TRAXyL, Inc., a Delaware corporation having its principal place of business in Virginia, has developed a new method for installing fiber optic communication lines by essentially painting them directly into pavement. TRAXyL’s vision is to solve the “last mile” (“last kilometer”) connectivity problem by leveraging their flagship product, FiberTRAX, the first of many new connectivity capabilities.

FiberTRAX is a patented and proprietary method for installing fiber cable by inlaying a low-profile cable into (or affixing onto) a surface. Generally, the cables are installed into an etched channel into pavement and secured using a quick curing, durable resin.

FiberTRAX is installed using TRAXtor installation machines. Short FiberTRAX links can be installed manually using TRAXyL hand tools and techniques.

TRAXtors are self-propelled machines that perform processes to install FiberTRAX (and other TRAX-able payloads) on demand. They vary in size and capability, and generally one or two machines can install FiberTRAX on pavement at up to 1,000 feet (305 meters) per hour.

The paint is a very durable and fast-curing resin provided specifically for use in FiberTRAX. The resin bonds to surfaces like pavement extremely well. The “painted fiber” moniker is used to describe the final FiberTRAX installation because it resembles a road paint marking.

FiberTRAX is already installed in numerous locations all over the United States and has been working for several years in some very harsh environments like shipping ports and flight lines. Factors that can affect performance include the quality of the underlying pavement, the FiberTRAX path location, and local traffic conditions. With proper installation, periodic inspection, and limited Top Coat refreshment if needed, FiberTRAX connectivity can be maintained indefinitely.

FiberTRAX that is installed on asphalt and concrete is designed to utilize the existing pavement as it provides a solid base to secure fiber cables (and other payloads). These surfaces include bike or cart paths, sidewalks, driveways, parking lots, roads, bridges, flightlines, piers, and tunnels. FiberTRAX can be installed anywhere there is pavement and has found itself at airports, shipping ports, military bases, campuses, in residential and business communities, and even indoors like convention centers, garages, factories, and warehouses.

FiberTRAX is currently not designed for use on surfaces such as dirt, grass, or gravel, or on vertical surfaces. We are continuing development to install FiberTRAX on a new type of surface (to include a new prototype TRAXtor), with more to come about this new development in the 2025-2026 timeframe.

The typical FiberTRAX installation is completely flush to the surface and the Top Coat completely covers the etched channel with an over-smear of approximately two inches (~50 millimeters) wide.

No, flush-mounted FiberTRAX is installed into the surface by etching or “smoothing” a small channel for the fibers and resins to reside. The channel is no more than several millimeters deep, and the installation does not cut through the surface layer of the pavement.

Costs vary from project to project. If your cost is dependent on time saving and labor reduction, then TRAXyL solutions may be much more efficient and include significant cost savings. A recent testimonial describes: “The price was a fraction of the rock-boring pricing. The other benefit we found was more productivity. One machine from TRAXyL was able to get more footage than 3-4 bore rigs in a week.” Contact TRAXyL directly to discuss your project or for more information.

FiberTRAX consists of multiple layers of protection that include resins, cable jacketing, aramid yarns, and steel armor that provide a robust installation. FiberTRAX samples have been tested in thermal chambers and subjected to extreme temperatures and humidity. FiberTRAX has survived heavy vehicular traffic, equipment, top loaders, and large aircraft.

FiberTRAX resins can be melted and removed. The cable can be removed using TRAXyL decommissioning methods, and the entire link can be removed from the surface using commercial scarifying equipment.

FiberTRAX is extremely resistant to snowplow and tracked vehicle risks. However, snowplow blades that gouge into the asphalt road surface and tracked vehicles that pivot on top of the FiberTRAX installation could potentially damage a FiberTRAX installation. To reduce these risks, TRAXyL suggests implementing design, installation, and operational guidelines that:

1. Avoid routes with the harshest traffic
2. Install FiberTRAX close to the curb or road edge
   
   

Additional measures could include:

3. Create redundant links to form mesh networks
4. Implement signage to identify the FiberTRAX links, such as “Lift Plow Blade Here”
5. Instruct plow drivers and contractors of proper equipment operation near FiberTRAX
6. Ensure proper preventative maintenance agreements are in place between end users and installers

1. FiberTRAX is an innovative fiber installation technique invented by TRAXyL. The technique is meant to provide installers a simple cost-effective installation option for complex situations. FiberTRAX reduces project costs, shortens the planning and approval cycle, speeds up the installation time, and eliminates the need to restore a work site.

Currently, the TRAXtor can deploy a 6, 12, or 24-count fiber cable with 250-micron single-mode or multimode fibers. TRAXyL is developing the technology to place 96 fibers and more in a single FiberTRAX installation. TRAXyL has also provided custom installations with multiple fiber cables into a single FiberTRAX etched channel.

A new asphalt layer may be installed directly on top of an existing FiberTRAX link. If the top layer of a road surface is milled prior to the new asphalt installation, then an existing FiberTRAX link will need to be installed after the road is resurfaced. A redundant FiberTRAX link or other temporary cable may be installed on an alternate path prior to the road surface replacement to maintain a connection.

Standard colors include black, gray, white, and yellow. Other colors can be ordered by Pantone® identifying number.

It is recommended that the surface, air, and material temperatures be between 40 – 105 degrees F (4 – 41 degrees C), and at least 5 degrees F (-15 degrees C) above the dew point, with relative humidity less than 75%. If operating outside of these conditions, consult with a TRAXyL representative to discuss options.

Once installed, FiberTRAX can handle extreme winter and summer conditions and temperatures.

Call TRAXyL at +1 (844)4-TRAXYL (+1(844)487-2995) or email [email protected] to speak with a TRAXyL representative today.

TRAXtors can install fiber at speeds up to 1,000 feet (305 meters) per hour. TRAXyL is continuing to develop new procedures and equipment to install FiberTRAX at an even faster rate. The Top Coat fully cures in roughly 30 to 60 minutes depending on ambient temperature. The Top Coat can be sprinkled with dust to make the line walkable or drivable immediately after installation.

The protective coatings that make up FiberTRAX hold up very well and are designed to be very resistant to road surface chemicals.

FiberTRAX is no more or less secure than other conventionally installed fiber cable such as an aerial cable coming down off a pole and into a junction box, or a buried cable that enters a handhole.

FiberTRAX can be installed over JACs of varying widths. JACs up to ~1” (~25 mm) have no appreciable effect. JACs that are ~1 – 2” (~25 – 50 mm) can be spot filled with TRAXyL resins in anticipation of the FiberTRAX installation. JACs exceeding ~3” (~75 mm) will utilize a TRAXyL defined method to span the crack or expansion joint.

An approved TRAXyL Installer provides warranty coverage based on their assessment of any potential installation.
TRAXyL provides a warranty against defects for all TRAXyL provided protective coatings and fiber.

Preventative maintenance procedures generally include periodic inspections and refreshing the Top Coat to repair small scuffs and gouges as needed.

Yes, generally there are multiple techniques that can be implemented to ensure continuous flow of traffic. After installation, the Top Coat resin can be sprinkled with the dust generated during the etching process so that the lines are walkable and drivable immediately after installation.

Industry standard tools, equipment, and procedures are used to identify where damage has occurred. Once identified, the links can be rerun at speeds up to 1,000 feet (305 meters) per hour using TRAXtors, or an in-situ FiberTRAX splicing can be performed by an Approved TRAXyL Installer.

All protective coatings are TRAXyL proprietary resins with specific formulas based on the geography and conditions at the installation site. Only TRAXyL provided materials can be used for FiberTRAX and dispensed by TRAXtors.

FiberTRAX has been used for Fiber to The Home (FTTH) projects at both single homes and Multi-Dwelling Units (MDUs), on military bases and campuses to extend network connectivity, to connect devices and cameras, and across a bridge over a river. For more use cases, visit traxyl.com/case-studies.

Email [email protected] or call 1-844-4-TRAXYL (1-844-487-2995) to speak with a TRAXyL representative.