Precast Duct Bank Installation Guide

ELECTRICAL PRECAST
DUCT BANK
INSTALLATION GUIDE
This document details the foundation preparation, lifting equipment selection, handling of Duct Banks,
alignment, integrating duct banks into an existing or cast-in-place system, backfilling and tool checklist
for installation of Forterra Precast Electrical Duct Banks.
ELECTRICAL PRECAST DUCT BANK INSTALLATION GUIDE
Contents
Foundation Preparation ................................................................................................................................. 2
Lifting Equipment Selection ......................................................................................................................... 2
Handling Duct Banks .................................................................................................................................... 3
Alignment ..................................................................................................................................................... 4
Troubleshooting Alignment Issues ........................................................................................................... 5
Integrating Precast Duct Banks to an Existing or Cast-in-Place System ...................................................... 6
Joining Precast Duct Banks to a Cast-in-Place System ............................................................................ 6
Joining Precast Duct Banks to Precast Utility Vaults ............................................................................... 6
Backfilling..................................................................................................................................................... 7
Tool Checklist ............................................................................................................................................... 8
Forterra Structural & Specialty Products Matthew Pearson

6655 Wedgwood Rd. N Suite 130 Technical Resource Engineer
Maple Grove, MN 55311 Page 1 Matthew.Pearson@forterrabp.com
T:(763)-694-3256 M:(612)-807-4471
Foundation Preparation
Forterra Precast Electrical Duct Banks require a level, compacted foundation. Subgrade preparation will
be in accordance with project specifications and/or any available geotechnical report prepared for said
project. A smooth consumable organic material such as a Masonite board with minimum dimensions to
allow for roughly 18-24” of overlap on each side of the joint will be placed on the floor of the trench at
each joint location. The use of a ‘slide board’ will prevent rock and soil from interfering with the Duct
Bank joint and Shear Key. Figure 1 details the specifications of a typical slide board installation. Slide
Boards should be cleared of any soil prior to setting the next precast duct bank section. Any consumable
left within the trench should be approved by the project engineer prior to use.
Figure 1: Typical Masonite Board Placement
Lifting Equipment Selection

Lifting equipment shall be rated for Duct Bank load or greater. Undersized equipment can be dangerous
and damage the product. Proper lifting angles will ensure easier alignment. Forterra recommends the
lifting configuration shown in Figure 2.

T:(763)-694-3256 M:(612)-807-4471
Figure 2: Recommended Sling Angle (Minimum 60 Deg)
Handling Duct Banks

Duct Banks will have either two or four lifting locations depending on the size and weight of the Duct
Bank. Care should be taken to avoid damage to Shear Key and conduit spigots. Conduit caps shall be left
in place until installation. If necessary, gaskets may need to be re-lubricated on-site prior to installation. A
visual inspection will determine if lubrication is needed. If the gasket does not have a glossy wet-like
appearance, then apply lubrication to the gasket.

T:(763)-694-3256 M:(612)-807-4471
Alignment
Duct Bank alignment is critical for successful installation. Alignment should occur while the Duct Bank
being installed is still attached to the lifting equipment. Each Duct Bank shall be lowered into place and
guided by hand to the mating Duct Bank Figure 3.
Figure 3: Hand Alignment
Pieces should be placed with the end of each spigot inserted roughly ¼” into the bell of the mating Duct
Bank. Once Duct Banks are aligned they can be pulled into place from the bell end using an excavator or
similar equipment. Duct banks MUST be installed by pulling/pushing the spigot into the mating bell.
Figure 4 details the correct procedure when pulling Duct Banks with an excavator or similar equipment.
An alternative method that may be used is the pulling sling cinch method shown in Figure 5. Using this
method, two adjoining duct banks are cinched together by a pulling sling attached to the forward and rear
lifting insert on the adjoining pieces.
Figure 4: Precast Duct Bank Pulling Procedure

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Figure 5: Cinch Method
Troubleshooting Alignment Issues

The following section details the most common installation issues and their solutions. Reference
the table below.
Issue Solution
Duct Bank Shear Key prevents full conduit Use the two adjacent lifting lugs on the mating
insertion. duct banks* and slowly lift each bank until the
shear keys are in alignment. Once shear keys
are aligned, push the duct banks together.
Issue Solution
Soil or rock has built up between the ducts and Duct banks cannot be pulled apart once the
prevents full conduit insertion. spigot engages the grip ring. Using the two
adjacent lifting lugs on the mating pieces*, lift
the pieces enough to clear the soil collection
trench. Once cleared try the push again.
Depending on soil type, soil collection trenches
may need to be oversized.
*See Figure 6 for shear key alignment lifting configuration.

T:(763)-694-3256 M:(612)-807-4471
Figure 6: Shear Key Alignment Lifting Configuration
Integrating Precast Duct Banks to an Existing or Cast-in-Place System
Forterra Precast Electrical Duct Banks are designed to function as an entire system, or as an addition to a
larger system. The Duct Banks utilize standard Schedule 40 PVC rated for 90C wire to ensure seamless
integration into any Duct Bank system.
Joining Precast Duct Banks to a Cast-in-Place System
Forterra Precast Electrical Duct Banks can be joined to an existing or cast in place system with
ease. Simply solvent cement the spigots of the mating Forterra Duct Bank conduit to conduit in a
cast-in-place system. Forterra Duct Banks use Schedule 40 Grey PVC and all applicable
standards and procedures for joining Schedule 40 Grey PVC apply. If joining to the bell end of a
Forterra Duct Bank, chamfer the ends of each conduit prior to inserting into each bell. For 4”
diameter conduit, mark 6” from the mating end of the conduit. For 6” diameter conduit, mark 7”
from the mating end of the conduit. 70lbs of insertion force is required for the conduit to seat
correctly. Use a wooden block and mallet to insert the joining conduit to the marked location.
Joining Precast Duct Banks to Precast Utility Vaults
Forterra Duct Banks can also be joined to Precast Utility Vaults. Using the methods described in
the previous section, shorter joining sections can be installed directly from the Utility Vault to the
Duct Bank. This requires only a small section of Cast-in-Place conduit to be placed at the end of
each line Figure 7.

T:(763)-694-3256 M:(612)-807-4471
Figure 7: Joining Precast Duct Banks to Precast Utility Vaults
Backfilling
Backfilling can begin as soon as Duct Banks are placed and joined. Fill will be in accordance with project
specifications and/or any available geotechnical report prepared for said project. In absence of either of
these two, contractor shall refer to applicable state requirements.

T:(763)-694-3256 M:(612)-807-4471
Tool Checklist
□ Long Reach Trowel

□ 2 pry bars
□ 48” Level
□ Transit Level
□ Mallet
□ 1’ Section of 2x4

T:(763)-694-3256 M:(612)-807-4471

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ELECTRICAL PRECAST

Forterra Structural & Specialty Products Matthew Pearson

Figure 1: Typical Masonite Board Placement

Lifting Equipment Selection

Forterra Structural & Specialty Products Matthew Pearson

Figure 2: Recommended Sling Angle (Minimum 60 Deg)

Handling Duct Banks

Forterra Structural & Specialty Products Matthew Pearson

Figure 3: Hand Alignment

Figure 4: Precast Duct Bank Pulling Procedure

Forterra Structural & Specialty Products Matthew Pearson

Figure 5: Cinch Method

Troubleshooting Alignment Issues

Forterra Structural & Specialty Products Matthew Pearson

Figure 6: Shear Key Alignment Lifting Configuration

Integrating Precast Duct Banks to an Existing or Cast-in-Place System

Joining Precast Duct Banks to a Cast-in-Place System

Joining Precast Duct Banks to Precast Utility Vaults

Forterra Structural & Specialty Products Matthew Pearson

Figure 7: Joining Precast Duct Banks to Precast Utility Vaults

Forterra Structural & Specialty Products Matthew Pearson

□ Long Reach Trowel

Forterra Structural & Specialty Products Matthew Pearson

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