corresponding optical fibers. Provide fiber pigtails buffered and strengthened with Kevlar to reduce the possibility that accidental mishandling will damage the fiber or connection. Provide FC style single mode bulkheads and pigtails. Provide ST style multi-mode bulkheads and pigtails. Provide bulkheads and connectors from the same manufacturer. Provide fiber optic jumper cables to cross connect the cable distribution panel to the fiber optic transmission equipment. Provide jumper cables matching in size, type, and attenuation. Provide jumpers orange in color for the multimode fiber and yellow for single mode. Provide fiber jumpers having a 900 micron or 1000 micron polymer coating with tight buffer tube, Kevlar strength member and a PVC jacket. 3-8 8540
B. Splicing. Provide jumpers 1 m in length or as directed by the Engineer. Provide duplex jumpers for data connections and simplex jumpers for video connections. Provide one end of each jumper with ST connectors for multimode fiber, or FC connectors for singlemode fiber. Provide the other end with the same connector styles, or the appropriate connectors specified to fit the fiber optic transmission equipment to be connected. Use epoxy style ST and FC connectors. Crimp-on connectors are not acceptable. Provide connector to connector mated pair loss not exceeding 0.4 db. Maintain this loss characteristic for a minimum of 500 connections (with periodic cleaning) and throughout the entire operating temperature range. Qualify and accept connectors on the basis of connector to connector mating of similar fibers using the test procedure described in this specification. Provide return loss for singlemode connectors not greater than -40 dbm. 1. General. Complete all conductor splices, including splice enclosures and encapsulations, in accordance with the requirements of the RUS Bulletin 1753F- 401, "RUS Standard for Splicing Copper and Fiber Optic Cables", PC-2, latest revision. Complete all splicing, shield and jacket bonding, grounding, and testing in accordance with the RUS Bulletin 1753F-401 (PC-2), National Electrical Safety Code, and National Electrical Code. Obtain approval of the Engineer prior to any splice location. Splice aerial cables only in ready access enclosures as shown in RUS Bulletin 1753F-401 (PC-2). 2. Optical Conductor Cable. Use the fusion technique for all fiber optic fibers. Provide fusion splicing equipment that has been cleaned, calibrated and specifically adjusted to the fiber and environmental conditions at the start of each shift. Splice fiber optic cable such that splice loss does not exceed 0.15 db. Record all splice losses in tabular form and provide to the Engineer for approval. Test splices that are made between 2 cables spliced fiber optic cable using an Optical Time Domain Reflectometer (OTDR). Test these splices at 1300 nm and 1550 nm and provide printouts of the splice test results for acceptance by Engineer. Test splices that are made between cable to pigtails with an optical light source and optical power meter. Conduct tests at 1300 nm and 1550 nm. Complete the test after both ends of the cable have been spliced. Pre-calibrate the power meter and light source to 0 dbm for the test. Use a 1 m jumper for calibration. Perform an end to end reading with the cable and 2 jumpers (one at each end) between the light meter and optical source after calibration. C. Inspection, Testing, and Test Reports. It is the policy of this Department to require performance testing of all materials and equipment not previously tested and approved. If technical data are not considered adequate for approval, samples may be requested for test by the Engineer. The contract period will not be extended for time lost or delays caused by testing prior to final Department approval of any items. 4-8 8540
Provide test procedures and forms in accordance with Special Specification Item, Testing, Training, Documentation, Final Acceptance, and Warranty, Testing Requirements, found elsewhere in the project specifications. Inspect and test all cable conductors in accordance with requirements described in RUS Form 515, "Telecommunications System Construction Contract", Article V. Perform tests specified in this Special Specification on all conductors. 1. Provide manufacturer's test data showing the conformance to the requirements described in this Special Specification for each reel of cable. 2. Conduct pre-installation inspection of representative samples of cable on reels with Engineer prior to installation. Replace nonconforming reels of cable. Conduct the following pre-installation inspections: a. Inspection for proper cable identification on reel identification labels by checking shield, number of pairs, gauge size, jacket, etc. b. Inspection for physical damage to cable and for wet cable c. Check for the presence of filling compound at the ends. d. Check for uniform jacket thickness and tightness of the jacket. Comply with requirements for cable placement described in Part III of RUS Forms 515b and 515c. 3. Perform continuity tests for all cable conductors under direct supervision of the Engineer on each length of conductor in a cable containing a splice immediately after installation and prior to backfilling the excavation. Include test for leakage, continuity, crosses, and splits. Inspect splice enclosures, terminals, surge protectors, loading coils (if necessary), and all other materials necessary for the complete installation with Engineer. Inspect each splice enclosure furnished during and after installation for proper encapsulation. Inspect and test all cable conductors in accordance with requirements of RUS Bulletin 1753F-401 "RUS Standard for Splicing Copper and Fiber Optic Cables", PC-2, latest revision. Test all cable conductors in accordance with the following sections of RUS Bulletin 1753F-201, "RUS Standard for Acceptance Tests and Measurements of Telecommunications Plant", PC-4, latest revision: 1. Metallic conductor cable: Ground Resistance Shield Continuity Conductor Continuity DC Insulation Resistance DC Loop Resistance Insertion Loss 5-8 8540
Voiceband Data Transmission Measurements Shield or Armor Ground Resistance Measurements 2. Optical conductor cable: Fiber Optic Cable Telecommunications Plant Measurements Shield or Armor Ground Resistance Measurements Prepare all necessary test forms. Install at least the number of pairs or conductors shown on the plans. No compensation will be provided for any pairs or conductors over the number shown on the plans. Provide all test equipment necessary for testing the cable conductors. Test all conductors as required above and identify any bad conductors if they cannot be made good and document results on RUS Form 517, latest revision. The maximum allowable loss, tested in accordance with this specification, is to be less than or equal to the total of the allowable cable loss, plus splice loss, plus connector loss. The allowable loss per fiber is calculated as follows: Cable: Km of cable @ 0.5 db/km for singlemode Km of cable @ 1.0 db/km for multimode Splices: 0.15 db per splice times a factor of two (0.3) Connectors: 0.4 db per mated pair of connectors times a factor of two (0.8) Total: 1.1 db + 0.5 x km for singlemode 1.1 db + 1.0 x km for multimode D. Training. In accordance with Special Specification Item, Testing, Training, Documentation, Final Acceptance, and Warranty, Training, conduct a minimum of 40 hours of training for up to 10 representatives designated by the Engineer on procedures of installation, splicing, terminating, testing, and troubleshooting of each type of cable. At a minimum, provide training material including standard compliance, pulling and installation techniques, use of installation tools, splicing and terminating equipment and test instruments, methods of recording installation and test data, locating, analyzing, and correcting different causes of trouble in a fiber optic network. Provide the Engineer with copies of the training material for approval. Unless otherwise shown on plans, provide training when total item unit of measure exceeds 5,000. Provide training earning BISCI credits. Provide trainers certified by BICSI. E. Documentation. In accordance with Special Specification Item, Testing, Training, Documentation, Final Acceptance, and Warranty, Documentation, provide complete sets of operation and maintenance manuals wherever material is furnished and installed. Provide one additional complete set of documentation for the control center. As a minimum, provide the following documentation: Complete and accurate schematic diagrams showing the fiber optic cable plant. Complete performance data of the cable plant showing the losses at each splice joint and each terminal connector. 6-8 8540
Installation, splicing, terminating and testing procedures. Complete parts list including names of vendors. Complete maintenance and trouble-shooting procedures. Provide installation practices with material information in accordance with Item 6. Provide installation practices including, at a minimum, list of installation equipment, and splicing and test equipment. Provide field quality control procedures, as well as, procedures for corrective action. F. Warranty. Provide warranty in accordance with Special Specification, Testing, Training, Documentation, Final Acceptance, and Warranty. G. Maintenance. Whether newly installed or existing material, provide periodic maintenance as described in this Special Specification and when directed by the Engineer. For materials provided by referenced specification, provide maintenance in accordance with the referenced specification and any additional requirements provided in this Special Specification. Periodic maintenance of furnished and existing materials and equipment consists of any and all testing described in this Item, inclusive of all referenced specifications, as shown on the plans, and as directed by the Engineer. Provide periodic maintenance with new materials and include in price bid for Item. Unless otherwise shown on the plans or directed by the Engineer, perform maintenance at intervals not exceeding 12 months. Provide non-periodic maintenance of existing material and equipment to remove, relocate, or replace any or all material and equipment described in this Special Specification when shown on the plans or as directed by the Engineer. Replace is defined as removing old material or equipment, furnishing new material or equipment, and installing the new material or equipment. Test material which is replaced or relocated. 4. Measurement. Measure telecommunication conductor cable of the various types and sizes shown on the plans by the foot, complete in place, along the cable. Existing telecommunication cable terminated will be measured as each telecommunication cable terminated, including splice to a pigtail or jumper, and tested in accordance with these Specifications. Existing telecommunication cable spliced will be measured as each telecommunication cable spliced and tested in accordance with these Specifications. Maintenance of existing telecommunication cable and equipment will be measured as each cable on which maintenance is performed or each unit of equipment on which maintenance is performed. 7-8 8540
5. Payment. The work performed and materials furnished in accordance with this Item and measured as provided under "Measurement", will be paid for at the unit price bid for "Telecom Cable", Telecom Cable (Terminate), Telecom Cable (Splice), of the various types, sizes, equipment, non-periodic maintenance, and Telecom Cable (Periodic Maintenance) specified. This price shall be full compensation for furnishing, installing, terminating, splicing, and testing all conductors, including messenger strand, and providing training, documentation, and warranty, for placing in conduit or attaching to overhead messenger strand, excavating and backfilling the trenches, replacing base, seal, riprap, pavement, sod, or other surface treatment; and for all labor, tools, equipment and incidentals necessary to complete the work. 8-8 8540