This presentation shows how to manufacture entirely dry stranded loose tube cables which are based on super absorbent polymer (SAP) technology. The traditional way of preventing the water penetration is to fill the tubes with filling compound. The messy filling compound is replaced with SAP powder and therefore dry loose tube cables can reduce fiber installation costs in several ways. It simplifies the splice preparation and cleanup of the fibers. In order to utilize benefits from diy cable designs one must solve the excess fiber length (EFL) and diameter control dilemma at today's production speeds. The new buffering process based on clenching concept will solve the EFL control problems when manufacturing dry sub units for robust access network cables. Normally the EFL will be extremely high when producing dry loose tubes. The clenching method can compensate the EFL increase and guarantee EFL levels suitable for high quality stranded dry loose tube cables. When filling compound is replaced with powder the diameter control of the loose tube will be more difficult. The cable design and the new manufacturing concept will be presented. Basic guidelines of the cable design have been maximal robustness combined with excellent low temperature characteristics. Also of interest is to ensure user-friendly installation. Test cable was based on SAP technology. Designs confirmed the excellent temperature stability for these dry stranded loose tube cables. It was possible to achieve optimized balance between the maximum fiber content and the minimum dimensions.
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