CASE STUDY
MaxWrap® Accelerates Long-Haul Fiber Optic Installation
Bluebird Fiber expanded capacity quickly and easily with no costly fiber construction thanks to MaxWrap flexible fabric innerduct.
Objective: Fiber Infrastructure Expansion
Bluebird Fiber, a communications infrastructure provider and data center operator headquartered in Kansas City, Missouri, provides internet and transport services via its fiber infrastructure to carriers and enterprises in Missouri, Illinois, Kansas, Iowa and surrounding states. Bluebird Fiber also owns two data centers that include an underground facility in Springfield, Missouri and a facility in the Quad Cities. The company operates more than 11,000 fiber route miles of high-speed broadband and fiber optic connections spanning major Midwestern cities. In business for over 25 years, Bluebird Fiber serves a diverse range of data-driven entities including businesses, schools and hospitals. To ensure a seamless experience for its customers and deliver world-class network solutions, Bluebird Fiber continues to focus on opportunities to expand its fiber network and services to a growing number of business customers.
Challenge: Overcoming Space and Distance Constraints
The company’s focus on expanding its fiber infrastructure included a long-haul fiber expansion project requiring a fiber optic installation that was challenging due to space constraints and distance requirements. Bluebird Fiber was out of duct space. The company had an inch and a quarter duct, 31.5mm with an existing 16mm cable in place and needed to add additional fiber throughout the long-haul run. There were also some very long pulling distances between the existing access points which could put stress on the cable and added complexity to the fiber optic installation. Traditional solutions required removing the existing cables, trenching, boring and installing new duct which was time-consuming and expensive. Permitting and right-of-way issues would add logistical challenges, approvals and significant delays. Bluebird Fiber was looking for a new way to complete the project on time and on budget.
Benefits of MaxWrap
A single-step cable and innerduct pulling solution
Reduces installation time
Provides a fast, flexible, no-dig solution
Accelerates time to market
Utilizes existing ducts/pathways efficiently
Reduces pulling tension
Protected design
Reduces new duct installation costs
Avoids new duct installation delays
Manufactured in the U.S.A.
Solution: A Smarter Path to Long-Haul Fiber Expansion
MaxCell® flexible fabric innerduct had proven effective for Bluebird Fiber in the past, so the company once again turned to the MaxCell team for expert insight and to recommend the best solution for the long-haul fiber expansion. After meeting with Bluebird Fiber and evaluating the project challenges, the MaxCell team recommended utilizing MaxWrap® fabric mesh solution which was strategically engineered to reduce cable load under tension during installations.
MaxWrap is an outside plant (OSP) fabric mesh solution that is applied around the cable as it is pulled into conduit and offers protection for both new and existing cables. MaxWrap allows new pathways to be added without removing existing cables, trenching or even interrupting service. Because this fabric pathway is installed directly over the existing cable where pulling speeds are not compromised, it is a perfect solution for providing a protected pathway alongside existing infrastructure. MaxWrap is also ideal for long pulling distances. It takes the load off the cable so it can be pulled harder on the tape or pulling medium, and the tension does not transition to the cable itself. With the tension all going into the fabric wrap, the cable can be pulled significantly longer distances.
The MaxCell team supported Bluebird Fiber throughout the fiber optic installation project. First, the installers needed to insert a pulling medium into the duct. The MaxCell team presented them with a method to install their tape, or their rope, by jetting over the existing cable. This method used a split shuttle that fit over the cable, then utilized air pressure to push the shuttle. It pulled the pulling tape through preventing spiraling around the existing fiber. The installers were able to utilize this method to install their pulling tape and were ready to move forward with the cable installation. To allow for a smooth process and seamless installation, MaxCell’s team was on site to train the installers on working with and installing the MaxWrap product. They made periodic visits back to provide additional oversight as the long-haul installation proceeded.
Results: Faster Deployment With Lower Cost
Utilizing MaxWrap allowed Bluebird Fiber to quickly complete the project within a one-month time span. Had new construction been done, along with trenching, boring and installing new duct, this could have taken triple the amount of time, or more. Added to the actual physical installation time needed for a new construction project, there would have been administrative time for right-of-way permits and approvals that would have been required. Most importantly, new construction for this same project would have been more expensive to complete and could have resulted in service interruptions. MaxWrap was installed with minimal disruption and the entire process was streamlined.
Summary: Reaching More Customers Faster
Bluebird Fiber has built its reputation on serving its customers and providing reliable internet. Using MaxWrap to solve challenges on this two and a half-mile fiber expansion allowed the company to quickly reach more customers throughout its network and deliver dedicated fiber internet, data center solutions and cloud connectivity services to new customers.
As part of its ongoing efforts to expand and offer service and capabilities to new customers, Bluebird Fiber placed an additional order of MaxWrap for another expansion project.