Armored Optical Cable Splicing

Splicing armored optical cables involves careful preparation, stripping of protective layers, precise fiber alignment, and testing to ensure signal integrity.

Preparation and Tools

Before splicing, gather essential tools such as fiber cutters, strippers, cleavers, cleaning kits, microscopes, and fusion splicers. Verify that all tools are in good working condition and suitable for armored cable handling. Measure and mark the required cable length according to the installation plan, ensuring proper allowance for the splice closure or enclosure.

Cable End Preparation

Cut the Cable: Use a fiber cable cutter adjusted to the armor thickness to make a clean cut. Strip Outer Jacket: Perform a ring cut to remove the outer PE or metallic jacket without damaging the inner fibers. Adjust blade depth carefully to avoid cutting the steel wires embedded in the armor.

Expose Armor and Kevlar: Use a hook blade or needle-nose pliers to peel back the armor tape and expose ripcords and Kevlar strength members. Cut Kevlar fibers with specialized scissors to prevent fraying. Clean Fibers: Strip the primary and secondary coatings (e.g., polyimide or acrylate) using mechanical strippers and clean with alcohol and lint-free wipes to remove debris.

Splicing Procedure

Slide Protective Tubing: Place heat-shrink tubing and stainless steel tubes over the cable ends before splicing to protect the splice later. Align Fibers: Use a fusion splicer and microscope to precisely align the fiber cores. Ensure the fiber end faces are clean and free of dust or oil.

Fusion Splicing: Perform the fusion splice according to the splicer manufacturer's instructions. The splicer melts the fiber ends together to form a low-loss joint. Protect the Splice: Slide the heat-shrink tubing over the splice and shrink it using a heat source to secure and protect the joint.

Stainless steel tubes may be used for additional mechanical protection.

Post-

Splice Testing

After splicing, perform optical testing using an Optical Time-Domain Reflectometer (OTDR) or power meter to verify signal continuity, insertion loss, and overall splice quality. Ensure the splice meets the required specifications before final deployment.

Best Practices

Avoid contact with fibers during stripping to prevent microbends or scratches. Maintain proper bend radius when routing fibers in closures or trays. Follow manufacturer-specific instructions for armored cable types, as blade depth and stripping techniques may vary.

Use flexible spiral split tubing if recommended to control bend radius and provide additional protection within the closure. By following these steps, armored optical cables can be spliced safely and reliably, ensuring long-term performance and protection against mechanical and environmental stresses.