brian_chee
Contributing Editor

Wiring and Cabling: How To Lace Cable Harnesses

analysis
Jan 8, 20082 mins

Many have described Cable Lacing as a lost art and rightly so. With zip ties down in the $0.01 each range it doesn't make any economic sense to expend the labor on lacing. However, anyone that has had to troubleshoot a cable bundle has found that the labor charges were just shifted. Tightly bound cable bundles tend to the norm with some installers actually using a zip tie gun to get them even tighter. (and oh by

Many have described Cable Lacing as a lost art and rightly so. With zip ties down in the $0.01 each range it doesn’t make any economic sense to expend the labor on lacing. However, anyone that has had to troubleshoot a cable bundle has found that the labor charges were just shifted. Tightly bound cable bundles tend to the norm with some installers actually using a zip tie gun to get them even tighter. (and oh by the way increasing cable cross talk by flattening out the cable pairs) The downside is that if you want to trace a cable’s physical path, digging it out of a tightly wrapped bundle starts becoming a big problem. With lacing you have the option of slipping a loop to one side to create a gap and make tracing a bit easier. The other advantage is that lacing doesn’t leave sharp ends in the cable trays like those on zip ties with the extra cut off.

So while cable harnesses are still used in the aircraft and auto industry, it might be something the computer industry to consider especially as clusters proliferate masses of cables in the back of our equipment racks. So maybe if folks like HP, Dell and IBM are listening; they might want to consider using a lacing board to pre-build cable harnesses so that the bundles lay nicely, and are easier to trace for troubleshooting? I’m sure it will add to the cost, but a pre-made harness for something like IBM’s SAN in a box product makes a lot of sense since they control everything in the rack, right down to the cable management.

So I’m fairly sure that I would love to see more cable lacing rather than zip ties, and I also really like that cable lacing makes my racks that much neater. My problem is justifying the upfront labor cost, especially when I know that some of my racks get changed around frequently. More than likely I’ll end up using lacing only for cables bundles that go between patch panels.

I’d love to know if anyone out there is still using cable lacing and why you feel the added expense is justified?

Here’s a website that has excerpts from a US Navy training manual on cable harness assembly.

Wiring and Cabling: How To Lace Cable Harnesses