Fiber used in an undersea cable encounters different stresses from fiber manufacture to final cable manufacture. Usually fiber experiences the highest stress at its required prooftest during fiber manufacture. For the processes of an undersea cable, fiber usually experiences much less stresses. However, one of the cabling processes was identified to have higher stress than expected, which is the insulation jacket extrusion of a deep-water cable. This paper models the fiber strain in this process and proves its consistency with observed data. The cause of higher fiber strain is believed to be from thermal expansion of the filling compound gel in the loose tube portion of the cable. This change of gel is modeled to demonstrate that the fibers are affected locally and are stretched simultaneously with gel movement. This phenomenon is temporary and the fiber strain changes with the gel temperature during the manufacturing process.
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