What Is A Cable Pull Plan?

A cable pull plan is how any technician working with structured or unstructured cable needs to prepare for an installation project. It’s a comprehensive breakdown of the locations, geometry, quantity of cable, conduit or plenum conditions, labeling convention, physical pulling constraints, and required tooling. 

It’s called cable pulling for the simple reason that it’s near impossible to push a rope or, as it is in this case, an electrical or fiber optic cable. 

Although cable pulling tends to be more challenging when upgrades to existing networks, it’s also recommended for new construction. A well-considered cable pull plan will minimize labor, prevent damage, and ensure optimal performance from the installed components.

What To Include In Your Cable Pull Plan

In new construction installations the environment is as easy to navigate as it gets. The plenums are empty and you don’t have to worry about the building’s everyday occupants. For upgrades you have to contend with a lot of unknowns and need to be considerate of people who are using the space and the network. Here are some of the main issues that your cable pull plan should cover.

Conduit, Raceways, and Plenum 

You need a clear idea of the spaces and supports that you’ll be pulling cable through. Open air cable supports often require far less planning, tooling, and labor for a successful installing. However, now all environments will have open air cable raceway or permit you to install such a raceway just to simplify a cable pulling project.

Power Feeder

When pulling a short distance, you’d be forgiven for thinking that elbow grease and a cable pulling jet line will suffice. In reality, a power feeder is the best way to deliver a consistent amount of force on the cable without exhausting your available man power. The duty rating of the power feeder you need should be based on the weight of cable you plan to pull. You also want to make sure that you can adjust the power feeder for the pulling limitations of your cable. 

Cable Positioning

The geometry of a cable pull is critical for the long term performance of the cable you’re installing. Regulations stipulate the amount of cable that can fill a given diameter of conduit, as well as the allowable radial deformation that a given cable can sustain before it comprises its conductivity or signal transmission. By plotting your cable routes and plenum/conduit volumes, you can avoid the unnecessary work that comes with replacing damaged cable or running supplemental conduit due to insufficient space. 

Conductor Weight

Light as strand of CAT 6e cable may seem in your hand, when you think about pulling 300 ft (more than 10 lbs) of it through a complex route with multiple turns and friction elements, the weight becomes a critical calculation. Even more so when planning pulling multiple strands at a time. This calculation also influences the weight rating of the raceway you plan to use as well as the jet line and power feeder. 

Headroom

Just because a raceway is a given diameter, doesn’t mean you can pack it full of cable. In fact, at a certain point the frictional force of an overfull raceway will prevent a successful pull entirely. 

Pulling Tension 

Some cables, such as CAT 6 can only endure pulling tension of 25 lbs before the cable is compromised and will no longer perform to specifications. You should have a clear schedule of the various cables you plan to pull, their max allowable tensions, and a clear way to ensure that technicians on both ends of the pull are complying with those constraints.

Labeling

If you let your labeling convention become an afterthought, you’ll create an unending stream of nightmares and work for yourself and anyone who performs maintenance on the network after you’re gone. The ANSI TIA 606-B Cable Labeling Standard is an excellent place to start. You want to have labels prepared ahead of time and pre-installed or ready to install as soon as the pull is complete. 

Cable Pulling Tools

We’ve already mention the importance of a power feeder. You’ll also need plenty of jet line that’s weight rated for the cable you’re pulling. Other necessary tools include reel carts, diagnostic devices to check signal/conductivity, tension meters, hole making tools, lubricant, adhesives or jet line fasteners and walkie talkies to keep both ends of the pull in communication.

Cable Pull Safety 

Aside from some of basics risks that come with any construction project (head, eye, hand protection is recommended/required), you also need to be aware of dangers such as when a cable snaps under tension or when the power feeder malfunctions. Pinched fingers are the least of your worries when applying hundreds if not thousands of pounds of force in an enclosed space. Your technicians should be trained on the equipment they’re using and the applicable regulations for workplace safety, and material constraints.

Cable pulling for structured cable (ethernet and fiber optics) carries a much lower risk than pulling structured electrical cable for power transmission. Especially in a heavy industrial setting, the cables can be 10-20X as heavy and the potential costs associated with damaged cables due to poor installation technique can be orders of magnitude higher as well.