GUIDE TO SPECIFYING
HDPE CONDUIT
TN-50
2019
Foreword
This technical note was developed and published with the technical help and financial
support of the members of the Plastics Pipe Institute (PPI). These members have
shown their commitment to developing and improving quality products by assisting
standards development organizations in the development of standards, and also by
developing design aids and reports to help engineers, code officials, specifying groups,
contractors and users.
The purpose of this technical note is to provide general information about the history of
the development of high-density polyethylene (HDPE) conduit and the various standards
which apply to these products. The technical note may also be used as a guide for
selecting appropriate standard specifications for users and specifiers.
PPI has prepared this technical note as a service to the industry. The information in this
report is offered in good faith and believed to be accurate at the time of its preparation,
but is offered “as is” without any express or implied warranty, including WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Additional
information may be needed in some areas, especially with regard to unusual or special
applications. Consult the manufacturer or material supplier for more detailed
information. A list of member manufacturers is available on the PPI website. PPI does
not endorse the proprietary products or processes of any manufacturer and assumes no
responsibility for compliance with applicable laws and regulations.
PPI intends to revise this technical note within 5 years or sooner if required, from the
date of its publication, in response to comments and suggestions from users of the
document. Please send suggestions of improvements to the address below.
Information on other publications can be obtained by contacting PPI directly or visiting
our website.
The Plastics Pipe Institute, Inc.
[Link]
This Technical Note, TN-50, was first issued in July 2016
and was revised in October 2016, August 2017 and February 2019.
© 2019 The Plastics Pipe Institute, Inc.
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GUIDE TO SPECIFYING HDPE CONDUIT
High-density polyethylene (HDPE) conduit is the preferred material to house and protect
electrical power and telecommunications cables within. It offers unmatched corrosion and
chemical resistance, is flexible, durable and available in long reel lengths to reduce joints
and installation time. HDPE conduit is available in a variety of sizes, colors, dimensions
and lengths.
1.0 HISTORY OF HDPE CONDUIT STANDARDS
The early driver behind the use of conduit produced from high-density polyethylene
(HDPE) was for deploying and protecting fiber optic (FO) cables placed underground
for the telecommunications industry. Tremendous growth occurred for the installation of
fiber optic cables during the early to mid-1980s for linking major metropolitan areas.
This era saw massive projects where FO cables were being deployed in both aerial
and underground installations. These fiber optic cables were typically made and
installed in very long lengths up to 30,000 feet (9,145 m), with the goal of using as few
splice locations as possible to minimize signal attenuation or decibel (dB) losses in a
complete system.
Fiber optic cable and the equipment used to send and receive light waves were in the
early stages of becoming the technology of choice for streaming huge amounts of
voice, video and data over fibers not much thicker than a human hair. However, FO
cable needed more protection and different handling procedures as compared to
traditional jacketed metallic cables.
For buried installations, there was an immediate need for a conduit system that would
offer improved installation efficiencies and cable protection. In metropolitan areas, the
smaller diameter FO cables were replacing very large diameter copper cables that
filled banks of conduits made up of individual lengths of 3 ½ inch to 6 inch diameter
conduits. As these large copper cables were being removed, telephone companies
began installing small conduits ranging from 1 to 1 ¼ inch, using HDPE water pipe as
the conduit. Multiple 1 or 1 ¼ inch HDPE water pipes, commonly termed “innerducts”,
would be pulled into the vacated larger diameter conduit left behind after the copper
cables had been removed.
The newly installed HDPE innerducts created multiple pathways that could be used for
initial and future fiber optic cable placement, or to use as spares for rapid FO cable
deployment in case the initial FO cable got damaged. Multiple 1 inch through 4 inch
HDPE innerducts were also being installed in the more rural parts of the network. Much
of this work was completed by using new trenchless methods like rail plowing and
horizontal directional drilling (HDD), also known as directional boring. This new
technique was employed to install pipes, conduits or cables below ground using a
surface-mounted drill rig that launches and places a drill string at a shallow angle to the
surface, and has tracking and steering capabilities. These procedures are intended to
minimize above and below ground surface damage, restoration requirements, and
disruption to traffic, with little or no interruption of existing services.
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2.0 HISTORICAL STANDARDS OVERVIEW
By the mid-1980s, Fiber Optic cable deployment was booming, and multiple
manufacturers of HDPE conduit were busy keeping up with demand. However, there
were no third-party product standards in place specifically for HDPE conduit, so the
industry adopted existing ASTM standards for HDPE pressure pipes, such as those
listed below. Many end-user specifications were developed using these HDPE
pressure pipe standards.
Examples of typical HDPE pressure pipe standards with title and scope:
ASTM D3035: Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR)
Based on Controlled Outside Diameter
“All pipes produced under this specification are intended for use as the distribution and
transmission of potable and non-potable water, grey water, reclaimed water,
wastewater, force main and gravity municipal sewage, etc. The user should consult the
manufacturer to determine whether the material being transported is compatible with
polyethylene pipe and will not affect the service life beyond limits acceptable to the
user.”
Extracted, with permission, from ASTM D3035. Copyright ASTM International, 100 Barr Harbor Drive,
West Conshohocken, PA 19428. A copy of the complete standard may be purchased from ASTM
International, [Link]
ASTM D2239: Standard Specification for Polyethylene (PE) Plastic Pipe (SIDR-
PR) Based on Controlled Inside Diameter
“This specification covers polyethylene (PE) pipe made in standard inside dimension
ratios (SIDR) and pressure rated for water. Included are requirements for PE
compounds and requirements and test methods for workmanship, dimensions,
elevated temperature sustained pressure, burst pressure, and marking.”
Extracted, with permission, from ASTM D2239. Copyright ASTM International, 100 Barr Harbor Drive,
West Conshohocken, PA 19428. A copy of the complete standard may be purchased from ASTM
International, [Link]
ASTM D2447: Standard Specification for Polyethylene (PE) Plastic Pipe,
Schedules 40 and 80, Based on Outside Diameter (Withdrawn 2010)
“This specification covers polyethylene (PE) pipe that is outside diameter controlled,
made in Schedule 40 and 80 sizes for use with socket-type fittings and butt fittings
joined by heat fusion, and pressure-rated for water.”
Extracted, with permission, from ASTM D2447. Copyright ASTM International, 100 Barr Harbor Drive,
West Conshohocken, PA 19428. A copy of the complete standard may be purchased from ASTM
International, [Link]
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ASTM F714: Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR)
Based on Outside Diameter
“This specification covers polyethylene (PE) pipe made in dimensions based on
outside diameters of 90 mm (3.500 in.) and larger. The piping is intended for new
construction and insertion renewal of old piping systems used for the transport of
water, municipal sewage, domestic sewage, industrial process liquids, effluents,
slurries, etc., in both pressure and non-pressure systems.”
Extracted, with permission, from ASTM F714. Copyright ASTM International, 100 Barr Harbor Drive,
West Conshohocken, PA 19428. A copy of the complete standard may be purchased from ASTM
International, [Link]
See Section 5.0 for the current versions of ASTM standards for HDPE conduit.
2.1. Other Polymer Raceway Standards - Historical
Beginning in 1965, Underwriters Laboratories (UL) has published a series of
standards for polymer raceway products, including rigid PVC conduit as well as
high-density polyethylene conduit. In older versions of these standards, PVC and
HDPE conduit were combined.
Examples of previous UL conduit standards:
UL 651, Standard for Rigid Nonmetallic Conduit
First Edition – Published September, 1965 (included HDPE for first 3
editions)
UL 651, Standard for Schedule 40 and 80 Rigid PVC Conduit
Fourth Edition – Published May 1981
UL 651A, Standard for Type EB and A Rigid PVC Conduit and HDPE
Conduit
First Edition – Published May, 1981
UL 651B, Standard for Continuous Length HDPE Conduit
First Edition – Published February 12, 1999
UL 651B, Standard for Continuous Length HDPE Conduit
Second Edition – WITHDRAWN – October 27, 2011
See Section 5.0 for the current versions of UL standards for HDPE conduit.
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3.0 FORMATION of the PPI POWER & COMMUNICATIONS DIVISION (PCD)
By the late 1980’s, HDPE conduit was gaining wider acceptance for use in protecting
power, electrical, fiber optic and coaxial cables placed underground. The Conduit
Division was added to the Plastics Pipe Institute during this period. In 2016, the division
was renamed the Power & Communications Division (PCD) to better reflect the focus
on solutions for the markets served by HDPE conduit.
The Power & Communications Division’s mission is to expand the knowledge of the
uses and benefits of HDPE Conduit. The PCD collaborates with standards
development organizations (SDOs) to keep product standards up-to-date with the
latest product developments. PCD also helps educate engineers, designers, installers,
and users about HDPE conduit, and maintains outreach with industry and government
agencies.
4.0 DEVELOPMENT of STANDARDS for HDPE CONDUIT
One of the first objectives of PPI’s Power & Communications Division was to develop
an ASTM standard specification for HDPE conduit.
In 1996, the American Society of Testing and Materials (now ASTM International)
published test method ASTM D6070, “Standard Test Methods for Physical Properties
of Smooth-Wall, Coilable, Polyethylene (PE) Conduit (Duct) for Preassembled Wire
and Cable”. This was not a product standard, but rather a test method to address
“environmental performance properties of smooth-wall, coilable, medium-density and
high-density polyethylene (MDPE and HDPE) conduit (duct) for preassembled wire
and cable.” In the meantime, this standard was not updated, as other standards took
its place. In 2016, PPI balloted for the withdrawal of this obsolete standard. The ballot
was successful, and therefore, ASTM D6070 is no longer published.
The first ASTM standard specification written and approved for HDPE conduit was
ASTM F2160 “Standard Specification for Solid Wall High Density Polyethylene (HDPE)
Conduit Based on Controlled Outside Diameter (OD)”, originally approved in 2001,
then revised in 2008 and 2010. In 2016, a significant revision of F2160 expanded the
Scope, consolidated 11 dimensional tables into four, clarified test procedures, added
pipe stiffness requirements, and revised other requirements, such as resistance to slow
crack growth.
To coincide with the advancing technology, a HDPE conduit specification was also
developed by NEMA (National Electrical Manufacturers Association). That specification
is known as NEMA TC 7 “Smooth-Wall Coilable Electrical Polyethylene Conduit”,
which was first published in 2000 and is updated regularly with input from PPI and its
members. The latest revision was released in March 2017, and includes a new wall
type, new UV stabilization requirements, and clarification of marking requirements.
However, these were not the first HDPE conduit specifications. Integral Corporation
was the first manufacturer of cable-in-conduit (CIC), whereby a cable or cables are
factory-installed within the conduit as it is extruded. Related to this product, ASTM
D3485 “Standard Specification for Coilable High Density Polyethylene (HDPE) Cable
In Conduit” was originally published in 1976.
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5.0 CURRENT STANDARDS for HDPE CONDUIT
Today, several state-of-the-art conduit standards exist for various applications and
industries.
The following is a list of five (5) current standard specifications for HDPE conduit, with
the latest year of issue shown:
ASTM D3485-15: Standard Specification for Coilable High Density Polyethylene
(HDPE) Cable In Conduit
“This specification covers cable in conduit (CIC), which is a smooth-walled, coilable,
high-density polyethylene (HDPE) conduit (duct) that contains preassembled wires and
cables. The outside diameter of the conduit is controlled and the wire or cable encased
within may be comprised of single or multiple configurations consisting of
electrical/power wires or cables, fiber optic, traditional copper communication, coaxial
cable, or any combination thereof. CIC configurations are preassembled into the
conduit during the extrusion process and in industry-specific designs for use in
commercial, industrial, transportation, government, and utility applications.”
Extracted, with permission, from ASTM D3485. Originally approved in 1976. Copyright ASTM
International, 100 Barr Harbor Drive, West Conshohocken, PA 19428. A copy of the complete standard
may be purchased from ASTM International, [Link]
ASTM F2160-16: Standard Specification for Solid Wall High Density Polyethylene
(HDPE) Conduit Based on Controlled Outside Diameter (OD)
“This specification covers material, dimensional, workmanship and performance
requirements for polyethylene conduit, duct and innerduct manufactured for use in non-
pressure applications for the protection of fiber optic and power cables. Applications
include telecom, SCADA command and control, highway lighting, ITS (Intelligent
Transportation Systems) and Underground Utilities with PE conduit installed using
methods such as Horizontal Directional Drilling (HDD), plowing and open trench.
“HDPE conduit meeting the requirements of this standard shall be made as OD or ID
controlled solid wall, with or without internal or external ribs in IPS types SDR 9, SDR
11, SDR 13.5, DR 15.5, Schedule 40, Schedule 80 and “True-sized” and SIDR
dimensions. The internal or external surface may contain a coextruded layer provided
the finished conduit meets the product requirements of this specification.”
Extracted, with permission, from ASTM F2160. Originally approved in 2001. Copyright ASTM
International, 100 Barr Harbor Drive, West Conshohocken, PA 19428. A copy of the complete standard
may be purchased from ASTM International, [Link]
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NEMA TC 7-16: Smooth Wall Coilable Electrical Polyethylene Conduit
“This standard covers several wall types of high-density polyethylene (HDPE) conduit
for use in providing a protective raceway for electrical cables or communication cables
buried underground or concrete encased. Note: Typical applications for HDPE conduit
include power distribution, site lighting, signal and control and Supervisory Control and
Data Acquisition (SCADA).”
Extracted, with permission, from NEMA TC 7. Originally approved in 2000. Available from NEMA
(National Electrical Manufacturers Association) at [Link]
UL 651A-11 (03/17): Schedule 40 and 80 High Density Polyethylene (HDPE)
Conduit
“These requirements cover straight conduit and coilable, smooth-wall, continuous
length conduit with a circular cross section: Extruded straight rigid Schedule 40 high
density PE (polyethylene) electrical conduit and the following fittings for use with this
conduit type: Elbows, and Rigid high density PE couplings; Schedule 40, Schedule 80,
EPEC-A, and EPEC-B coilable, smooth-wall continuous length high density PE
electrical conduit. The conduit and fittings mentioned in Section 1.1 of the specification
are intended for use at 50°C (122°F) and lower ambient temperatures. Extruded
straight rigid and continuous length conduit, where directly buried or encased in
concrete in trenches outside of buildings, may be used with 90°C (194°F) wiring. The
conduit and fittings covered in these requirements are intended for use as rigid
nonmetallic raceway for wires and cables in accordance with the National Electrical
Code, NFPA 70. Extruded straight rigid Schedule 40, Schedule 40, Schedule 80,
EPEC-A, and EPEC-B coilable conduit is for aboveground use where encased in not
less than 2 inches (50 mm) of concrete and for underground use by direct burial or
encasement in concrete.”
Note 1: A revised version of UL 651A was announced on June 24, 2016 containing several revisions
requested by PPI. A minor revision was published on March 10, 2017. However, UL no longer
updates the “Effective Date” for new and revised requirements within existing standards.
Therefore, the latest edition of UL 651A still shows as “Fifth Edition - October 26, 2011” even
though it contains these new revisions.
Available from UL (Underwriters Laboratories) at [Link]
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UL 1990-13 (01/17): Standard for Nonmetallic Underground Conduit with
Conductors
“These requirements cover nonmetallic underground conduit with conductors. These
products consist of a factory assembly of conductors or cables inside a coilable,
smooth-wall, continuous length conduit with a circular cross section. The conduit is
Schedule-40, Schedule-80, EPEC-A or EPEC-B High Density Polyethylene (HDPE) in
trade sizes 1/2 (16) - 4 (103). This product is intended for installation in accordance
with the National Electrical Code, NFPA 70. The values in parentheses are metric
trade designators of conduit. The designations Schedule-40, Schedule-80, EPEC-A
and EPEC-B refer to conduit having specific outside diameters and wall thicknesses.
This product is for aboveground use where encased in not less than 2 inches (51 mm)
of concrete and for underground use by direct burial or encasement in concrete.”
Available from UL (Underwriters Laboratories) at [Link]
Note 2: A revised version of UL 1990 was announced on January 20, 2017 containing several
revisions requested by PPI. However, UL no longer updates the “Effective Date” for new and
revised requirements within existing standards. Therefore, the latest edition of UL 1990 still
shows as “Third Edition - November 22, 2013” even though it contains these new revisions.
6.0 INDUSTRY PRACTICES and GUIDELINES
Industry organizations AASHTO and NEMA have published additional documents
related to the use of HDPE conduit. These are AASHTO R63 and NEMA TCB-4:
AASHTO R63-13 (2017): Standard Practice for Solid Wall High-Density Polyethylene
(HDPE) Conduit for Non-Pressure Applications Used for the Protection of Power and
Telecommunications Cables
“This standard practice provides guidance to engineers in the specification of HDPE
conduit used in buried applications for the protection of power cables for use in
highways, airport lighting, traffic control, and fiber optic (cables for use in) data and
command and control applications in State Transportation Projects.”
“This standard practice covers conduit used in the following manner:
• HDPE pipe used as a casing for the protection of smaller individual conduits,
innerducts, in road crossings;
• HDPE conduit in coils, on steel reels, or in straight sticks; and
• CIC (cable in conduit), when power cable (conductors), CATV (coaxial), or fiber
optic cable is installed in the conduit at the conduit manufacturing facility.
• HDPE pipe is commonly installed in standalone duct installations for the
protection of power cable (conductors), CATV (coaxial cable), or fiber optic
cable.
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• HDPE pipe is commonly installed in standalone duct applications for road
crossings when the bury depth is sufficient to avoid degradation effects to the
road.
• HDPE pipe is commonly installed in standalone duct applications parallel to the
roadway.”
Copyright American Association of State Highway and Transportation Officials (AASHTO), 444 North
Capitol Street NW, Suite 249, Washington DC 20001. A copy of the complete standard may be
purchased from the AASHTO Store, [Link]
NEMA TCB 4-16: Guidelines for the Selection and Installation of Smooth-Wall
Coilable High-Density Polyethylene (HDPE) Conduit
“This guideline covers recommendations for the selection, handling, and installation of
underground High-Density Polyethylene (HDPE) conduit or raceway for power, lighting,
signaling, and communications applications.”
Extracted, with permission, from NEMA TCB 4. Originally approved in 2016. Available from NEMA
(National Electrical Manufacturers Association) at [Link]
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7.0 SELECTING APPROPRIATE STANDARD/s BASED on CONDUIT SIZE, WALL TYPE
To help clarify the HDPE conduit products available in the current conduit standards,
Table 1 lists the wall types and range of diameters found within each of these
standards.
Table 1: HDPE Conduit Diameters Available per Wall Type and Standard Specification
HDPE Conduit Standards with Available Diameters
Wall Type
ASTM D3485 ASTM F2160 NEMA TC 7 UL 651A UL 1990
Schedule 40 1/2" to 3" 1/2" to 12" 1/2" to 8" 1/2" to 6" 1/2" to 6"
Schedule 80 1/2" to 3" 1/2" to 6" 1/2" to 6" 1/2" to 6" 1/2" to 6"
SDR 17 N/A N/A 1/2" to 2" 1/2" to 6" 1/2" to 6"
DR 15.5 1/2" to 3" 1/2" to 12" 1/2" to 6" N/A N/A
SDR 13.5 1/2" to 3" 1/2" to 12" 1/2" to 8" 1/2" to 6" 1/2" to 6"
SDR 11 1/2" to 3" 1/2" to 12" 1/2" to 8" N/A N/A
SDR 9 N/A 1/2" to 12" N/A N/A N/A
SIDR N/A 1” to 5” N/A N/A N/A
True-size 9 N/A 13 mm to 2" N/A N/A N/A
True-size 11 N/A 13 mm to 2" N/A N/A N/A
Note 3: Wall types Schedule 40, Schedule 80, SDR 17 and DR 15.5 in diameters 4" and greater are
typically available only in stick lengths, with limited availability in coils. Diameters greater than
6" are available in stick lengths only.
Note 4: Consult the HDPE conduit manufacturer for their complete list of qualified conduit types made
to the listed standards which have been certified or listed by a recognized third-party
certification agency or a Nationally Recognized Testing Laboratory (NRTL).
DR Dimension Ratio, the average specified outside diameter of a pipe or tubing divided by the
minimum specified wall thickness.
SDR Standard Dimension Ratio, the ratio of the average specified outside diameter divided by the
minimum specified wall thickness, the value of which is derived by adding one to the pertinent
number selected from the ANSI Preferred Number Series 10. While all SDRs are DRs, not all
DRs are SDRs.
N/A Not applicable or not available.
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8.0 SUMMARY
Initially, water pipe specifications were used to establish minimum standards covering
the dimensions, materials and test requirements for conduit made from high-density
polyethylene. This was out of necessity, because HDPE conduit specifications had not
yet been developed.
Over the past 25 years, multiple product standards have been published for specific
types and applications of HDPE conduit. Unfortunately, many end users and specifiers
utilize specifications that cite inappropriate pressure pipe standards, and have not
revised them to list the appropriate conduit standards, whether for power,
telecommunications or other applications.
It is important that end users, engineers and specifiers update project specifications to
reference the correct HDPE conduit product standard. Accordingly, references to
pressure pipe standards should be removed from product or project specifications for
HDPE conduit. In other words, pressure pipe standards should be replaced with the
most appropriate of the HDPE conduit standards listed above by selecting the single
HDPE conduit standard that is the closest match for the application. It is recommended
that if a product or project specification currently lists multiple HDPE conduit standards,
then it should be revised to select the one standard that is the best fit for the
application.
Why update product or project specifications? HDPE conduit manufacturers, such as
PPI Power & Communications Division members, design and produce their conduit
products to ensure compliance with the latest, relevant HDPE conduit standards. While
HDPE pressure pipe and conduit standards may appear similar, there are technical
differences that are critical to the performance of the products in specific applications.
Specifying a water pipe for a conduit application may even violate requirements of
relevant electrical codes while potentially increasing costs, with no value for the
customer.
In addition, conduit standards are continuously reviewed, maintained and revised by
manufacturers through participation in organizations like PPI, which facilitates interface
between manufacturers, users, and standards development organizations such as
AASHTO, ASTM, NEMA, UL, TIA and others. This continuous connection ensures that
HDPE conduit standards meet the various code and regulatory requirements for the
intended uses.
To assist end users, engineers and specifiers, the attached flow chart can help guide
selection of the correct HDPE conduit specification to fit the application. Additionally,
the flow chart helps identify other technical information such as color, pull tape
selection options and other unique wall options that can be added.
The PPI Power & Communications Division and member companies may be reached
through our website, [Link] and [Link]
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