Draka USA Comparative Testing of Longitudinally Corrugated vs. Helically Applied Shields for Transit Applications

PURPOSE OF TESTSPURPOSE OF TESTS ALTERNATIVE CONSTRUCTIONSALTERNATIVE CONSTRUCTIONS TEST SAMPLES MADETEST SAMPLES MADE TESTS CONDUCTEDTESTS CONDUCTED TEST RESULTSTEST RESULTS CONCLUSIONSCONCLUSIONS Draka USA DISCUSSION ITEMS

PURPOSE OF TESTS DEMONSTRATE EQUIVALENT PERFORMANCE TO STANDARD CLASS 1 RAILROAD SIGNAL CABLE DESIGNS EMPLOYING HELICALLY APPLIED BRONZE TAPES. DEMONSTRATE EQUIVALENT PERFORMANCE TO STANDARD CLASS 1 RAILROAD SIGNAL CABLE DESIGNS EMPLOYING HELICALLY APPLIED BRONZE TAPES. Draka USA

PURPOSE OF TESTS TEST PROGRAM PURPOSE: EVALUATE ALTERNATIVES PURPOSE: EVALUATE ALTERNATIVES NUMBER OF ALTERNATIVES: 3 NUMBER OF ALTERNATIVES: 3 KEY PERFORMANCE ISSUES: FLEXIBILITY KEY PERFORMANCE ISSUES: FLEXIBILITYDURABILITY Draka USA

CONSTRUCTIONS CURRENT ARMORED SIGNAL CABLE: EPR INSULATION TINNED COPPER CONDUCTORS SBR TAPE or BEDDING LAYER SBR TAPE or BEDDING LAYER HELICAL BRONZE TAPE HELICAL BRONZE TAPE PE, NEOPRENE OR LSZH JACKET PE, NEOPRENE OR LSZH JACKET Draka USA

CONSTRUCTIONS PROPOSED ARMORED SIGNAL CABLE: EPR INSULATION TINNED COPPER CONDUCTORS TINNED COPPER CONDUCTORS SBR TAPE or BEDDING LAYER SBR TAPE or BEDDING LAYER LONGITUDINAL CORRUGATED BRONZE SHIELD LONGITUDINAL CORRUGATED BRONZE SHIELD PE, NEOPRENE OR LSZH JACKET PE, NEOPRENE OR LSZH JACKET Draka USA

ALTERNATIVE CONSTRUCTIONS ALT. 1: MYLAR/LC BRONZE SHIELD MYLAR TAPE LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELD ALT. 2: SBR/LC BRONZE SHIELD SBR TAPE LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELD ALT. 3: SBR/LC STEEL SHIELD SBR TAPE LONGITUDINALLY APPLIED, CORRUGATED, STEEL SHIELD Draka USA

TEST SAMPLES MANUFACTURED SAME CABLE CORE AND JACKET FOR ALL FOUR SAMPLES: 5 Conductors Tinned copper EPR Insulation 78 MIL PE Jacket Draka USA

TEST SAMPLES MANUFACTURED STANDARD CONSTRUCTION: SBR TAPE 10 MIL HELICAL, BRONZE SHIELD ALT. 1: MYLAR/LC BRONZE SHIELD MYLAR INSTEAD OF SBR TAPE LC INSTEAD OF HELICAL SHIELD ALT. 2: SBR/LC BRONZE SHIELD LC INSTEAD OF HELICAL SHIELD ALT. 3: SBR/LC STEEL SHIELD 6 MIL COATED, LC STEEL SHIELD Draka USA

TESTS CONDUCTED CRUSH TEST Measures compressive force needed to cause electrical failure CYCLIC FLEXING TEST Measures capability of cables to withstand multiple flexes FLEXIBILITY TEST Measures force required for a single bend CUT THROUGH TEST Measures the force on a 90 o wedge required to cut through to the armor and to the conductors Draka USA

CRUSH TEST APPARATUS Draka USA

CRUSH TEST RESULTS CABLE FORCE (LB) AT FAILURE TYPE AVE.MIN. TYPE AVE.MIN. STD. 9,000 7,000 STD. 9,000 7,000 ALT. 1> 10,000> 10,000 ALT. 1> 10,000> 10,000 ALT. 2 9,100 8,300 ALT. 2 9,100 8,300 ALT. 3 9,5008,600 ALT. 3 9,5008,600 Draka USA

CRUSH TEST RESULTS TEST CONDITIONS: ONE 4 FT. SAMPLE PER TYPE TEN APPLICATION POINTS PER SAMPLE LOAD RATE: 0.5 IN/MIN. MAX. APPLIED FORCE: 10,000 LB. FAILURE WHEN SHORT DETECTED Draka USA

CYCLIC FLEXING TEST APPARATUS Draka USA

CYCLIC FLEXING TEST RESULTS CABLE TYPE NO. OF CYCLES DESCRIPTION OF FAILURE____ STD233 CONTINUITY LOST IN ONE COND. 426 JACKET SPLIT OPEN 538 JACKET & ARMOR SEVERELY SPLIT 538 JACKET & ARMOR SEVERELY SPLIT ALT CONTINUITY LOST IN ARMOR 282 CONTINUITY LOST IN ONE COND. 282 CONTINUITY LOST IN ONE COND. ALT CONTINUITY LOST IN ONE COND. 482 CONTINUITY LOST IN ARMOR 482 CONTINUITY LOST IN ARMOR ALT JACKET SPLIT OPEN 288 CONTINUITY LOST IN ONE COND. 288 CONTINUITY LOST IN ONE COND. 322 CONTINUITY LOST IN ARMOR 322 CONTINUITY LOST IN ARMOR Draka USA

CYCLIC FLEXING TEST RESULTS TEST CONDITIONS: ONE 3 FT. SAMPLE PER TYPE ONE 3 FT. SAMPLE PER TYPE ONE CYCLE: TWO 90 O BENDS ONE CYCLE: TWO 90 O BENDS 15 CYCLES PER MIN. 15 CYCLES PER MIN. Draka USA

FLEXIBILITY TEST APPARATUS Draka USA

FLEXIBILITY TEST RESULTS Draka USA NO STANDARD TYPE NO ALTERNATIVE TYPE 1 NO ALTERNATIVE TYPE 2 NO ALTERNATIVE TYPE 3

FLEXIBILITY TEST RESULTS TEST CONDITIONS ONE SAMPLE PER TYPE SINGLE BEND, 90 O 2.8 INCH MANDREL RATE: 20 INCHES PER MIN. Draka USA

CUT THROUGH TEST APPARATUS Draka USA

CUT THROUGH TEST RESULTS CABLEAVE. FORCE (LB) TO REACH TYPEARMORCONDUCTOR STD.2,8005,000 ALT. 13,1005,100 ALT. 23,1005,000 ALT, 34,3004,700 Draka USA

CUT THROUGH TEST RESULTS TEST CONDITIONS: ONE 4 FT. SAMPLE PER TYPE ONE 4 FT. SAMPLE PER TYPE TEN APPLICATION POINTS PER SAMPLE TEN APPLICATION POINTS PER SAMPLE LOAD RATE: 0.5 IN/MIN. LOAD RATE: 0.5 IN/MIN. MAX. APPLIED FORCE: 10,000 LB. SHORT TO WEDGE DETECTED SHORT TO WEDGE DETECTED Draka USA

CONCLUSIONS CRUSH TEST MYLAR TAPE WITH LONGITUDINAL CORRUGATED BRONZE SHIELD SIGNIFICANTLY BETTER CYCLIC FLEXING TEST NO SIGNIFICANT DIFFERENCES FLEXIBILITY TEST THE LONGITUDINAL SHIELD IS AS FLEXIBLE AS THE HELICAL SHIELD CUT THROUGH TEST HELICAL SHIELD SLIGHTLY LESS RESISTANT TO CUT THROUGH Draka USA

RECOMMENDATION ALLOW THE USE OF MYLAR TAPE AND 10 MIL, LONGITUDINAL CORRUGATED BRONZE SHIELD IN UNDERGROUND SIGNAL CABLE Draka USA

BENEFITS ANNUAL COST SAVINGS NO REDUCTION IN PERFORMANCE NO REDUCTION IN PERFORMANCE SAFER HANDLING DURING TERMINATION Draka USA