CASE STUDY

MaxWrap^® Fiber Optic Installation Drives Mission-Critical Results

Finding an effective solution for long, difficult cable pulls is critical — especially at a strategic military base, where network reliability is paramount.

Objective: Fiber Redundancy and Failover for a Strategic Military Installation

In a recent fiber redundancy project at a strategic military base, the military wanted to ensure network reliability by incorporating redundancy and failover mechanisms. Network redundancy is a crucial solution that would provide them with an additional layer of protection and access to a high-bandwidth, low-latency connection. With redundant pathways, a network would have to fail in multiple environments to cause an outage, meaning a single point of failure would not take a network down.

This logistically challenging project required innovative thinking and scalable solutions to be successful. As a mission-critical project, this needed to be expedited. Because the military knew it was important to work with fiber construction specialists, they turned to the team from MaxCell^® to find an appropriate product for this project. Having worked with MaxCell on numerous projects in the past, the military knew that MaxCell had deep industry experience, engineering expertise and proven knowledge to provide them with unique solutions for specific application issues. With a robust portfolio of network construction products, MaxCell could help them navigate the hurdles on this project with confidence and would deliver solutions they could count on.

Challenge: Fiber Optic Installation Over Distance and Depth

The project involved an exceptionally difficult underground crossing nearly 4,000 feet long and 150 feet deep. To meet bandwidth and capacity requirements, the installation required three high-density fiber cables: one 3,456-count fiber cable and two 864-count fiber cables.

Despite being made of glass, fiber optic cable is surprisingly durable, but with the distance and depth that the cable would have to be pulled there was concern that it would exceed the tensile strength of each cable. Tensile strength is vital for cable durability and network reliability. The length of a pull, the weight of the cable and the amount of friction and twisting can all affect tension as well. Excessive pulling can stretch or break the fibers within the cable and cause damage or future failures.

Benefits of MaxWrap

A single-step cable and innerduct pulling solution
For difficult or long conduit spans
Reduces pulling tension by 85%
Protective design
Prevents delays and added costs for overbuilds
Faster installation with minimal disruption
Cut and abrasion resistant
Resistant to ground chemicals and petroleum
Manufactured in the U.S.A.

Solution: Protection and Speed With Fiber Installation Process

After reviewing the project objectives and specifications, the team from MaxCell recommended utilizing MaxWrap OSP fabric mesh innerduct solution to safeguard the fiber cable. MaxWrap is a single-step pulling solution that shortens installation time by encompassing the cable as the cable is being installed. It eliminates the need for new duct installation in an overbuild application. MaxWrap delivers significant protection to the cable during the entire pulling process.

Results: Significantly Faster Fiber Optic Installation Without Performance Loss

The MaxCell staff and installation engineers were on-site to oversee the installation and assist with training and guidance. Each of the three cables was pulled individually, with the tension on them never exceeding 150 lbs. With 85% of the tension being on MaxWrap, this resulted in minimal tension on the actual cable product and made for an easy and quick installation.

Prior to the actual installation, it was estimated that this job would take three days to complete. With the ease of the MaxWrap installation process, all three cables were pulled quickly, and the project was completed in less than five hours.

Even more impressive, the cables were tested after they were pulled and results were as good as when they arrived from the manufacturer.

Summary: Proven Performance Leads to Broader Military Adoption

Installing MaxWrap proved to be a fast, non-invasive process that delivered superior cable protection and load reduction. By supporting higher fill percentages and longer pulls, MaxWrap demonstrated that even long, difficult installations could be completed efficiently, while its engineered fabric protected fiber cables from sheath damage.

With the success that was achieved by using MaxWrap on this time-sensitive and essential project, the government and military have specified MaxWrap on additional projects.