Armored Vs Unarmored Fiber Optic Cables Key Network Considerations

In today's hyperconnected world where information travels at lightning speed, fiber optic cables have become the unsung heroes of modern communication infrastructure. These glass-thin strands carry our data, voices, and video across continents with unparalleled speed and reliability. However, not all fiber cables are created equal. Network administrators and IT professionals face a critical decision when designing their infrastructure: armored or unarmored fiber optic cables?

The fundamental difference between these two cable types lies in their physical protection levels. While both perform the same core function of transmitting data through pulses of light, the choice between armored and unarmored can significantly impact your network's long-term performance, reliability, and total cost of ownership.

Unarmored fiber optic cables, sometimes called non-protected or standard fiber cables, feature a simple design with a protective outer jacket surrounding the delicate optical fibers. These cables lack the additional protective layers found in their armored counterparts.

Cost Efficiency: Without the need for specialized armor materials, unarmored cables typically cost significantly less than armored versions. This makes them particularly attractive for budget-conscious projects or deployments where enhanced protection isn't necessary.

Easier Installation: The increased flexibility and smaller diameter of unarmored cables allow them to navigate crowded conduits and tight spaces more easily. This simplifies installation, reduces labor costs, and speeds up network deployment.

Compact Design: The streamlined structure of unarmored cables makes them more efficient for storage and transportation. This proves particularly valuable for network operators with limited storage space or those needing to frequently move cables.

Unarmored fiber optic cables excel in indoor applications or controlled outdoor environments with minimal physical risks, such as low-traffic areas or protected conduits. However, their lack of additional protection makes them less suitable for harsh environments where cables might face physical damage, rodent activity, or extreme weather conditions.

Armored fiber optic cables incorporate additional protective layers to shield the delicate optical fibers from various physical threats. These protective layers typically consist of materials like aluminum, stainless steel, or Kevlar, significantly enhancing the cable's resistance to impact, crushing, and other forms of physical damage.

Enhanced Physical Protection: Armored cables are designed to withstand harsh environmental conditions including rodent attacks, extreme weather, and heavy equipment. This protection helps prevent fiber damage, ensuring reliable data transmission while minimizing costly repairs or replacements.

Superior Durability: The additional protective layers extend the cable's lifespan and maintain performance in demanding environments. This reduces maintenance costs and network downtime caused by cable failures.

Harsh Environment Ready: Armored fiber optic cables are ideal for outdoor deployments, underground installations, and industrial settings where physical damage risks are high. They provide the necessary protection to safeguard network infrastructure in challenging conditions.

While armored fiber optic cables offer superior protection, they come with trade-offs. Compared to unarmored cables, armored versions are typically more expensive, bulkier, and less flexible, which can complicate installation and transportation.

The decision between armored and unarmored fiber optic cables primarily depends on the level of physical protection required for your specific network application.

Unarmored cables work best for indoor environments or outdoor deployments with minimal physical risks. In these scenarios, the cost savings and easier installation outweigh the need for enhanced protection. These cables often represent a more cost-effective upfront choice, making them suitable for budget-constrained projects or applications that don't require the extra durability of armored designs.

Conversely, armored cables are the preferred choice for outdoor installations, underground deployments, and harsh industrial environments where cables might face physical threats like impacts, crushing, or rodent activity. While armored cables carry higher initial costs, they often provide a more reliable and cost-effective solution in the long run by reducing the risk of cable failures and maintenance expenses.

When selecting the appropriate fiber optic cable solution, carefully evaluate the deployment environment, potential risks, and long-term maintenance requirements. The added expense of protective measures like conduits can quickly negate the initial cost savings of unarmored cables, making armored designs the wiser choice for certain applications.

Various materials are used in fiber optic armor construction, ranging from Kevlar-impregnated jackets to composite materials, though most fiber armor utilizes metal—typically aluminum or stainless steel.

Aluminum Interlocked Armor (AIA) fiber optic cables are designed to withstand extreme physical abuse, making them suitable for demanding applications in environments like petrochemical plants, asphalt facilities, and steel mills. These cables feature a plenum or riser-rated outer jacket, water-blocking Kevlar, and an aluminum interlocked armor layer surrounding the fiber core.

Compared to unarmored cables, AIA cables can handle heavier loads and pulling tension, providing protection against rodent damage, extreme weather conditions, and rough handling. However, they're not impervious to crushing or extremely heavy loads, which might be necessary in some particularly harsh environments.

While AIA cables offer undeniable durability, their substantial size and weight present significant challenges. These cables occupy considerable space, making storage, transportation, and deployment more expensive. Additionally, their limited flexibility can hinder installation in confined spaces, often requiring specialized equipment and increased labor costs.

Stainless steel micro-armored fiber optic cables provide an excellent alternative to traditional armored cables. These cables feature a thin, flexible stainless steel armor layer beneath a durable outer jacket, offering substantial physical protection while maintaining greater flexibility than conventional armored designs.

Key advantages of stainless steel micro-armored cables include:

• Smaller size enables easier installation through tight spaces, curved pathways, and congested areas
• Exceptional flexibility that pushes the physical limits of what glass fibers can achieve
• Crush-resistant stainless steel micro armor combined with Kevlar and outer jacket provides superior armored fiber cable protection
• Compact size translates to significant cost savings in storage, transportation, and installation labor
• Suitable for both indoor and outdoor installations, including direct burial without conduit (subject to local regulations)

Whether you choose armored or unarmored cables, proper installation is crucial for ensuring long-term performance and reliability of your fiber optic network. Consider these best practices:

Always follow the manufacturer's cable handling guidelines, including recommended bend radius, pulling tension, and installation temperature. Proper cable preparation (such as stripping or termination) is equally important to prevent damage during installation.

Before installation, thoroughly inspect and prepare cable pathways. Remove any debris or obstacles that might damage the cable, and ensure pathways are properly sized to accommodate the cable's dimensions.

Proper cable routing and support are essential to prevent excessive stress or tension on the cable. Follow recommended cable routing practices, including maintaining proper bend radius and providing adequate support at regular intervals.

After cable installation, proper termination and testing are critical for ensuring optimal performance and identifying any potential issues. Follow manufacturer guidelines for cable termination and conduct thorough testing, including Optical Time Domain Reflectometer (OTDR) and power meter tests.

Accurate documentation and labeling are essential for future maintenance and troubleshooting. Maintain detailed records of cable routes, termination points, and relevant installation details, and clearly label cables and termination points for easy identification.

By following these best practices, you can ensure successful installation and long-term performance of your fiber optic cable network, regardless of which cable type you choose.