UK's largest network operator Doubles Fibre Capacity with HFCL's 96F ULW Aerial Cable
Case Study Highlights
- Doubled network fibre capacity from 48F to 96F
- Tool-free access simplifies installations and reduces labour costs
- Passed 16-day storm loading test
- Lower transportation costs and reduced environmental footprint
- ~2,000 km of cable delivered for the initial deployment phase
Background
A leading network operator in the UK needed to significantly increase network fibre capacity to support the expansion of their nationwide broadband network. The challenge was to achieve this without increasing aerial cable pole congestion and to minimize installation costs.
Customer’s Overview
The customer is a leading multinational telecommunications holding company based in London, England, with operations across the globe. As the UK's largest provider of fixed-line, broadband, and mobile services, the company also offers subscription television and IT services. Its Enterprise division supplies telecommunications services to corporate and government customers worldwide. The customer is known for its commitment to technological innovation and operational excellence in telecommunications.
Challenges Faced
Capacity and Congestion
The existing 48-fibre (F) cable solution could not meet the growing demand, especially in rural and remote areas where digging costs and environmental impact are high. Doubling the fibre capacity while keeping the same cable diameter was essential to avoid pole congestion and additional infrastructure costs.
Regulatory Challenges and Installation Requirements
Regulatory guidelines categorize aerial cables based on strength—light, medium, and heavy—dictating installation requirements. Cables classified as 'light' can be installed without pole inspection, whereas higher-strength cables require inspection and potential pole maintenance. This setup incentivizes using 'light' category cables for trunk and distribution purposes. However, challenges in design and performance, particularly in accommodating increased fibre density, are notable within this category.
Loading Requirements
One of the most challenging requirements involved cable loading. The new design of the 96F ULW aerial cable had to meet stringent loading criteria: it needed to support a load range of ≥ 1300 N (292 lbf) to ≤ 2000 N (450 lbf). The lower limit was set to withstand storm loading conditions, while the upper limit ensured the cable would break before pulling down a pole.
Cost Efficiency
Implementing the solution needed to be cost-effective, avoiding significant increases in installation and maintenance costs.
HFCL’s Approach to the Challenges
Facing the challenge of optimizing FTTx installations in smaller microducts, HFCL approached the task with determination and innovation.
- Design and Performance
HFCL developed a 96-fibre Ultra Lightweight (ULW) aerial cable that doubled the fibre capacity compared to the legacy 48F solution. The design used twenty-four 200µm fibres in each micromodule and optimized braided steel wire to meet both break and storm load requirements.
- Rigorous Testing
The new 96F ULW aerial cable underwent comprehensive testing, including a 16-day overhead installation test with 5 cycles of simulated storm loading. This ensured the cable met all customer-specified performance requirements.
- Innovative Features
High tensile strength up to 980N with endurance up to 2000N, robust durability against crushing and water penetration, reliable performance in extreme temperatures (-30°C to +70°C), and tool-free access for simplified installation and reduced labour costs.
- Seamless Integration
The solution was designed to be compatible with existing connectivity infrastructure and installation methods, allowing for a smooth transition and minimal disruption.
Success Metrics
Result
HFCL developed a 96-fibre Ultra Lightweight (ULW) aerial cable solution that provided a significant boost in network capacity while maintaining a compact and lightweight design. This innovation allowed the customer to effectively double their fibre capacity without increasing aerial congestion or installation costs. The solution’s success is marked by its adherence to stringent performance standards and extensive deployment across the UK. Additionally, the design received a patent in April 2024, underscoring its uniqueness and technical advancement.
