Case Study
Highlights

Doubled
network fibre
capacity

from 48F to 96F

Tool-free access

simplifies installations and

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

  • 1

    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.

  • 2

    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.

  • 3

    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.

  • 4

    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

Achieved cost-effective installations

 

Reduced pole congestion

Reduced storage and inventory expenses

Enhanced environmental sustainability

Maintains rigorous performance
standards

~ 2,000 km of 96F ULW cable delivered
for initial deployment

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.

Contact Us
About HFCL

HFCL is a leading technology company specializing in creating digital networks for telcos, enterprises, and governments. Over the years, HFCL has emerged as a trusted partner offering sustainable high-tech solutions with a commitment to providing the latest technology products to its customers. Our strong R&D expertise coupled with our global system integration services and decades of experience in fiber optics enable us to deliver innovative digital network solutions required for the most advanced networks.

The company’s in-house R&D Centres located at Gurgaon and Bengaluru along with invested R&D houses and other R&D collaborators at different locations in India and abroad, innovate a futuristic range of technology products and solutions. HFCL has developed capabilities to provide premium quality Optical Fiber and Optical Fiber Cables, state-of-the-art telecom products including 5G Radio Access Network (RAN) products, 5G Transport Products, Wi-Fi Systems (Wi-Fi 6, Wi-Fi 7), Unlicensed Band Radios, Switches, Routers and Software Defined Radios.

The company has state-of-the-art Optical Fiber and Optical Fiber Cable manufacturing plants in Hyderabad, an Optical Fiber Cable manufacturing plant in Goa, and its subsidiary HTL Limited in Chennai.

We are a partner of choice for our customers across India, Europe, Asia Pacific, the Middle East, Africa, and the USA. Our commitment to quality and environmental sustainability inspires us to innovate solutions for the ever-evolving customer needs.