Utility projects demand underground conduit systems that are durable, cost-effective and optimized for efficient cable pulling across varied terrain. Traditional conduit materials present challenges including burn-through at elbows, complex installations, heavy components, long cable pulls and high costs. Below, we examine these challenges and how fiberglass conduit elbows provide effective solutions.
Key challenges in utility projects
- High costs – Steel and PVC-coated steel conduits are heavy, increasing material, labor and handling expenses.
- Complex underground installations – Heavy conduit materials require additional manpower and equipment, increasing installation time and safety risks.
- Elbow burn-through – PVC elbows are prone to burn-through from high-friction cable pulls, leading to costly repairs.
- Long cable pulls – Excessive friction in long conduit runs increases installation difficulty and the potential for conduit or cable damage, especially at bends.
- Cable fault issues – Cable faults can cause wires to melt and fuse to the conduit interior, resulting in expensive repairs.
The fiberglass conduit elbow advantage
Fiberglass conduit elbows address these common challenges, offering significant benefits that improve project efficiency and cost-effectiveness.
Reduced material and installation costs
Fiberglass elbows are lighter than GRC, PVC-coated steel and most PVC sizes, lowering both material and labor costs. Their lightweight nature allows for easier portability in the field and a more streamlined installation. Specifically, labor is reduced because lightweight conduit allows installers to position and connect elbows faster without specialized equipment. And since fiberglass conduit is manufactured in the United States, it also reduces shipping costs.
Simplified installation
Compared to traditional materials, fiberglass conduit elbows are easier to handle and install. According to the NECA Manual of Labor Units, fiberglass installs faster than many conduit types. Contractors frequently note that a single person can easily move and position fiberglass elbows on-site. Additionally, gasketed connections speed up assembly, reducing the need for heavy equipment and lowering installation risks in confined or difficult spaces.
Eliminates burn-through
Fiberglass conduit elbow’s superior mechanical strength withstands high-tension cable pulls without burn-through. Its high flexural strength reduces the risk of cable damage, ensuring long-term reliability. No burn-through eliminates the risk of elbow damage in high-stress areas and reduces maintenance costs.
Lower friction for easier cable pulling
Fiberglass has a low coefficient of friction—0.38 compared to 0.55 for PVC-coated steel and galvanized rigid steel, and 0.90 for SCH 40 and 80 PVC. This allows cables to move more smoothly through conduit, decreasing labor time, costs and risks.
Cable fault resistance
Fiberglass conduit prevents cables from fusing to the conduit interior in the event of a fault. This allows for easy cable removal and replacement, eliminating the need for expensive conduit repairs.
Case study: Fiberglass conduit in a high-demand data center
Similar to utilities projects, data center projects also involve complex buried installation. In Virginia’s Data Center Alley, Rosendin Electric Inc., San Jose, Calif., needed to install extensive telecom and transformer duct banks. By choosing Champion Fiberglass® conduit and elbows, the project benefited from the material’s lightweight properties, reducing equipment needs and enhancing safety in the trench. Prefabricated duct banks streamlined the installation, while Champion Fiberglass provided expert guidance throughout. Compared to PVC, fiberglass cut material costs by nearly 50% and labor costs by 60%, which contributed to a lower total cost of ownership. It also delivered a 63% productivity boost—helping the project stay on time and within budget.
Learn more about this project in this video.
Fiberglass conduit elbows offer a durable, efficient, and cost-effective solution for underground utility projects. They eliminate common installation challenges, reduce labor costs and improve overall system reliability. For infrastructure requiring long-term resilience, fiberglass is a smart and high-performance choice.
