The foundation of smart buildings is the structured cabling system. A standards-­based structured cabling system is designed to provide a vendor-independent solution that is not application-specific and can transmit a diverse range of analog and digital signals, including voice/data/­video, security, access control, building automation, lighting and more. This flexibility makes structured cabling indispensable for modern building operations. 

While a standards-based structured cabling system provides for a non-application-specific solution, the advent of the internet of things (IoT) and the proliferation in the types and quantities of devices powered by power over ethernet (PoE) means we must assume PoE is a de facto application. With power and data enabled through these applications, inherent heat generation and fire safety concerns require even more important installation considerations.

Plus, as power delivery technology evolves, the premise of globally standardized consumer power solutions is becoming more technically feasible. Innovations such as PoE, USB-C and fault-­managed power are disrupting traditional electrical systems by offering efficient, low-energy alternatives that align with modern energy conservation goals. Converging with data, power and control over the same infrastructure becomes a reality. And the data-driven insights facilitate real-time control for efficiency and safety.

Ethernet and PoE standards are recognized worldwide and ensure interoperability. The 8P8C (also known as the RJ-45 jack/plug) is already recognized as a global connector.

Meanwhile, USB-C is already achieving widespread adoption. The journey toward USB Type-C standardization has covered a lot of ground. On Dec. 28, 2024, the European Union’s new common charger directive requires all mobile devices sold in the EU to be equipped with a USB-C port. 

These technologies present a compelling case for unifying power delivery standards. With global adoption of balanced twisted-pair and the RJ-45 jack, manufacturers can reduce costs, expand global reach, enhance user convenience and contribute to sustainability efforts while accelerating innovation.

The root of the problem: Installation and compliance

The benefits facilitated by structured cabling can be negated by a poor installation. The design and installation of these systems remain a largely unlicensed industry, with voluntary certifications for designers and installers. Poor installations are compounded with the proliferation of noncompliant cabling and connectivity, raising significant concerns for reliability, safety and performance.

Poor installation practices have long been the crux of network performance problems. It is estimated that 80% of device failures are the result of inadequate cables and improper cable terminations. Fluke Networks, Everett, Wash., reports that the physical layer accounts for up to 80% of all network downtime.

In the case of optical fiber, connector contamination is the leading cause of network failures. Despite the availability of best practices for ensuring reliable and high-performing networks, basic tasks such as keeping fiber connectors clean remain a persistent challenge.

PoE technology further illustrates the consequences of poor workmanship. Excessive DC resistance unbalance, which can prevent PoE from functioning, is frequently caused by inconsistent terminations, substandard cable quality and poorly designed connectors.

“While seemingly simple, the RJ-45 and other connectors face a critical challenge: counterfeit and substandard components flooding the market. These knockoffs, produced by vendors prioritizing profit over quality, can be the weakest link in the network, leading to costly downtime and even jeopardizing mission-critical systems,” said Dave Kiddoo, executive director of the Communications Cable and Connectivity Association (CCCA).

The risks of noncompliant and counterfeit components

CCCA plays a vital role in addressing performance issues caused by noncompliant and counterfeit structured cabling components. These substandard products compromise network reliability and pose risks to public safety. A growing concern is the proliferation of copper-clad aluminum (CCA) conductors in cables and other noncompliant cable components and materials.

The problem with CCA cables

While CCA cables are permissible for traditional AC power applications, they are prohibited for balanced twisted-pair cabling. These cables do not meet industry standards and are unsuitable for PoE applications due to their higher DC resistance. For instance, the resistance of solid aluminum cables is approximately 55% greater than that of equivalent copper cables. This increased resistance leads to higher heat generation and lower voltage availability at powered devices. 

“When we were just considering data over these systems, it was bad enough. But now with limited-energy power also being transmitted through this same cabling infrastructure, the degradation of these cables and subsequent fire safety dangers are even greater threats,” Kiddoo warned.

CCA cables also violate the National Electrical Code and UL 444 standards for multiconductor communications cables. They are ineligible for fire safety listings from UL or other independent testing agencies, making them dangerous for installation in walls and ceilings. Noncompliant cables use flammable materials that can act like a fuse, spreading fires rapidly within buildings. These materials also produce toxic smoke, endangering occupants and first responders.

CCCA warns in its 2012 white paper “Potential Liability for Contractors Installing or Manufacturers Marketing Falsely Labeled Copper Clad Aluminum Cable” that noncompliant and counterfeit cabling pose significant risks to health and safety and could cause major damage to critical infrastructure.

Category (5e, 6, 6A, etc.) cables and connectors are readily available online and from big box stores. Many come preterminated in lengths up to 150 feet or more, and, unfortunately, often without specifications as to the current-carrying capability or UL listings. 

Identifying and avoiding noncompliant cables

Noncompliant cables and connectors can compromise the reliability of critical systems infrastructure, including hospitals, air traffic control centers, data centers and emergency response facilities. To mitigate these risks, building owners and contractors must be vigilant when selecting cabling and connectivity products.

For more detailed guidance on identifying noncompliant cables before they are installed, consult the resources provided by the CCCA, including their CableCheck App or the educational tools and case studies on their website (www.cccassoc.org). 

The importance of certification testing

Field performance testing is a critical step in ensuring the reliability of structured cabling installations. Certification testing validates that cabling links and channels meet all transmission performance requirements, including bandwidth and signaling capacity. These tests are essential for compliance with ANSI/TIA-568.2-E and ISO 11801-1 standards.

Manufacturers often require certification test results to issue warranties. Certification tests include up to 16 parameters with pass/fail criteria, such as wire map, length, propagation delay, delay skew and insertion loss. Among these, DC loop resistance and DC resistance unbalance have become increasingly important to check due to the growing adoption of PoE. 

The role of DC resistance unbalance testing

DC resistance unbalance testing measures the difference in resistance between two conductors within a cable pair. Excessive unbalance can cause distorted data signals, power delivery issues and device malfunctions, particularly in PoE applications. Uneven resistance leads to uneven current flow, disrupting both power delivery and data transmission.

By verifying that conductors in a pair have equal resistance, DC resistance unbalance testing ensures the reliable operation of PoE-powered devices. 

Previously a test that was “for information only,” resistance unbalance testing is now mandatory on all cable certification tests. 

Protecting critical systems and infrastructure

Structured cabling systems form the backbone of critical infrastructure, including hospitals, data centers and emergency services. The reliability and safety of these systems depend on using standards-­based installation practices and compliant, high-quality cabling and connectivity products. Noncompliant and counterfeit components jeopardize network performance and endanger lives and property.

To ensure the success of structured cabling installations, building owners, contractors and network professionals must:

Source products from reputable manufacturers with verified third-party certifications.

Conduct thorough field-performance testing, including certification tests.

Stay informed about industry standards and the risks associated with noncompliant components.

Nothing new under the sun 

The common law of business balance is the idea that you get what you pay for, and that paying less doesn’t guarantee a good quality product. 

This classic quote attributed to John Ruskin explains the folly of choosing low cost when making a purchasing decision: “There is hardly anything in the world that someone cannot make a little worse and sell a little cheaper, and the people who consider price alone are that person’s lawful prey. It’s unwise to pay too much, but it’s worse to pay too little. When you pay too much, you lose a little money—that is all. When you pay too little, you sometimes lose everything, because the thing you bought was incapable of doing the thing it was bought to do. The common law of business balance prohibits paying a little and getting a lot—it can’t be done. If you deal with the lowest bidder, it is well to add something for the risk you run, and if you do that, you will have enough to pay for something better.”

In other words, buyer beware; if it sounds too good to be true, it is.

According to Oleg Fishel, vice president of marketing and retail for Tempo Communications Inc., Vista, Calif., “There are a large number of best practices that quality-minded, experienced technicians follow, which ensure a high-quality installation of structured cabling, particularly PoE installations. Unfortunately, since those are not mandatory in any standard, a large number of technicians ignore best practices in favor of expedience. The best-case scenario would be for these best practices to be codified and subject to inspection and verification, ensuring safety and quality across all installations. In lieu of mandatory requirements, training is the best way to get technicians to understand the importance of following best practices both from a safety, quality and lifetime cost of an installation.”

Structured cabling systems have the potential to transform building operations by supporting a wide range of applications, from voice and data to IoT devices and PoE-powered systems. However, the advantages of these systems can be nullified by poor installation practices and the use of noncompliant or counterfeit components.

By adhering to best practices, using compliant products and performing rigorous certification testing, stakeholders can ensure the reliability, safety and performance of their structured cabling systems. As the industry continues to evolve, maintaining these standards will be essential for meeting the demands of modern building technologies and safeguarding critical infrastructure.

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