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The AirES product range of cables are a true innovation in struc-
tured cabling. In most evolutionary processes the gain in one
attribute often sacrifices another. With the AirES revolution all
attributes, both physical and electrical, are improved to provide a
“Win-Win” situation for both the installer and customer.
This white paper will focus on the mechanical attributes and
advantages of AirES. Herein, we will discuss the development of
the technology and the by-product effects on any and all
mechanical parameters.
The industry migration to UTP cables in the first place was a push
to make the cabling plant more cost effective and less obtrusive.
Since the days of Coax and Type 1 cables, the industry has
moved to reduce the size and cost through the introduction of
UTP cables.
Over several years the electrical performance of UTP cables has
increased dramatically. We’ve migrated from Cat 3 cabling sup-
porting 10BaseT to Cat 5 supporting 100BaseTX and now our
progression has taken us not only to Cat 5e for 1000BaseT, but
to a cabling standard designed to meet the next technology
wave in Cat 6.
The IEEE develops these advances in transmission protocol and
hands it off to the TIA to develop the latest and greatest UTP
cable that can support the electrical requirements. At the same
time our market has become more and more competitive. The
price of materials has dropped dramatically, as well as the price
of installation…or has it?
TrueNet
®
AirES
®
Technology
Mechanical Attributes
TrueNet
®
AirES
®
Technology: Mechanical Attributes
Page 2
Installers now find that they need to install cables more
quickly than before to be competitive. While at the same
time the cables have become more difficult to install!
We here at ADC have been listening to our installers
and decided enough is enough. It’s time to deliver a
product whose electrical performance is superior and at
the same time is actually easier to install.
Several attributes are taken into consideration when
pulling cable into an installation.
1. The raceways that will be used.
2. The access to drop locations.
3. Timeline for installation.
4. Fire codes.
5. Product set for both the Telecommunications Closet
and Workstation.
6. Testing of the product after the installation is complete.
7. Warranty.
8. Reliability of brand for installer reputation.
The magic number 32:
The number of cables pulled simultaneously makes for
faster installation times. With AirES cable the pulling
tension has been reduced by 32% on average. This
means 32% more cables can be pulled at the same
time, reducing installation time.
The number of cables that can fit into the space sup-
plied has also dramatically increased. Fill rates have
gone up with AirES by an average of 32% for C6T and
28% C5eT.
The example below is from the NEC fill rate chart. We
compared 5 of our leading competitors equal Category
cables against our own. They ranged from a fill rate of
47 to 60 cables at a 40% fill rate in 3” conduit.
In both the Cat 5e and Cat 6 examples the fill rate of
the AirES cables were much greater than that of all
competitors. Typically the AirES cable has a 28-32%
advantage for C5eT and C6T. On the left is a bundle of
24 AirES Cat 6 0.20” cables. On the right a bundle of 24
“Industry Standard” Cat 6 0.25” outer diameter cables.
The above example is dramatic in showing the size dif-
ference between the new and old style cables. This is
achieved through reducing the size of our primary con-
ductor. The effect over a total of 8 conductors in a 4
pair UTP cable is dramatic.
What this means to the customer is more cables in the
same space or less space needed for the same number
of cables! A reduction in cable tray, conduit, raceway,
etc. For the installer this means less frustration due to
limited access space.
From a safety prospective the AirES cable is better than
industry standard designs. We currently use FEP insula-
tion in the Plenum space to reduce the risk of fire speed
and intensity. With AirES the amount of fuel is reduced
by 32% through the introduction of AIR.
The number of cables that can be pulled in at the same
time increases greatly for the installer. When a cable is
larger in diameter it is also heavier in weight. The effect
is an increased amount of force in pulling tension to
Cable Fill 3” Conduit @ 40%
140
120
100
80
60
40
20
0
C5eT
AirES
Competitor
Average
137
93
Cat 6 Cable Fill 3” Conduit @ 40% to NEC Specifications
100
90
80
70
60
50
40
30
20
10
0
C6T
AirES
Competitor
Average
85
57
Cable Fill 3” Conduit @ 40%
C6T C5eT
AirES
Conductor
Industry Standard
Conductor
AirES
4 pr. UTP Cable
Industry Standard
4 pr. UTP Cable
TrueNet
®
AirES
®
Technology: Mechanical Attributes
Page 3
remove it from the box and an increase in cross sectional
area for friction during the pull. The smaller bundle size
also decreases the surface area of the same number of
cables vs. the industry standard design, which allows for
more cables to be pulled at the same time.
Lets take a 1000 drop Cat 6 installation for example. If
the installer was to pull 6 cables simultaneously for the
entire installation there would be a total of 167 bundles
for the site. With the AIRES Cat 6 design 32% more
cables can be pulled in due to the reduced pulling ten-
sion. Now we are pulling 8 cables in simultaneously.
The job is now finished with only 125 bundles pulled.
The amount of force needed to terminate has also been
greatly reduced due to the smaller conductor size and
the introduction of Air. On Cat 6 the reduction in force
is even greater through the use of a smaller conductor
size and less insulation. This is achieved through the
increased electrical performance of the cable, which you
can learn more about in our "Electrical Characteristics of
AirES" white paper.
In the following example an 11% reduction in force is
realized. This reduces the amount of fatigue experi-
enced by the installer during the termination phase of
the installation.
Through the use of a smaller conductor, fewer twists,
the reduced insulation size and the use of a tape filler
rather than a star for Cat 6, the time to terminate is
reduced as well. In the example below there was an
18% time savings using AirES cable.
Through the reduction in cable size, the overall weight
of a box of AirES cable is greatly reduced. This now
allows ADC to put 2000’ of cable on a standard 1000’
put up reel and stay below the 50lb limit for lifting, set
by OSHA. After each reel of cable is complete there is a
length of scrap left over. Through the introduction of
2000’ put ups this is reduced in half.
The ability of a cable to withstand the rigors of installa-
tion must also be taken into account during design. Too
often for the sake of transmission performance the cable
becomes more fragile and susceptible to damage.
Through the reduction in twist lay variation in AirES the
cable becomes less prone to performance loss due to
pulling tension, as the effect of the different twist lays is
not as critical. What this means to the installer is fewer
field issues to investigate during the testing phase.
Structural integrity with regards to crush resistance has
not been compromised with the use of the AirES
design. The first question on everyone’s lips after
understanding how the AirES cable is designed seems
2.5
2
1.5
1
.5
0
C6T
AirES
Pulling Tension in Lb
Competitor
Average
2.3
1.5
Amount of Force Needed to Pull One Cat 6 UTP Cable
180
160
140
120
100
80
60
40
20
0
C6T
AirES
Bundles Needed for 1000 Drop
Competitor
Average
167
125
Effect of Cable Pulling Tension Reduction
of AirES on 1000 Drops
100
90
80
70
60
50
40
30
20
10
0
C6T
AirES
Competitor
Average
77
87
Insertion Force in N
Comparison of AirES vs Competitor Average
Force for Insertion into a KRONE Block 45 IDC
120
100
80
60
40
20
0
C6T
AirES
Average Time in to Terminate
Competitor
Average
110
90
Termination Time in seconds for a Cat 6 Cable
Web Site: www.adc.com
From North America, Call Toll Free: 1-800-366-3891 • Outside of North America: +1-952-938-8080
Fax: +1-952-917-3237 • For a listing of ADC’s global sales office locations, please refer to our web site.
WHITE PAPER
ADC Telecommunications, Inc., P.O. Box 1101, Minneapolis, Minnesota USA 55440-1101
Specifications published here are current as of the date of publication of this document. Because we are continuous-
ly improving our products, ADC reserves the right to change specifications without prior notice. At any time, you
may verify product specifications by contacting our headquarters office in Minneapolis. ADC Telecommunications,
Inc. views its patent portfolio as an important corporate asset and vigorously enforces its patents. Products or
features contained herein may be covered by one or more U.S. or foreign patents. An Equal Opportunity Employer
1317031 5/05 Original © 2005 ADC Telecommunications, Inc. All Rights Reserved
to involve its ability to resist crush. With other
designs that involve the foaming of insulation
materials to introduce air, crush has been a
large problem.
Type 1 cables of old were able to withstand crush
due to each pair being individually shielded, but for
UTP applications the concerns are founded. AirES
through its arched air pocket construction uses sev-
eral solid insulation beams distributed evenly
around the conductor, coupled with the arch shape
of the pocket. The result is a total cable exceeding
the UL444 requirements for crush resistance by
>4X the requirement. Once again eclipsing our
nearest competitor.
UL444 Scope:
This standard applies to 60-250ku8C single- or
multiple-conductor jacketed or unjacketed, inte-
gral or nonintegral cables and single or multiple
coaxial cables for telephone and other communi-
cation circuits such as voice, data, and audio for
on-premise customer systems. These cables are
not prohibited from containing one or more opti-
cal fiber members. For the purpose of this stan-
dard, a coaxial cable or coaxial member conductor
is single conductor with a shield. For the purpose
of this standard, a single or multiple-conductor
unjacketed cable is a crossconnect wire.
This standard applies to communications cable
intended primarily for installation in accordance
with Section 60 of the Canadian Electrical Code
(CEC), Part 1, and Article 800 of the National
Electrical Code (NEC). They are rated for 300 V
applications but are not so marked.
This standard does not apply to communication cords.
KRONE
®
is a registered trademark of ADC Telecommunications, Inc.
. installation…or has it?
TrueNet
®
AirES
®
Technology
Mechanical Attributes
TrueNet
®
AirES
®
Technology: Mechanical Attributes
Page 2
Installers now find that they. the mechanical attributes and
advantages of AirES. Herein, we will discuss the development of
the technology and the by-product effects on any and all
mechanical
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