
For underground transmission and distribution utility projects, conduit systems must be resilient, cost-effective, and support efficient cable pulling through various terrain. However, traditional materials often introduce challenges, including elbow burn-through, complex installations, heavy conduits, long pulls, and high costs. Let’s break down each of these issues and explore solutions.
Utility project challenges
- Cost: Traditional conduit materials like steel and PVC-coated steel are significantly heavier than other options. Heavier conduit increases labor, material costs, and handling challenges.
- Complex Buried Installation: Utility projects frequently involve complex, underground installation. Heavy conduit materials require not only extensive equipment but also manpower, adding risk and time to the installation.
- Elbow Burn-Through: Traditional elbows used in underground systems, such as PVC, can experience burn-through, particularly with high friction from dense, extended cable pulls. Burn-through compromises system integrity and requires costly conduit repairs or replacements.
- Long Cable Pulls: Long pulls with traditional conduit can produce excessive friction, increasing installation time and the likelihood of conduit or cable damage, particularly at bends.
- Fault concerns: Cable faults that meld or weld to the inside of the conduit cause expensive repairs.
Fiberglass conduit elbows: Practical solutions for utilities
Fiberglass conduit elbows address each of these challenges, providing essential benefits that lead to better project outcomes.
Lower material and installation costs: Fiberglass elbows are significantly lighter than alternatives such as GRC, PVC-coated steel and most sizes of PVC, lowering material and installation costs. Labor is reduced because the lightweight material allows installers to position and connect elbows faster without specialized equipment. Made in America fiberglass conduit offers substantial savings in both material costs, labor efficiency, and also shipping costs.
Seamless installation: Fiberglass elbows are lighter and easier to handle than traditional options, simplifying buried installations. Fiberglass installs faster than many sizes of electrical conduit types per the NECA Manual of Labor Units. Contractors are frequently amazed at the ease with which a single elbow can be picked up by a person at the jobsite. Additionally, gasketed connections speed installation and reduce the need for heavy equipment, lowering costs and installation risks in tight or challenging spaces.
No burn-through: Fiberglass conduit’s mechanical strength withstands high-tension cable pulling without burn-through. And flexural strength helps eliminate the risk of cable damage when pulling. This reliability eliminates the risk of elbow damage in high-stress areas, lowering maintenance needs.
Low coefficient of friction: With a low coefficient of friction, .38 compared to .55 for PVC-coated steel and galvanized rigid steel and .90 for SCH 40 and 80, fiberglass allows cables to be pulled more smoothly through conduit with less labor time, cost and risk.
Cable fault resistance: Fiberglass conduit is cable fault resistant meaning the wire does not melt to the inside of the conduit. This means damaged or faulted cable can be easily pulled through and replaced, since the conduit has not been damaged.
Case Study: Underground Advantage
How Smart Conduit Choices Powered a Solar Farm to Early Completion
When AES Corporation set out to build a major solar farm in Virginia, they faced tight corridors, long underground cable runs, and supply delays. The challenge: install multiple high-capacity circuits underground while minimizing costs, materials, and delays. The solution came with Champion Fiberglass® conduit. Its wide temperature tolerance, durability, and fast procurement enabled a streamlined, concrete-free installation. The project was completed weeks ahead of schedule, meeting capacity demands, budget targets, and quality expectations.
See the full case study for the complete story, including engineering decisions, installation innovations, and how the team overcame supply chain hurdles to deliver a complex renewable energy project on time.
Fiberglass conduit elbows offer transformative benefits for utility projects, addressing common challenges with solutions that prioritize durability, ease of installation, and cost efficiency. For projects requiring resilient underground infrastructure, fiberglass presents a smart and reliable choice.
Learn more about fiberglass conduit in utilities applications.