Installation

Inside or Outside Plant Cables
Communications Cables: Fiber Optic, Coax, Twisted Pair, Copper, Cat 5, etc.
Utility Cables: Power, Control, Lighting

The recommended maximum fill ratio is 45%. Above that level, testing and experience has shown a marked increase in cable pulling tensions. Remember to check local codes for allowable maximum fill ratio.

The distance MaxCell can be pulled is affected by the type of duct structure, the number of horizontal or vertical changes within a run, the presence of incumbent cables or innerduct, and the number of sweeps or bends. The longest pull to date is 8,200 feet.

We recommend installing cables starting with the middle cell in a 3-cell configured product. This allows ease of entry into other cells at later dates.

Yes. The recommended technique is to rod an occupied conduit with a “paddle” attachment which rides on to the existing cable. See our document – Placing MaxCell in Occupied Conduit – for step-by-step instructions.

The weight of cables can be a factor in increased pulling tensions, but experience has shown this increase to be minor – less than 50 lbs. A more important factor in cable pulling tensions is the condition of the conduit. Pull length, total degree/radius, and number of bends in the outer duct contribute significantly to overall pulling tensions.

Yes, MaxCell is designed so cables can be installed, removed, and reinstalled at any time.

No. MaxCell is pre-lubricated and additional lubricants are not necessary. However, additional lube will ensure an easier pull which may be useful on more difficult runs.

Although pre-lubed, we recommend that additional lubricant be applied to the cable during installation. Extensive testing has shown that this step can reduce cable pulling tensions by 15-20%.

MaxCell is incrementally marked every 5 feet. The pulling tapes within MaxCell are incrementally marked every foot.

Using proper installation equipment and techniques insures MaxCell will not spiral. The key component of this procedure is to use a swivel between the pull rope and the MaxCell pack(s).

Either. MaxCell is very easy to install and many customers pull MaxCell through multiple maintenance holes in a single pull to save time.

Yes, MaxCell can be incrementally installed. One pack can be installed now and another pack installed later. This is a major benefit of MaxCell. For this reason, we recommend that a spare pull rope be installed along with the MaxCell pack.

When space is available, MaxCell can be pulled into almost any conduit structure.

In conduits where contaminants may be suspected, we recommend flushing the duct with water prior to placing cables within MaxCell. Similar to rigid innerduct, cable pulling tensions may increase due to the presence of these contaminants.

Although there are methods to repair MaxCell, we do not generally recommend splicing. The best solution is to place a handhole at the damaged location.

Standard sealing practices include inflatable bags, termination plugs, and foam applications. For watertight applications, split termination plugs are recommended. For non-watertight applications, inflatable bag termination systems are recommended. These bags, when inflated by CO2, compress to the structure of the cable placed. This method offers a silt, water, and chemical resistant solution.

  See Also Installation Accessories and Installation Instructions

 

Materials

MaxCell is manufactured from internally processed polyester and nylon resins.

No. MaxCell uses only 100% virgin resin.

Standard, Riser, and Plenum MaxCell are Halogen free.

The materials used in MaxCell are rated for 20+ years of use with less than a 15% reduction in strength. The design of MaxCell was based upon geo-textile materials used in underground environments. The physical properties provide excellent tenacity and toughness as well as abrasion, temperature and chemical resistance. The materials used have excellent resistance to fuels and ground chemicals.

Prolonged exposure or immersion in water, salt-water or mud will not affect the life expectancy of MaxCell.

MaxCell has a melt temperature of 419° F, almost twice that of standard HDPE innerduct. MaxCell is unaffected in standard OSP temperature operating ranges (-50°F to 120°F).

MaxCell itself is unaffected by temperatures down to -50° F. When water freezes within a conduit, standard methods such as steam may be used to clear a pathway.

The lubricant used in MaxCell is unaffected in normal OSP temperature operating range of -50°F to 120°F.

The lubricant on MaxCell will not degrade nor be removed due to water or chemicals such as jet fuels.

The pulling tape is constructed from multi-filament polyester yarns.

 

Strength

The tensile strength of MaxCell varies by the particular product. Refer to the Literature Section for individual product specifications.

The pull tape supplied in MaxCell has a rated breaking tensile of 1250 lbs.

Similar to rigid innerduct, UV exposure can reduce the tensile strength of MaxCell. MaxCell is shipped with a UV protective wrap on the outside to minimize exposure.

 

Self-Supporting MaxCell

Self-Supporting MaxCell is designed for maximum efficiency in straight sections. It is recommended that a new section be placed where a 90° bend is required.

Self-Supporting is UL certified in US and Canada and also is classified as UL94 V-0.

Yes. Cables can be mixed but the installer must verify whether cables can be placed In proximity to each other. The individual pathways of MaxCell will keep the cable bundles from coming into contact with each other.

Self-Supporting MaxCell is a flexible fabric that contains no shielding. The product will not prevent or reduce crosstalk.

The cables should be pulled horizontally from the leading end of the run starting with the middle cell and moving to the two outer cells. Self-Supporting MaxCell is designed to withstand appropriate direct downward force.

If there is an application where cables cannot be placed in a relatively horizontal direction, then it is recommended to use an assist tool such as the “Cable Joe”, “Fas Roller” or pulley and eyebolt system.

There are many variables that effect the pulling tension of cables (e.g. bundle diameter, jacket material, weight., etc.). A good rule of thumb is that the pulling tension will rise proportional to the total weight of the cables being pulled.



 

Other

Yes. The plant that produces MaxCell is ISO 9002 certified. Documentation is available upon request.

Plenum & Riser MaxCell meet the UL required burn tests for indoor installation (testing data available upon request). Local codes vary widely and may also apply. It is recommended that you refer to local code requirements to ensure safe network design.

Yes. MaxCell is considered by the USDA-Outside Plant Branch an accessory item for a conduit system, and as such, can be purchased using RUS financed loans. Documentation is available upon request.