Amend_0003_Atch7_Cable_Distro_Sys_Standards_1Mar2008_V7.pdf

UNCLASSIFIED

U.S. ARMY IN EUROPE

CABLE DISTRIBUTION SYSTEM (CDS)

CONSTRUCTION STANDARDS

Solicitation W912GB-13-R-0009 Amendment 0003 - Attachment 7

U.S. Army in Europe

Cable Distribution System (CDS) Installation Standards

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TABLE OF CONTENTS

PARA DESCRIPTION PAGE

1 Purpose 2

2 System Design and Integration Services 3

3 Underground Systems (Manhole and Duct) 10

4 General Trenching Requirements 14

5 Cables 16

6 General Cable Installation 17

7 Cable Labels 21

8 Specific Requirements for ICDS 23

9 Cabinets 30

10 Protected Distribution Systems 36

11 Quality Assurance Inspections, Testing and Assistance 39

12 Document Samples 42

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1. PURPOSE: This document details U.S. Army in Europe installation standards and requirements for outside Cable Distribution Systems (CDS), Inside Cable Distributions Systems

(ICDS), Protected Distribution Systems (PDS) and other cabling systems within and between

U.S. Army in Europe facilities/offices and buildings. The 5th Signal Command, in the role of the ultimate NIPRNet/SIPRNet connectivity and/or telephone service provider, has the authority standards. This document is a cooperative collaboration between the 5 th

Signal Command, Deputy Chief of Staff, G3, Projects and Engineering (P&E) Office and the USAREUR G6 Office of the Information Assurance Program Manager’s (OIAPM) Certification & Accreditation

(C&A) Branch. From this point forward, the 5th Signal Command refers to the 5 th

Signal

Command, Deputy Chief of Staff, G3, P&E. The “OIAPM”, unless otherwise indicated, refers to the IAPM’s C&A Branch.

1.1. Installation networks provide data connectivity between building LANs on an installation and provide connectivity to outside networks. Engineering, installation, operation, and maintenance of installation LANs is part of the 5 th

Signal Command mission and will not be done by any other unit without a wavier from the G3, 5 th

Signal Command. The 5 th

Signal

Command, G3 will engineer and install installation networks; local Signal Battalions, RSC/OC personnel will operate and maintain them. All CDS/ICDS projects will be installed to meet current commercial standards, I.E. TIA/EIA 568, ISO 11801, NEC, NFPA, VDE -800, and EN

50-173/174.

1.2. All cabling installations accepted by and supported in any way by 5 th

Signal Command, its

Brigades and Battalions are under the complete and sole control of 5 th

Signal Command and/or its designated representative. This includes, but is not limited to, all types of communications

/network cables and duct systems (inside and outside), network cabinets, network equipment, and wall jacks. Private networks or LANs are not permitted without the specific authorizations of the 5

Signal Command Deputy Chief of Staff, G3.

1.3. These standards may be supplemented by a Site Unique Requirements (SURs) email. The email must state the purpose of a SUR. It must justify situations that are not addressed or cannot comply with this standard or other regulatory guidance. The SUR must be reviewed by and coordinated through the OIAPM and subsequently approved by the 5 th

Signal Command G3 representative prior to contractual commitment.

1.4. Comments, recommendations or questions regarding this document may be submitted to

Commander, 5 th

Signal Command, Projects and Engineering (P&E) Office, ATTN: NETC-SEC-

O, Unit 29800, APO AE 09056-9800 and/or Mr. Ken Lovell, DSN 380- 5639, email:

Kenneth.w.lovell@eur.army.mil or Michael Falter, DSN 380-5658, email:

Klaus.michael.falter@eur.army.mil.

1.5. All contracting companies responsible for telecommunication installation shall have the

DIN EN ISO 9001 or 9002 accreditation or be a candidate for accreditation. A copy of the certificate or supporting documentation for candidates shall be provided with the contract proposal.

mailto:Kenneth.w.lovell@eur.army.mil mailto:Klaus.michael.falter@eur.army.mil

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1.7. This document is currently available in English only. It is the contractor’s responsibility to ensure that the requirements are well understood and adhered to.

1.8. This document is available on the 5

Signal Command Portal:

https://www.5sigcmd.army.mil for government owned computer access. There is also an iAssure link to the same 5th Signal Command page in the Accreditation section.

1.9. This document is reviewed and if necessary, annually.

2. STARTING A PROJECT / SYSTEM DESIGN AND INTEGRATION SERVICES. A

CDS project begins with the unit generating a Capability Request (CAPR). See figure 1 below for the process. The contractor shall provide information systems engineering, installation and testing support in response to tasking documents that define the specific tasks. The various elements of work are described in, but not limited to, the following paragraphs. Any unique tasks not covered below will be specified in the SUR. The OIAPM provides advice and assistance to ensure Information Assurance (IA) and Defense Information Assurance

Certification & Accreditation Process (DIACAP) controls, requirements and provisions are incorporated into the project, while 5 th provides guidance and advice regarding cable infrastructure (CDS/ICDS), and quality assurance.

2.1. Information System Engineering. Information systems engineering will be performed by the contractor to translate the requirements and performance objectives of a selected system approach into design criteria and specifications for the implementation of individual elements and subsystems that make up the system. More specifically, the elements within the information systems integration arena shall include the following: supporting structures (manhole and duct), copper cable, fiber-optic cable and systems, video, carrier systems, timing equipment, Synchronous Optical Network (SONET) equipment, power systems, digital systems, equipment cabinets/racks, and cross connect systems. The contractor's systems integration process shall incorporate system-of-systems planning and design to include, but not limited to the items listed in the following sub-paragraphs.

2.1.1. Ensure all new CDS will be capable of supporting voice, data, video, Integrated Services

Digital Network (ISDN) and the US Army’s single line concept that allows a simultaneous connection of all telephone jacks in the building to the Dial Central Office’s (DCO) Main

Distribution Frame (MDF). This will allow flexibility and ease of connection for current and future communication service requirements. Minimum building entry cable sizes are as follows:

TYPE OF SPACE QUANTITY

Administrative Space 1 pr per 80 ft (7.5 m

) plus 25% for future growth

Technical Space 1 pr per50 ft (4.6 m

) plus 25% for future growth

Living Space 1 pr per 315 ft (29 m

) plus 25% for future growth

Warehouse/Motor Pool/Hangers 1 pr per 1000 ft (92m

) plus 25% for future growth

Other 1 pr per 80 ft (7.5 m

) plus 25% for future growth

Solicitation W912GB-13-R-0009 https://www.5sigcmd.army.mil/

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2.1.2. Existing resources that meet current I3MP, USAREUR, 5

th

Signal Command standards shall be incorporated.

2.1.2.1. Housing Area requirements. Authorized customers (Senior Officers and Enlisted) may be authorized LANWAR Net Unclass and LAN WAR Net Class. In these cases a minimum of

10 pair copper cabling will be installed from the customer quarters to the Post Dial Central

Office (DCO) Main Distribution Frame (MDF) or an Immediate Distribution Frame (IDF) located in a Communications building installed in the housing area.

2.1.2.2. Minimum cable count shall not be less than 30 copper pairs and 12 strands of single mode fiber optic cable to a building. Except as noted in paragraph 2.1.2.1 or in the SUR.

2.1.3. Determine the interoperability of all interfaces within and external to the system

(hardware and software) including necessary support equipment and facilities and other systems and equipment that are present or will be required in the operational environment.

2.1.4. Conduct and/or support investigations of systems performance, systems integration, systems interoperability, and problems with fielded systems and recommend alternative solutions.

2.1.5. Determine power loss calculations showing the fiber optic loss budget limitations.

2.1.6. Conduct comprehensive facility, link and system tests upon completion of each segment of the installation or at project completion. The contractor will notify the Quality Assurance

Branch of the Projects and Engineering (P&E) Office, ATTN: NETC-SEC-O, Unit 29800, APO, AE 09056-9800, or Mr. Bob Carper, DSN 380-5629, email: robert.l.carper@eur.army.mil two

(2) weeks prior to testing so that the tests can be observed and certified by QA personnel.

Electronic copies of the test results (raw data) will be provided to the 5th Signal Command representative.

2.2. Site Survey. The contractor shall perform site surveys. The contractor shall collect, collate, analyze, and document the technical and supporting information required to complete the detailed engineering of the supporting structures and cable plant upgrade, including cable spreadsheets and documentation IAW paragraph 2.7 of these standards.

2.2.1. The contractor shall survey and physically verify all existing manhole and duct systems serving any affected buildings/areas to determine their adequacy to support the required cable upgrades. In order to be considered sufficient, the manhole and duct system must have enough spare capacity to support the current cable upgrades plus allow 25% vacant duct for future expansion. The contractor will not utilize the last duct available in any existing duct segment.

There are situations where placing sub-duct into vacant duct may provide sufficient growth potential for the future. An example of this would be an entrance duct into a small building where the new cable could be installed in sub-duct with sufficient room remaining to allow for installation of the largest copper cable required to accommodate the single line concept for current users in the building. If no sub-ducts are available, the contractor shall include the installation of a minimum of 2 x 30mm and 2 x 400mm ducts, or fabric (Maxcell type) sub-duct, Solicitation W912GB-13-R-0009 mailto:robert.l.carper@eur.army.mil

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in a vacant 125 mm (5 in) inside diameter conduit. Fiber optic cable shall not be installed directly in a 125 mm (5 in) inside diameter duct. If the contractor proposes a specific situation where this would be acceptable, the government must insure that it is documented in a SUR.

2.2.2. The contractor may also propose the installation of new cable into duct which is already occupied if they feel the new cable can be installed without damaging it or the existing cable(s).

The contractor's proposal shall identify where they plan to use this approach. The contractor shall provide the size of the duct, number, size and type of existing cables, and the number, size and type of new cables to be installed in this manner. If this approach is approved, it will be documented in the SUR and the contractor shall be liable for any damage to any of the manholes, ducts, and/or cables during installation.

2.2.3. The contractor shall inspect all building entrances to determine their adequacy (i.e.

existing spare duct capacity/building ground adequacy, etc) to support the proposed cable plant upgrades.

2.2.4. The contractor shall meet with the site Directorate of Public Works (DPW) to verify any specific site construction requirements identified in the SUR. Some areas for consideration are roads, sidewalks, parking areas, railroads, stream or river crossings, bridge crossings, etc. The contractor shall also verify the specific installation procedure to be utilized prior to start of construction.

2.3. Site Survey Report. The contractor shall prepare a site survey report (SSR) in a commercially acceptable format. The contractor shall deliver the SSR to the 5th Signal

Command Project Manager or his designated representative. The SSR shall include the following as a minimum:

2.3.1. A list of any discrepancies found within the SUR, site map or cable route.

2.3.2. A list of all details and agreements made pertaining to equipment, equipment locations, and facilities.

2.3.3. A list of any expected problem areas, along with proposed solutions.

2.3.4. A detailed schedule for the engineering and implementation of the project.

2.4. Site Preparation. As part of an overall system design and installation, the contractor may be required to perform site preparations. All proposed site preparations must be documented in the

SSR. Site preparations shall include, but is not limited to the following.

2.4.1. Mechanical requirements may include, but are not limited to, environmental control to allow for equipment operating temperatures and humidity, heat emission of electronic equipment, and ventilation requirements, etc.

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2.4.2. Electrical requirements may include, but are not limited to, power requirements; technical and non-technical power panels, lighting and receptacle requirements, and proper grounding of facilities.

2.5. Equipment Configuration. The equipment configuration shall be determined by the contractor to translate the design approach and system requirements into a configuration that can be produced, installed, tested, integrated, and supported within the state of existing or economically achievable technology and support capability. The equipment configuration shall include, but is not limited to the considerations in the following sub-paragraph.

2.5.1. Provide a review of the proposed equipment configuration.

2.5.2. Provide a review of the detailed wiring diagrams and single-line diagrams for circuits to be installed or modified by the installers and a review of single-line diagrams and block diagrams of representative communications complexes.

2.5.3. If needed, the PWS / SOW will identify what type of software and switch configuring is required to be performed by the contractor.

2.5.4. Sizing of data network switches will be a coordinated effort with the contractor, user, and the local Signal Battalion, ROC/OC. Minimum switch size is calculated by determining the current (or planned, if building is new or completely renovated) amount of data network devices plus 20%, for growth. Switch size is not determined by the total amount of dual outlets installed in the building, as this will far exceed the actual user potential.

2.6. Reviews, Meetings and Reports.

2.6.1. Initial Design Review (IDR). The contractor shall notify the Project Manager when they are prepared to conduct the IDR to allow government review of their initial design. The Project manager will coordinate a time and location to conduct the meeting. The PM will also notify the local DPW, DCO, ROC/OC, and signal battalion of the planned meeting. Copies of all documents (i.e. PCM, IBOMs) shall be provided in hard copy and in electronic format. Project information to be reviewed shall include any potential safety issues (i.e. asbestos reports supplied by DPW), project status and schedule, engineering drawings, bill of materials, and material specifications. The engineering drawings shall depict the routes and/or placement of all ICDS cable routes, CDS cable routes, manholes, hand holes, pedestals and direct buried cable.

Utilization of existing manholes and ducts shall be clearly depicted. The drawings shall also define all road cuts and/or bores as agreed to by the local DPW. The contractor shall develop minutes of the meeting. Copies of the minutes shall be provided to the site POC and 5th Signal

Command PM and/or representative via email.

2.6.2. Critical Design Review (CDR) / Final Design Review (FDR). The contractor shall notify the Project Manager when they are prepared to conduct the CDR to allow a government review of their final design. The Project manager will coordinate a time and location to conduct the meeting. The PM will also notify the local DPW, DCO, ROC/OC, and signal battalion of the planned meeting. Project information to be reviewed shall include any potential safety issues (i.e.

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asbestos reports supplied by DPW), project status and schedule, engineering drawings, bill of materials and material specifications. Copies of all documents (i.e. PCM, IBOMs) shall be provided in hard copy and in electronic format. The contractor shall develop minutes of the meeting. Copies of the minutes shall be provided to the site POC and 5th Signal Command PM and/or representative via email.

2.6.3. Pre-Construction Meeting. Prior to the start of construction, the contractor and their on-site project manager shall notify the 5 th

Signal Command Project Manager to coordinate and schedule a pre-construction meeting with the site POCs, DPW, DCO, ROC/OC, Fire, Safety, Security, the Installation Coordinator, the local signal battalion representative and any other affected personnel. This meeting will be conducted at the construction site. The contractor is responsible for notifying the project COR if the Project Manager has not coordinated this meeting. Construction cannot begin until the 5 th

Signal Command Project Manager has given final approval to the design and implementation plan.

2.6.3.1. The contractor and their on-site project manager shall work with the appropriate DPW, local DCO and ROC/OC, personnel and 5th Signal Command representative to confirm the exact location of all new cable, equipment, manholes, and duct prior to start of excavation. This will be reviewed at the pre-construction meeting.

2.6.3.2. On US government installations, the contractor and their on-site project manager shall coordinate with the DPW and submit written requests for digging permits for all excavation to include scheduling of all road closings, the cutting/boring of roadways and marking of conduit paths. Local post policy regarding in-ground installation of conduit and manholes shall have precedence and override any stated directives contained within this document. This will be reviewed at the pre-construction meeting.

2.6.3.3. Most military installations have areas that may be affected by environmental or historical matters. Environmental hazards may include toxic waste, fuel spillage/leakage, asbestos, unexploded ordinances, etc. Wildlife preservation may be another area of concern at some sites. Compliance with historical restrictions shall require special engineering considerations (type of exterior facing, mounting of terminals, placement of pedestals, etc.).

These types of situations will be further defined in the SUR.

2.6.3.4. Disposing of waste materials shall be accomplished by the contractor in accordance with the local requirements for clean and/or hazardous material.

2.6.4. In Progress Reports (IPR) / Periodic Report. The contractor shall provide comprehensive status and progress (IPRs) reports every two weeks to the 5th Signal Command PM and/or representative. The reports shall include a description of work accomplished during the reporting period, problems encountered and status of resolution, work planned for the next reporting period, problems anticipated that may impact the cost and scope, and recommendations for schedule changes. It shall also include fiscal data for the reporting period, cumulative fiscal data, and revisions to the milestone.

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2.6.4.1. As the installation progresses, the contractor shall make recommendations of components required to overcome unforeseen obstacles in order to meet installation requirements

(i.e. verify measurements, power requirements, floor space and cable routes) and submit red-lined project drawings to the 5th Signal Command representative for review. All proposed changes/solutions shall be reviewed and approved by the PM (or their representative) prior to implementation.

2.7. Required Documentation

2.7.1. Engineering Drawings. The contractor shall develop engineering drawings using the scaled site map and/or plant-in-place drawings. As a minimum, contractor developed drawings shall show all work involving manholes, duct routes, cable routes, and splice points.

2.7.2. Manhole, hand holes, and Duct Routes. The contractor shall annotate the proposed manhole, hand holes, and duct route on the DPW installation map. The updates shall be completed as required.

2.7.3. Cable routes and splice points. The contractor shall annotate proposed cable routes, splice points, and cable counts.

2.7.4. Cable vault schematic diagrams depicting existing and new cables.

2.7.5. Equipment locations with rack elevations.

2.7.6. Floor plan/main distribution frame layout.

2.7.7. An ICDS cable running list, identifying user outlet locations and outlet numbers, will be developed and a hard or paper copy placed in the network cabinet prior to final acceptance testing.

2.7.8. Manhole Butterflies. The contractor shall develop manhole butterfly drawings for all newly installed manholes and update or create manhole butterflies for existing manholes which depict the work performed by the contractor. The butterfly drawings shall depict the duct assignments, cable routing, splicing, and racking as it is to be installed in the manhole.

2.7.9. As-Built Drawing Package. Throughout the installation process, the contractor shall maintain up to date “redline” (as-built) drawings of all changes made to the original project design. Upon completion of the acceptance tests, the contractor shall furnish redline drawings showing the duct routes, cables routes, cable pair counts in: manholes, hand holes, ducts and buildings, placement of terminals, all splice points, manhole butterflies, building ISP, and all major components. The redline project drawings shall follow the same format as the

Engineering drawings, including cabinet and equipment placement. All hardware/equipment shown on the redline drawings is uniquely labeled so the physical equipment identification label and the drawing label coincide. Three sets (one electronic and two hard copies) of the As-Built drawings shall be provided to the 5th Signal Command G3 PM. All drawings shall meet the

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standards and guidelines set forth in FED-STD-1037B, ANSI Y31.9-1972, IEEE-315-1975, and

IEEE-315A-1994.

2.7.10. The contractor shall use the latest version of AutoCAD for all drawings per DOD requirements.

2.7.11. The contractor shall report any utilities, cables, or other items not shown on DPW drawings to the DPW whether or not they affect the current design.

3. UNDERGROUND SYSTEMS (MANHOLE AND DUCT). Underground systems shall be used on all CDS projects, unless otherwise specified in the SUR. Aerial/overhead cable plant systems are not authorized. Underground cable/splice installation (direct buried cable) in range areas shall be IAW ISEC OSPR (Outside Plant Requirements).

3.1. Manholes. Manhole requirements will be determined during the design phase of the project. Manhole size will meet project requirements plus 50% to allow for future expansion.

Pre-cast, multidirectional manholes shall be used.

3.1.1. The manholes and associated conduits in the main runs must be sized to support both copper and fiber optics connectivity of all buildings. The conduits and manholes in the main runs shall be designed in such a manner that future projects can be implemented without modification or duplication of a previously installed conduit system.

3.1.2. Basic Layout for Manholes. Except for Tie Cable projects, manholes shall not be placed more than 185 meters (600 ft) apart. Measurements between manholes are from lid to lid (center to center). Measurements from manholes to buildings are from the manhole lid to outside wall

(center to point). New manholes shall be placed to support the locations of junction points, offsets, load points and curvature in the duct line.

3.1.3. Manhole Marking

3.1.3.1. Request assistance from the local DCO and/or the DPW to select a start point for the numbering sequence (1st manhole location and its number). If a good numbering sequence that builds off the existing manhole numbers cannot be established, use the format indicated below with the project name as a header before each number.

3.1.3.2. A letter/number designator will be painted or stenciled with the manhole information will placed on the inside riser collar of each manhole approximately 12 inches below the cover.

If a metal or plastic placard is used, the same painting requirements will apply.

3.1.3.3. A yellow or white rectangular area, sized to fit all the lettering, will be painted as a base/background. Letters/numbers will be in black paint.

3.1.3.4. Format: (Project) (Project)

MH XXX HCDS MH XXXX

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3.1.3.5. Letters and numbers will be 3-5 inches (7- 12 cm) tall.

3.1.3.6. Ensure manhole numbers on the As-Built drawings coincide with the numbers assigned to the manholes.

3.1.4. Manhole Accessories. Each new manhole shall be equipped with pull irons, ground rod or bonding ribbon, ladder with handrail/guardrail, cable racks and hooks.

3.1.4.1. Cable hooks and/or racks shall be placed in such a way as to prevent exceeding the cable’s bending radius and to adequately support the weight of the cables and splice cases.

Cable racks shall be placed so as not to interfere with future cable placement.

3.1.4.2. Ground Rod or Bonding Ribbon. A ground rod or bonding ribbon shall be installed in all new manholes and attached to all rack anchors.

3.1.4.3. Ground System. A ground system shall be installed in each manhole. The resistance to ground shall be less than 10 ohms as measured. Test results will be furnished to the 5 th

Signal

PM or representative in the final deliverable packaged. All manhole copper cable splices shall be bonded to the manhole ground. New ground systems in existing manholes shall be added at each splice location if none presently exist.

3.1.5. Cable Racking and Duct Assignment. Cable racking and duct assignment shall be engineered and installed as per the engineering design. Cables shall be pulled through the lowest available duct to facilitate installation of future cables.

3.2. Hand Holes. Hand holes will be engineered or installed in situations where a pull point is required into a building or to temporary or limited use buildings (guard shacks). Hand holes will not have more than six 125 mm (5 in) inside diameter ducts installed. Grounding and marking requirements for hand holes are the same as for manholes.

3.3. Hand Holes Marking

3.3.1. Request assistance from the local DCO and/or the DPW to select a start point for the numbering sequence (1st hand hole location and its number). If a good numbering sequence that builds off the existing hand hole numbers cannot be established, use the format indicated below with the project name as a header before each number.

3.3.2. A letter/number designator will be painted or a placard with the manhole information will placed on the inside riser collar of each manhole approximately 12 inches below the cover.

3.3.3. A yellow or white rectangular area, sized to fit all the lettering, will be painted as a base/background. Letters/numbers will be done in black paint.

3.3.4. Format: (Project) (Project)

HH XXX HCDS HH XXX

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3.3.5. Letters and numbers will be stenciled and 3-5 inches (7- 12 cm) tall.

3.3.6. Ensure hand hole numbers on the As-Built drawings coincide with the numbers assigned to the hand holes.

3.4. Pull Boxes. Pull boxes will only be used when authorized by HQ, 5th Signal Command or designated representatives.

3.5. Pedestals. Pedestals will be used to service temporary buildings, railheads, and other remote locations where permanent building terminations are not practical. Pedestals will be fitted with an access point to allow customers to terminate their cabling. This access point will be connected but, separate from the main termination point located in the pedestal. This applies to all pedestals with copper or copper and fiber cabling. Pedestals with fiber optic cabling will have duplex SC type of connector bulk heads installed.

3.6. Duct. Duct shall be rigid duct and meet DIN 8075 standards. Flexible duct will only be used in areas specifically authorized (in writing) by the 5 th

Signal Command PM or their representative.

3.6.1. Minimum Duct Bank Sizing. The minimum sizing for new duct bank sizes shall be designed to allow for current cable, new cable under this effort and 25% growth. Additional sizing requirements are listed below.

NOTE: Duct bank sizing does not apply to Hand Holes.

3.6.2. Duct between the cable vault and the first manhole shall provide for current cable and new cable plus 25% growth.

3.6.3. Main duct runs shall be a minimum of 6-way, 125 mm (5 in) inside diameter, one of which will contain sub-duct (i.e. fabric mesh or multi cell flex) for fiber optic cabling.

3.6.3.1. Lateral duct runs shall be a minimum of 4-way, 125 mm (5 in) inside diameter, one of which will contain sub-duct with longitudinal ribbing (i.e. fabric mesh or multi cell flex) for fiber optic cabling.

3.6.3.2. Building entrance ducts shall be a minimum of 2-way, 125 mm (5 in) inside diameter, one of which will contain sub-duct with longitudinal ribbing (i.e. fabric mesh or multi cell flex) for fiber optic cabling.

3.6.3.3. Multi cell sub-duct shall be installed in such a manner that a continuous non-spliced length of sub-duct exists between manholes. To prevent elongation of the sub-duct and reduction of the sub-duct diameter, the maximum allowable pulling load (per manufacturer specifications) for installation of the sub-duct must not be exceeded. Any duct sections that are deformed will not be accepted. To ensure sub-duct has not been deformed during installation, mandrelling will be performed. See paragraph 3.4.6.3 for details on mandrelling procedures.

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3.6.4. Duct Placement. Changes in duct direction of more the 10 degrees, either vertically or horizontally, will be accomplished by long sweeping bends having a minimum radius of 7.5 meters (25 feet). In no instance shall the total of all bends and sweeps in a duct run exceed 180 degrees. Manufactured bends may be used on subsidiary/lateral conduit at the riser pole or building entrance. Long sweeps may be made up of one or more curved or straight sections or in combination. Manufactured bends shall have a minimum radius of 60 cm (24 in) for all conduits

125 mm (5 in) inside diameter or larger. Bends and sweeps shall have 5 cm (2 in) of concrete encasement to protect the duct from the pressures developed while pulling cables.

3.6.4.1. Depth of Cover. Unless otherwise noted, at least 60 cm (24 in) of cover is required above the top of the duct run.

3.6.4.2. Trench Width. The trench width shall allow for 5-10 cm (2-4 in) of clearance on either side of the duct bank being installed unless more space is required to work in deep trenches.

3.6.4.3. New Duct Placement. In a new duct run the duct shall be swept down into the lowest available duct window of the manhole/hand hole.

3.6.4.4. New duct installed to supplement an existing duct bank shall be placed above the existing duct bank if the minimum top cover of 60 cm (24 in) can be maintained. If sufficient top cover is not available, the new duct shall be placed beside the existing duct bank.

3.6.4.5. Re-Routing of Existing Duct. Existing duct shall be joined to new manholes by re-routing the designated ducts from the abandoned manhole to a new manhole. Re-routing shall begin far enough back from the old manhole to allow for standard bending radius and pulling tension to be maintained. Continuity of operations on any affected cables shall be maintained during duct re-routing as much as possible.

3.6.5. Galvanized steel pipe or 10 cm (4 in) concrete encased duct shall be placed under all paved road surfaces and heavy traffic non-surfaced roads. The encasement/pipe shall extend a minimum of 1.8 meters (6 ft) beyond the roadbed for all road crossings on ranges.

3.6.6. Duct Preparation and Accessories. Pull strings shall be installed in each new duct or duct/sub-duct. A minimum of 1 meter (3 ft) of pull string shall be provided at each end of the duct. The pull string shall be coiled and secured to the wall.

3.6.6.1. Plugs. All ducts and sub-duct shall be waterproofed by using duct plugs or plugging compound.

3.6.6.2. Roding. Prior to using existing ducts, roding must be accomplished. Roding a duct entails inserting or pushing a rod into the duct to (1) determine the length of the duct; (2) locate the other end of the duct; (3) determine if the duct is usable or blocked; (4) insert a pull string in the duct.

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3.6.6.3. Mandrelling a duct consists of pulling a mandrel or slug through the duct to clean any obstructions from the duct. Mandrelling also insures that the duct diameter is intact and available for cable installation. The mandrel's diameter shall be 0.6 cm (1/4 in) less than the inside diameter of the duct. Ducts with cable inside shall not be mandrelled.

3.7. Warnings. Buried cable warning tape shall be used for all duct and cable routes. The tape shall be installed 30 cm (12 in) above the duct/cable.

3.7.1. If only fiber optic cable without copper cable is run in a duct bank the warning tape shall have encapsulated aluminum foil for tracing purposes.

3.7.2. Route markers for under ground duct systems shall be provided no less than every 75 meters (250 feet) or at each change in route direction and on both sides of street crossings.

NOTE: All materials, accessories, hardware, etc. that are utilized in the construction/ installation shall be used in accordance with the manufacturer’s design specifications.

4. GENERAL TRENCHING REQUIREMENTS

4.1. Digging Permits. The contractor shall coordinate with the site DPW to schedule all excavation and obtain the required digging permits.

4.2. Utility Location. The local DPW maintains records for the locations and markings of all utilities. The contractor shall furnish a schedule of proposed excavation to the DPW. The contractor shall survey, locate, and mark existing utilities prior to excavation and report discrepancies to the DPW. After excavation, the contractor will mark all new utilities IAW local requirements and provide an updated drawing to the DPW.

4.3. Rights-of-Way. The contractor is responsible for obtaining required right-of-way permits in a timely manner to ensure compliance with established completion dates.

4.4. Road Crossings. Road crossings shall be constructed by cutting or sawing perpendicularly across the road, by trenching perpendicularly across the road, by directional boring under the road, or by pipe pushing under the road.

4.5. Cut and Resurface.

4.5.1. Certain streets or roadways may have cutting restrictions or special conditions.

Pavements, curbs, sidewalks, and other hard surfaces including graveled and grassy surfaces shall be restored to the same condition as found within 72 hours after completion of construction work.

4.5.2. Roadways will be resurfaced with same type material and shall have a minimum thickness of 9 cm (3.5 in) of resurfaced pavement.

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4.6. Hand Digging/Pot Holing.

4.6.1. The contractor is responsible for positively determining the exact location and depth of all marked utilities by hand digging and/or pot holing to insure they are not damaged by the trenching or boring equipment. When pot holing road surfaces prior to boring operations, the initial hole shall not be larger than 30 cm by 30 cm (12 in by 12 in). The hole may be increased in size as necessary to determine the exact size and depth of the utility being located.

4.6.2. The contractor shall hand dig at all existing manhole or hand hole locations, building entrance points, utility crossings, through tree roots, under curbs, etc. to prevent damaged to existing manmade or natural assets.

4.7. Plowing. Plowing may be used in range environments or other areas where there are no significant obstacles and cable runs typically exceed 305 meters (1000 feet) between splices.

4.8. Backfilling and Restoring. All excavated areas around new manholes, ducts, or cables shall be backfilled with earth, loam, sandy clay, sand and gravel or soft shale that is free of large clumps of earth, blasted rock, large boulders, broken concrete or pavement, construction debris or litter.

4.8.1. Backfill materials shall be deposited and tamped in 15 cm (6 in) layers until the conduit entering the manholes has a minimum cover of 30 cm (12 in). The remainder of the backfill materials shall be placed into the excavation while moist and tamped in 30 cm (12 in) layers.

The earth shall be graded to a reasonable uniformity and left in a uniform and neat condition. A minimum of 60 cm (24 in) of total duct coverage will be maintained.

4.8.2. Restoration to the same or better condition prior to construction shall be completed within

72 hours for all areas where no additional intrusion by heavy equipment for cable placement is required. For durations of longer than two weeks between construction and cable placement, the contractor shall rough seed the area to provide cover until final grading and seeding is accomplished.

4.8.3. Trenching/digging in Rock. Boulders measuring .75 cubic meters (1/2 cubic yard) or more or other material, such as rock in ledges, bedded deposits, un-stratified masses and conglomerate deposits or below ground concrete masonry structures that cannot be moved without systematic drilling and blasting or the use of a rock saw shall be excavated to a minimum of 10 cm (4 in) below the trench depths required for proper placement of duct bank or cable. Backfill the rock excavation and all excess trench excavation with a 10 cm (4 in) cushion of sand prior to placing the duct or cable.

4.8.4. Unstable Soil. When wet or otherwise unstable, soil incapable of properly supporting the conduit or manhole is encountered in the trench bottom, the contractor shall remove such soil to the depth required to establish a sound base and backfill the trench to the appropriate trench bottom grade with coarse sand or fine gravel.

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5. CABLE REQUIREMENTS

5.1. Outside Plant Copper and Fiber Cable Requirements.

5.1.1. Type A-2YSOF (L) 2Y-…x2x0.6 St III Bd (foam filled) Outside Plant copper cable may be used throughout a CDS cable installation project, but must be terminated to protected LSA+

Quick Disconnect blocks in a Protected Entry Terminal (PET) and transitioned to indoor cable to connect to the cabinet.

5.1.2. Type A-2YF (L) 2Y-…x2x0.6 St III Bd (petrol-jelly filled cable) Outside Plant copper cable may be used throughout a CDS, but must be terminated to protected LSA+ Quick

Disconnect blocks in a PET and transitioned to indoor cable to connect to the cabinet.

5.1.3. Type A-DF (ZN) 2Y … Outdoor fiber optic cable may only be terminated directly to patch panels in TR1 cabinet if it has been certified by the manufacturer as safe for indoor use. If the manufacturer has not certified the cable for indoor use, cable must be spliced, at the building entry point, to an approved type of indoor cable.

5.1.4. Type A-DSF (ZN) 2Y Fiber Cable Equipped with Copper Conductors will be used when merited by the requirements of alarms, telemetry, talk circuits or cable location purposes. The cable shall include two or more insulated (color coded) 0.6 mm diameter copper conductors built into the standard sheath.

5.1.5. Type A-DF (ZN) 2Y… Long haul fiber optic cable will be GB 655 or the latest type of long haul fiber available.

5.2. Inside plant cable requirements

5.2.1. Plenum Areas. If cabling is required to be installed in a plenum area, the cable must meet all requirements for the plenum areas.

5.2.2. Type J-2Y (ST) Y…x2x0.6 St III Bd or J-H (ST) H …x2x0.6 Bd Capable of 16 Mbps indoor copper cable shall be used as tipping cable and riser cable inside buildings.

5.2.3. LAN copper cables will be Category 6, Shielded Twisted Pair (STP - overall shielded wrapped cable), Screened – Shielded Twisted Pair (Sc-STP - overall screen wrap and individually shielded pairs) or Foiled Twisted Pair (FTP - overall foiled wrapped cable) are authorized for use. All types of CAT 6 cabling will have a minimum rating of 250 MHz in accordance with ISO/IEC 11801, EN-50173 and TIA/EIA 568-B.2-1 standards. Unshielded

Twisted Pair (UTP) cabling is not authorized for use in the European theater.

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5.2.4. Type I-V (ZN) Y… indoor multimode fiber optic cable is authorized for use in the buildings from the TR to the room outlets only. This cable will also be OFNP (plenum) rated.

5.2.5 Type I-V (ZN) H… or I-D (ZN)H…indoor single mode fiber optic cable shall be used from TR1 to other TRs within buildings. This cable will also be OFNP (plenum) rated.

6. GENERAL CABLE INSTALLATIONS

6.1. Evaluating Existing Cable/Testing New Cable. When the installation includes work on an existing cable the contractor shall test all affected pairs before completing any throws or splices.

A list of the defective pairs shall be submitted to the 5th Signal Command PM before the work proceeds. After the cable work has been accomplished, the contractor shall test all affected cable pairs. The contractor shall clear any trouble on any existing pairs that were not on the original submitted list.

6.2. Cables shall be installed in such a manner as to avoid kinks and other sheath deformities.

Minor stealth damage (scratches, shallow cuts, etc) is a normal byproduct of installation.

Moderate or serious cable damage will be repaired.

6.2.1. Pulling Tension. The manufacturers specified pulling tension will not be exceeded when pulling cable into ducts and sub-ducts. A lubricant shall be used in the amount specified by the lubricant manufacturer. The lubricant shall be a water-based, slow-drying fluid that will not stress crack low-density polyethylene and will not damage cable jackets.

6.2.2. Bending Radius for CDS. The minimum-bending radius for copper cables (10 times the outside diameter, unless otherwise specified by the manufacturer) and fiber optic cables (20 times the outside diameter, unless otherwise specified by the manufacturer) will not be exceeded.

6.3. Cable Entry Points. Outside cable duct will continue through building walls or through basement floors. Building wall entrances or basement floor entrances will be cut flush or have appropriate duct left exposed to attach a collar. All duct entrances will be cleanly finished and sealed with an approved sealant.

6.3.1. Outside copper cables will be transitioned to inside cables as close to the cable entry point as possible, but no further than 7 meters (23 ft). The outside copper cable shall be terminated to a PET (with protector modules). The PET will be located within 7 meters (23 ft) of the cable entry point. Under no circumstances will the outside cable be allowed to leave the entry room.

6.3.2. Outside fiber cable that has not been certified as safe for indoor use will be spliced, in a wall mounted splice box, to indoor fiber cable as close to the cable entry point as possible, but no further than 7 meters (23 ft). Under no circumstances will the outside cable be allowed to leave the entry room.

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6.3.3. Cables will be labeled on both sides of the splice canister and/or PET IAW paragraph 7 of this document.

6.3.4. Cable racks or raceways will be installed on the wall of the cable entry point to provide support for cables. Racks/raceways will be installed at the bottom of the wall to provide support, protection and easy and orderly installation of future cables. Racks/raceways will be positioned so that the cable-bending radius will not be exceeded. All cable racks/raceways splice canisters, and PETs will be grounded.

6.3.5. Cables will be supported by racks, ducting or cable tray throughout the building installation. The racks, ducts, or cable trays will be routed following the contours of the building and secured to the walls or hung from the ceiling. All metallic ducts/raceways and cable trays will be strapped together with ground straps and grounded.

6.4. Grounding. All outside copper cables, riser cables, and PETs shall be grounded to a

Telecommunications Main Ground Busbar (TMGB). If no building ground exists, then a building telecommunications ground must be established, installed, and tested.

6.4.1. PETs shall be grounded with 16mm (6 AWG) plastic insulated solid copper green and yellow wire in runs less than 50 meters (164 ft). Any ground wire runs over 50 meters will need to sized according to voltage/current it may carry in case of a power malfunction. The ground wire shall run from the grounding lug or the grounding strip of the terminal to an existing building ground or a driven ground rod. The ground wire shall be continuous with no breaks or splices and shall be placed in properly supported conduit/duct. If a ground rod is used, it shall be a minimum of 1.3 cm (1/2 in) in diameter and 2.5 m (8 ft) in length. It shall be installed a minimum distance of 30 cm (12 in) from the building wall and have at least 15 cm (6 in) of earth cover between the top of the ground rod and ground level.

6.4.2. A maximum measured resistance of 5 ohms to ground is required. When it is necessary to place more than one ground rod to meet this requirement the minimum separation between the ground rods shall be 1.8 m (6 ft). Two or more ground rods shall be connected using 16 mm (6

AWG) plastic-insulated green and yellow solid-copper wire or larger depend on voltage/current it may carry in case of a power malfunction. The ground wire connection to the ground rods may be made with compression sleeves or an exothermic weld connection. The connections shall be compression sleeves or exothermic welded if buried. Impedance measurements shall be made using a direct reading ground resistance meter and the results will be part of the test data submitted in the delivery package.

6.4.3. Any renovation building projects or buildings where a grounding system must be designed, a multi point grounding grid system will be designed and installed. A Main Ground

Busbar (MGB) will be installed and numbered for all incoming ground points. A detailed grounding drawing will be furnished in the deliverable package.

6.4.4. The Telecommunications Main Ground Busbar (TMGB) will be located at the cable entry point (normally located in TR1). A Telecommunication Ground Busbar (TGB) will be installed

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in any additional TRs and be connected to the TMGB with a continuous cable. Ground wires will be continuous (un-spliced). See Figure 2, Typical Grounding Diagram.

Main Building

Ground (MGB)

Figure 2. Typical Ground Diagram (Single point ground system) with established building ground.

Figure 2A. Typical Ground Diagram (Multi point ground system) with multi TR’s on one or several floors.

MGB

MGB

M

G

B

M

G

B

TMGB

P.E.T.

T

M

G

B

Cable Entry

Point TR1

Cabinet Cabinet

TGB

TGB

TR 2

Cable Entry

Point TR1

TR2

TMGB TGB

Cabinet

P.E.T.

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6.5. Cable Counts and Splices

6.5.1. When assigning cable counts, the wires at the center of the cable shall be the last pairs assigned on a cable route. The upper or higher cable pair counts shall be used first. Therefore, the highest pair count in a cable shall be located closest to the switch location and the lowest pair count shall be farthest away.

6.5.2. Fiber cable count assignments shall be assigned in a similar manner as copper counts.

The high number counts shall be dropped off first and strand one count shall be the farthest from the serving node.

6.5.3. Splices and Power Budget. Only fusion splicing shall be used for all types of fiber optic cable. Splice loss shall be no more than 0.1 dB averaged in both directions.

6.6. Fiber cables shall be spliced using “loop through” splicing. In "loop through" splicing, only the fiber strands breaking off from the main cable are cut and spliced. The continuing fibers are not cut. The sheath is cut from the cable, the exiting fibers cut and spliced and the remaining fibers are simply folded back within the case and are then routed on.

6.7. Transfers, Cuts and Throws. Cable transfers, cuts, and throws shall be performed to maximize existing resources. All cables and terminals affected by cable count transfers shall be retagged in the field and documented on cable running lists, drawings, etc. to reflect the new changes.

6.8. LSA+ Termination. Termination color code on the LSA+ blocks is as follows:

RED GREEN GREY YELLOW WHITE

I I I I I I I I I I I I I I I I I I I I

Color Coding Bundled Cable

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7. CABLE LABELS - Cables shall be labeled at all termination points, splices boxes, PETs, and manholes/hand holes. If there is a splice box in the manhole/hand hole the cables shall be labeled between the splice and the end wall on both sides of a splice canister. For un-spliced

(straight though) cables, a label is required at each end where the cable enters and exits the manhole. For cables that penetrate walls or floors a label is required on at least on side of the penetration. Labels will be mechanically generated and not hand written.

7.1. Copper cables will be identified by cable type, cable number and count at the terminal points for a direct cable run or to first splice point:

OR

7.2. Copper cables will be labeled at splice points (other than cable entry points) on both sides of the splice. Any spare pairs will be identified on the first cable label.

7.3. Copper cables at building entry points will be labeled on both sides of the PET.

7.4. Fiber optic cable will be identified by type, cable number, count and cable size at the terminal points for a direct cable run or to first splice point.

7.5. Fiber optic cable will be labeled on both sides of splices. Any spare pairs will be identified on the first cable label

A-02YF (L) 2Y

CA 001, 500PR

FM: BLDG 22

TO BLDG 501

A-02YF (L) 2Y

CA 001, 500PR

FM: BLDG 22

TO: MH #1

A-02YF (L) 2Y

CA 001, 500PR

FM: BLDG 22

SPARE: 301 TO 500

A-02YF (L) 2Y

CA 001, 001 to 300

TO:…