2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
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UK’s Largest Network Operator
Doubles Fibre Capacity with HFCL’s
96F ULW Aerial Cable
Home (index.html) / UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
Case Study
Highlights
Doubled
network fibre
capacity
from 48F to 96F
Tool-free access
Passed 16-day
storm loading
test
Reduced labour cost
Patent Received
Lower transportation costs and
reduced environmental footprint
~2,000 km of cable delivered
for the initial deployment phase
Background
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2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
A leading network operator in the UK needed to significantly increase network fibre capacity to support the
expansion of their nationwide broadband network. The challenge was to achieve this without increasing aerial
cable pole congestion and to minimize installation costs.
Customer’s Overview
The customer is a leading multinational telecommunications holding company based in London, England, with
operations across the globe. As the UK's largest provider of fixed-line, broadband, and mobile services, the company
also offers subscription television and IT services. Its Enterprise division supplies telecommunications services to
corporate and government customers worldwide. The customer is known for its commitment to technological
innovation and operational excellence in telecommunications.
Challenges Faced
Capacity and Congestion
The existing 48-fibre (F) cable solution could not meet the growing demand, especially in rural and remote areas
where digging costs and environmental impact are high. Doubling the fibre capacity while keeping the same
cable diameter was essential to avoid pole congestion and additional infrastructure costs.
Regulatory Challenges and Installation
Requirements
Regulatory guidelines categorize aerial cables based on strength—light, medium, and heavy—dictating
installation requirements. Cables classified as 'light' can be installed without pole inspection, whereas higher-
strength cables require inspection and potential pole maintenance. This setup incentivizes using 'light' category
cables for trunk and distribution purposes. However, challenges in design and performance, particularly in
accommodating increased fibre density, are notable within this category.
Loading Requirements
One of the most challenging requirements involved cable loading. The new design of the 96F ULW aerial cable
had to meet stringent loading criteria: it needed to support a load range of ≥ 1300 N (292 lbf) to ≤ 2000 N (450
lbf). The lower limit was set to withstand storm loading conditions, while the upper limit ensured the cable would
break before pulling down a pole.
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2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
Cost Efficiency
Implementing the solution needed to be cost-effective, avoiding significant increases in installation and
maintenance costs.
HFCL’s Approach to the Challenges
1
Design and Performance
HFCL developed a 96-fibre Ultra Lightweight (ULW) aerial cable that doubled the fibre capacity compared to the
legacy 48F solution. The design used twenty-four 200µm fibres in each micromodule and optimized braided
steel wire to meet both break and storm load requirements.
2
Rigorous Testing
The new 96F ULW aerial cable underwent comprehensive testing, including a 16-day overhead installation test
with 5 cycles of simulated storm loading. This ensured the cable met all customer-specified performance
requirements.
3
Innovative Features
High tensile strength up to 980N with endurance up to 2000N, robust durability against crushing and water
penetration, reliable performance in extreme temperatures (-30°C to +70°C), and tool-free access for simplified
installation and reduced labour costs.
4
Seamless Integration
The solution was designed to be compatible with existing connectivity infrastructure and installation methods,
allowing for a smooth transition and minimal disruption.
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2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
Success Metrics
Achieved cost-effective installations
Reduced pole congestion
Reduced storage and inventory expenses
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2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
Enhanced environmental sustainability
Maintains rigorous performance
standards
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2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
~ 2,000 km of 96F ULW cable delivered
for initial deployment
Result
HFCL developed a 96-fibre Ultra Lightweight (ULW) aerial cable solution that provided a significant boost in network
capacity while maintaining a compact and lightweight design. This innovation allowed the customer to effectively
double their fibre capacity without increasing aerial congestion or installation costs. The solution’s success is marked
by its adherence to stringent performance standards and extensive deployment across the UK. Additionally, the
design received a patent in April 2024, underscoring its uniqueness and technical advancement.
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2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
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About HFCL
HFCL is a leading technology company specializing in creating digital networks for telcos, enterprises, and governments. Over the years, HFCL has
emerged as a trusted partner offering sustainable high-tech solutions with a commitment to providing the latest technology products to its
customers. Our strong R&D expertise coupled with our global system integration services and decades of experience in fiber optics enable us to
deliver innovative digital network solutions required for the most advanced networks.
The company’s in-house R&D Centres located at Gurgaon and Bengaluru along with invested R&D houses and other R&D collaborators at different
locations in India and abroad, innovate a futuristic range of technology products and solutions. HFCL has developed capabilities to provide premium
quality Optical Fiber and Optical Fiber Cables, state-of-the-art telecom products including 5G Radio Access Network (RAN) products, 5G Transport
Products, Wi-Fi Systems (Wi-Fi 6, Wi-Fi 7), Unlicensed Band Radios, Switches, Routers and Software Defined Radios.
The company has state-of-the-art Optical Fiber and Optical Fiber Cable manufacturing plants in Hyderabad, an Optical Fiber Cable manufacturing
plant in Goa, and its subsidiary HTL Limited in Chennai.
We are a partner of choice for our customers across India, Europe, Asia Pacific, the Middle East, Africa, and the USA. Our commitment to quality and
environmental sustainability inspires us to innovate solutions for the ever-evolving customer needs.
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2/9/25, 10:11 AM UK’s Largest Network Operator Doubles Fibre Capacity with HFCL’s 96F ULW Aerial Cable
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