PVC Duct(DB2/ES2)Pipe & FittingsFor usage in direct burial and concrete encased applications.

Product Description 1

Features and Benefits - Cutting and Joining 1

Solvent Cementing 2-3

Expansion and Contraction 4

Installation - Direct Burial and Concrete Encased 4-5

Fittings - Spacers and Couplings - Dimensions 6

Fittings - Information 7-9

MonoBloc Spacers 10-11

Table ofContents

Note: This brochure is not intended to assume the authority of the Design Engineer. Actual jobsite conditions will vary significantly. The sole responsibility for all design and installation decisions lies with the Design Engineer. All local health and safety regulations must be followed.

1

Product Description & ApplicationsRoyal Building Products® Electrical Solutions manufactures a complete line of PVC Duct pipe and fittings. We produce two types of duct for direct burial and concrete encasement.

The two types of PVC Duct are:

• Solid Wall Duct (DB2/ES2) • Split Duct (DB2/ES2)

Our PVC Duct products are available in 50 to 150mm (2 to 6 inch) diameters and 3 and 6 metre (10 and 20 foot) lengths with solvent weld bell ends.

Standards and Codes Royal Electrical Solutions Duct pipe and fittings are certified to CSA Standard C22.2 No. 211.1. All PVC Duct pipe and fittings shall be installed according to the Canadian Electrical Code (CEC) Part I, Rules 12-1150 - 12-1166.

Features and BenefitsSaves LabourRoyal Electrical Solutions PVC Duct is simple to cut and join.

Easy Wire PullsThe smooth interior surface reduces friction when pulling conductors and wires through long runs and 90° bends.

Corrosion Resistant PVC Duct is non-metallic, therefore there is no risk of corrosion when exposed to naturally corrosive soil conditions, such as electrochemical and/or galvanic environments.

High Tensile and Impact StrengthsPVC Duct provides high tensile and impact strengths even in cold weather.

Direct Burial Royal Electrical Solutions PVC Duct can be used for direct burial, and requires no additional protection when installed according to the CEC. Note: Safety guidelines should be followed with trenching and backfilling operations.

A Choice of FittingsWe produce a full range of quality fittings to ensure fast, reliable installations.

Cutting and Joining CuttingRoyal Electrical Solutions PVC Duct can easily be cut with a hacksaw or fine-toothed hand saw. To ensure a square cut, use a mitre box or saw guide. Deburr the cut end using a knife or file.

Joining – Solvent CementingSolvent cement joins are used to connect lengths of duct and fittings. These joints are strong, permanent and leak-proof. Royal Electrical Solutions EcoVoc solvent cement should be used on all connections.

PVC Duct(DB2/ES2)Pipe & FittingsFor usage in direct burial and concrete encased applications.

C22.2 No. 211.1

2

knife or sharp object over the coated surface. If a few thousandths of an inch of the primed surface can be scratched or scraped away, proper penetration has occurred. Varying weather conditions affect priming and cementing action and may require more time or repeated applications to either or both surfaces.

9. If using primer, use the correct applicator size (see #7) and aggressively work the primer into the socket, keeping the surface and applicator wet until the surface has softened, re-dipping the applicator as required. When the surface is primed, remove any puddles of primer from the socket.

10. Aggressively work the primer on to the end of the pipe, to a point ½” beyond the depth of the socket.

11. Perform a second application of primer in the socket.

12. While the surfaces are still wet, the appropriate solvent cement should be applied.

13. Using the correct applicator size, aggressively work a full, even layer of cement onto the pipe end to a point equal to the depth of the socket. Do not brush out to a thin paint type layer, as this will dry within a few seconds.

14. Aggressively work a medium layer of cement into the fitting socket; avoid puddling cement in the socket. On the pipe end, do not coat beyond the socket depth or allow cement to run down into the pipe beyond the socket.

15. Apply a second full, even layer of cement on the pipe.

16. Immediately, while the cement is still wet, assemble the joint. Use enough force to ensure that the pipe is fully inserted into the socket. Twist the pipe a ¼ turn as it is being inserted.

17. Hold the joint together for approximately 30 seconds to avoid push out.

18. After assembly, inspect the joint to ensure that there is a ring or bead of cement completely around the juncture of the pipe and socket. If there are voids in this ring, sufficient cement was not applied and the joint may be defective.

19. Remove the excess cement from the pipe and socket (including the ring or bead) using a cloth. Avoid disturbing or moving the joint.

20. Handle newly cemented joints with care until initial set has taken place. Follow set and cure times before handling or testing the system.

Procedure for Solvent Welding Joints• Use solvent cement and primer prior to expiration date marked on container.• Above 0° C ambient temperature, joints may be assembled without the use of primer, provided adequate penetration and softening of the pipe/fitting surface can be achieved with solvent cement alone.

1. Assemble materials for the job, including correct solvent cement, primer and correctly sized applicator.

2. Cut pipe as square as possible using a hand saw and miter box or mechanical saw. Do not use a diagonal cut, as it reduces the bonding area in the joint.

3. If plastic tubing cutters are used, care must be taken to remove any raised bead at the end of the pipe, caused by cutting. A file or reamer may be used to remove the bead.

4. Use a knife, file or reamer to remove burrs from the inside and outside of the pipe end, as these will hinder the integrity of the joint. All sharp edges should be removed from the inside and outside edges of the pipe to prevent the pipe from pushing the solvent cement into the fitting socket, thereby causing a weak spot to form. The pipe end should be chamfered, as shown below.

5. All dirt, grease and moisture should be removed from the pipe and socket by thoroughly wiping with a clean, dry cloth.

6. Dry fit pipe and fitting joints prior to cementing. For proper interference fit, the pipe should go easily into the socket approximately ⅓ to ⅔ of the socket depth. If this is not the case, other pipe or fittings should be used.

7. The applicator should be sized according to the size of pipe and fittings being joined. The brush width of the applicator should be equal to approximately ½ of the pipe diameter.

8. Primer is used to penetrate and soften the surfaces so that they will fuse together under a wide variety of conditions. The penetration or softening can be checked by dragging the edge of a

Chamfered Pipe

10° - 15°

3

Solvent CementingAll connections should be made using and applying Royal Electrical Solutions solvent cement.

Set Times

Joint Cure Schedule

In damp or humid weather allow 50% more cure time.

Estimated Solvent Cement Requirements

Estimated Primer Requirements

Solvent Cementing in Cold Weather:• Store pipe and fittings in a heated area. Prefabricate as much of the system as possible in a heated area.• When not in use, store sealed solvent cement and primer between 5°C and 21°C. Do not use open flame or electric heaters to warm cements and primers.• Take care to remove moisture, ice and snow from the mating surfaces.

Solvent Cementing in Hot Weather:• At the time of assembly, the surface temperature of the mating surfaces should not exceed 45°C. Shade or shelter the joint surfaces from direct sunlight for at least 1 hour prior to joining and during the joining process. If necessary, swab the mating surfaces with clean, wet rags to reduce the surface temperature (thoroughly dry surfaces before applying primer or cement).• Make joints during the cooler early morning hours.• Apply cement quickly and join pipe to fitting as quickly as possible after applying the cement.• Keep solvent cement container closed or covered when not in use, to minimize solvent loss.

Solvent Cementing in Wet Conditions:• Mating surfaces must be dry when the joint is made.• Work under a cover or canopy to keep rain off pipe and fittings.• Work quickly after drying the pipe and fitting to avoid condensation.• Allow a longer cure time before the system is tested or used.

Storage and Handling of Solvent Cement and Primer:• Solvent cement and primer contain highly flammable solvents. Follow all specific safety precautions provided on container label and Material Safety Data Sheet.• Keep primer and solvent cement away from heat, sparks and open flame.• Keep containers tightly closed except when in use.• Ensure proper ventilation of work area and avoid inhaling solvent vapours.• Where the possibility of splashing exists, wear proper eye protection or a face shield.• Avoid contact with skin.

Support Straps Rigid PVC conduit must be supported with straps when installed in above ground applications. These straps should be installed snugly, while allowing linear movement of the conduit. See the table below for recommended maximum spacing of support straps.

Temperature RangeDuring Assembly & Cure Periods

Pipe Sizes½” to 1¼”

15˚C to 40˚C5˚C to 15˚C-16˚C to 5˚C

2 min.5 min.

10 min.

Pipe Sizes1½” to 2”5 min.

10 min.15 min.

Pipe Sizes2½” to 6”30 min.2 hrs.

12 hrs.

Average Joint Cure Times

Temperature Range Pipe Sizes½” to 1¼”

15˚C to 40˚C5˚C to 15˚C-16˚C to 5˚C

2 min.5 min.

10 min.

Pipe Sizes1½” to 2”5 min.

10 min.15 min.

Pipe Sizes2½” to 6”30 min.2 hrs.

12 hrs.

Average Initial Set Times

200 125 90 60 40 40 30

Pipe/FittingDiameter

Number ofJoints

300

½” ¾” 1” 1½” 2” 2½” 3” 4”

10

6”

Average Number of Joints per Litre of Solvent Cement

400 250 180 120 80 80 60

Pipe/FittingDiameter

Number ofJoints

600

½” ¾” 1” 1½” 2” 2½” 3” 4”

20

6”

Average Number of Joints per Litre of Primer

Nominal Sizemm (in)

CEC RecommendedSpacing ft (m)

NEC RecommendedSpacing ft (m)

16 (½)21 (¾)27 (1)

35 (1¼)41 (1½)53 (2)

63 (2½)78 (3)-129 (5)

155 (6)

2½ (0.75)2½ (0.75)2½ (0.75)

4 (1.20)4 (1.20)6 (1.80)6 (1.80)7 (2.10)8 (2.50)

3 (0.91)3 (0.91)3 (0.91)5 (1.50)5 (1.50)5 (1.50)

3 - 6 (1.80)3½ - 5 (2.10)

8 (2.50)

Maximum Recommended Spacing of Support Straps

4

Pipe Sizemm (in)

½ Pint(250ml)

50 (2)75 (3)

90 (3½)100 (4)125 (5)150 (6)

17151310

85

Pint(475ml)

353025201510

Quart(950ml)

706050403020

Gallon(4/L)

280240200160120

80

Number of Joints per CanExpansion and ContractionRoyal Electrical Solutions PVC Duct expands and contracts with extreme variations in temperature. Therefore it is important to allow extra duct footage for contraction at each tie-in when the duct temperature is higher than the surrounding soil temperature. Also allow for expansion when the surrounding soil temperature is higher then the duct temperature. When backfilling, start at the tie-in point and work to the end of the duct run.

Expansion Joints - Temperature ChangeUse expansion joints if the PVC Duct will be permanently exposed (e.g. bridge crossings). Typically the PVC Duct will contract or expand 10mm (⅜ inch) per 30.48 metres (100 feet) of duct for every 5.5˚C (10˚F) of temperature change.

Thermal ExpansionThe co-efficient of thermal expansion for Royal PVC duct is 5.4 x 10-5 mm/mm/˚C (3.0x10-5 in/in/˚F). To calculate the expansion and contraction of a buried or encased system, use 50% of the thermal expansion coefficient.

Note: EcoVoc solvent cement has a shelf life of 24 months if stored unopened at 22˚C (72˚F). Check the bottom of the can for the date of manufacture before using.

Installation Guidelines – Direct BurialTrench Bottom The trench bottom should be firm and graded to support the duct bank. Remove all lumps, ridges, depressions and stones on the trench bottom to prevent point loads on the PVC Duct.

When installing a duct bank in rock or shale, excavate an additional 75mm (3 inches) below the desired depth. Place and compact with 75mm (3 inches) of backfill to create a uniform, level bedding surface.

When soil conditions are poor, such as marshy or swampy areas,follow the recommendations of the Design Engineer and/or Soils Consultant.

First TierPlace the first tier of duct in the trench, then backfill and tamp around it. Backfill should not contain any stones larger than 10mm (⅜ inch). Tamp the backfill around ducts to provide maximum supporting strength. Backfill over the duct to the required thickness and tamp with a hand tamper. The thickness of backfill between tiers of duct is determined in the design process. Typically it ranges from 50mm to 75mm (2 to 3 inch). Refer to the project design specifications for details.

Direct Burial Application.

20406080

100120140160180200

0.721.442.162.883.604.325.045.766.487.20

∆ T (°C) Expansion/Contraction (in)per 100 ft Length

102030405060708090

100

16.4632.9249.3865.8482.3098.76

115.21131.67148.13164.59

∆ T (°C) Expansion/Contraction (mm)per 30.48m Length

5

Stagger the spacers on each tier (see drawing on the next page). Each MonoBloc spacer should be placed approximately every 2.4 metres (8 feet). Vertical Lock spacers require a spacing of 1.7 metres (5.5 feet).

Pouring the Concrete and BackfillUse caution when pouring the concrete. Do not allow a large mass of concrete to fall on the duct. Use a plank or board to direct the concrete down the sides of the duct bank to the bottom of the trench. The concrete will flow into the centre of the duct bank and fill up all void spaces. To ensure all voids are eliminated, work a long, flat slicing bar or spatula up and down the vertical rows of duct.

Backfill once the concrete has set. (Minimum 24HR after pouring)

Pressure GroutingWhen using pressure grouting to encase duct in concrete, use extreme caution. Excessive pressure and/or high temperatures during pressure grouting can cause the ducts to collapse.

Field BendingDuct has some flexibility that allows for bending in the field for minor changes in elevation and direction. The table below shows the allowable offset for bending PVC Duct.

Concrete Encased with Spacers (Entire bank tied with wire)

DuctSpacers 2 turns of

#10 wire

6" (150mm) min.

Concrete Encased with Spacers (Duct with Spacers)

Spacers

Final Backfill

TrenchBottom

Duct

Concrete

Additional Tiers Place the next tier on top of the first using the procedure outlined above. Repeat until the required number of tiers is reached.

Final BackfillOnce the final tier of duct is placed, place a 100mm (4 inch) thick lift of backfill over the duct banks: stones should be no larger than 10mm (⅜ inch). Tamping this layer is optional. Refer to the design specifications for each installation. Then place backfill in 100mm to 300mm (4 to 12 inch) lifts, compacted with a hand or pneumatic tamper to specified compaction. Apply 300mm (12 inches) of backfill over the duct. At this point the backfill can have some stones in it.

Notes:Spacers should not be used with duct when it is being direct buried, as they create point supports, not the continuous bedding support required. PVC Duct should not be direct buried in road crossing applications. Consult the project engineer regarding installing duct in road crossing applications.

Installation Guidelines – Concrete Encased (With Spacers)Trench BottomDig the trench slightly wider than the width of the duct bank. The trench bottom should be firm and graded to support the duct banks. Pour a 75mm (3 inch) thick, graded and smoothed concrete foundation.

Separation of SpacersWhen it is essential for spacing to be even horizontally and vertically in the duct bank, use MonoBloc or Vertical Lock spacers to provide the separation required between runs of duct.

First Tier Place spacers on the trench bottom and lay the first tier of duct before the concrete foundation has taken its initial set. Place the next layers of spacers and duct on top of the first. Continue in this manner until you reach the required number of ducts. Use wire to tie the entire bank of ducts together.

Final Backfill

Trench Bottom

Duct

Backfill

4"

2-3"

Direct Burial Reference Guide

6

Fittings – Spacers and Push-fit CouplingsRoyal Building Products® Electrical Solutions offers a complete line of fittings for use with our PVC duct pipe.

Spacers Our product offerings include two styles of spacers: Vertical Lock and MonoBloc. Vertical Lock spacers allow for any number of ways in each duct bank.

Cost-effective, flexible and durable, MonoBloc spacers simplify the installation of duct banks. They can be used as both base and intermediate spacers, but cannot be more than 4 ways in each row. Spacers are available in a wide range of sizes and configurations. Constructed from HDPE (high density polyethylene), they resist corrosion and deterioration.

Polyethylene Push-Fit CouplingsThese couplings are used to rapidly assemble cut lengths of duct pipe being encased in concrete. To install these couplings, push the spigot end of the duct into the coupling socket. Place a piece of wood on the end of the coupling, and hammer lightly until the end of the duct butts up against the inside shoulder of the fitting.

Note: Polyethylene push-fit couplings are not watertight and are only recommended for use with PVC Duct encased in concrete.

DimensionsCSA DB2/ES2

CSA DB2/ES2 - Split DuctSplit duct can be used to install duct around existing cables and to repair damaged duct without cutting and splicing the cables.

NominalSize

mm (in)

Avg. OutsideDiametermm (in)

53 (2)78 (3)

91 (3½)103 (4)129 (5)155 (6)

57 (2.250)83 (3.250)95 (3.730)

107 (4.216)135 (5.299)159 (6.275)

Avg. InsideDiametermm (in)

53 (2.090)78 (3.056)89 (3.522)

101 (3.978)127 (4.989)151 (5.949)

Avg. WallThicknessmm (in)

2 (0.080)2 (0.097)3 (0.104)3 (0.119)4 (0.155)4 (0.163)

Approx.Weight

lb/100ft (kg/m)

34 (0.506)60 (0.893)80 (1.190)96 (1.429)

155 (2.307)216 (3.214)

Pipe Size

mm (in)

53 (2)78 (3)

91 (3½)103 (4)129 (5)155 (6)

Max. AllowableOffset For 10’ Length

mm (in)

508 (20)356 (14)305 (12)279 (11)

178 (7)178 (7)

Max. AllowableOffset For 20’ Length

mm (in)

2,007 (79)1,422 (56)1,245 (49)1,092 (43)

889 (35)737 (29)

Allowable Offset

Offset

7

PVC Duct Fittings

90B2x2490B2x3690B2x6090B3x2490B3x3690B3x6090B35x2490B35x3690B35x6090B4x2490B4x3690B4x6090B5x4290B5x6090B6x60

414104141641422414644147641494416474165041653415604156641584416084161441638

2 x 242 x 362 x 603 x 243 x 363 x 60

3½ x 243½ x 363½ x 604 x 244 x 364 x 605 x 425 x 606 x 60

100100100100100100

707070707070202015

90˚ Long Sweep Bend

45B2x2445B2x3645B3x2445B3x3645B35x3645B4x2445B4x3645B4x6045B5x4245B6x60

41392413984143441440414524153041536415484160241626

2 x 242 x 363 x 243 x 36

3½ x 364 x 244 x 364 x 605 x 426 x 60

100100100100

707070703520

45˚ Long Sweep Bend

22B3x2422B3x3622B4x3622B5x42

41428414294151241590

3 x 243 x 364 x 365 x 42

----

22½˚ Long Sweep Bend

PLUG02PLUG03PLUG04PLUG05PLUG06

4201042016420284204042026

23456

176200180100

90

Universal Plug(With pulling eye)

DRP02DRP03DRP035DRP04DRP05DRP06

419144192041926419324193841944

23

3½456

100100100100

5035

Tapered Poly Plug(With pulling eye)

RC3x2RC4x2RC4x3RC4x35RC5x4RC6x4

418604187241878418844189041896

3 x 24 x 24 x 3

4 x 3½5 x 46 x 4

252020202025

Reducing Coupling

Description Sizein

UPCNumber

ProductNumber

Carton Quantity

8

PVC Duct Fittings

PFC02PFC03PFC035PFC04PFC05PFC06

417824178841794418004181241818

23

3½456

200100150100

5035

PFC503PFC5035PFC504PFC505

41824418274183041836

33½45

10090

10045

Push Fit Poly Coupling

SWC502SWC503SWC5035SWC504SWC504LSWC505SWC506

42274422804228642292422934230442310

23

3½4

4 LONG56

---

404020

-

SWC02SWC02LSWC03SWC03LSWC035SWC04SWC04LSWC05SWC06

422324223442238422394224442250422534225642262

22 LONG

33 LONG

3½4

4 LONG56

252550505040402514

Solvent Weld PVC Coupling

Solvent Weld PVC 5˚ Coupling

BEL02BEL03BEL035BEL04BEL05BEL06

412604126641272412784128441290

23

3½456

506020603060

Bell End

CAP02CAP03CAP035CAP04CAP05CAP06

412964130241308413144132041326

23

3½456

252025501010

Cap

Push Fit Poly 5˚ Coupling

TERM35TERM04(w/holes)

4198241986

3½4

-60

Terminator - Bell End Fitting(With Knockout Plug)

Description SizeUPCNumber

ProductNumber

Carton Quantity

9

PVC Duct Fittings

FEMA02FEMA03FEMA035FEMA04FEMA05FEMA06

413504135641362413684137441380

23

3½456

2525

-20

--

Female Adapter

Description Size in

UPCNumber

ProductNumber

Carton Quantity

EXPJ02EXPJ03EXPJ035EXPJ04

41332413384134541344

23

3½4

----

Expansion Joint

ADAP35ADAP04

4199641998

3½4

-25

Adapter to A.C. or Fiber Type 1

ARIG02ARIG03ARIG03LARIG035ARIG04ARIG04LARIG05ARIG06

4120041206412074121441218412194123641248

23

3 LONG3½4

4 LONG56

2530305040402012

Rigid PVC Conduit Adapter

ARIG3X2ARIG3X2LARIG4X2ARIG4X3

41212412134122441230

3 x 23 x 2 LONG

4 x 24 x 3

15154015

Reducing AdapterDuct to Rigid PVC Conduit

SPLY02SPLY03SPLY035SPLY04

41965419684196941974

23

3½4

-As

Required-

Split Y (Wyes)

10

PVC Duct Fittings

IS2015IS2020IS2030IS3015IS3020IS3030IS4010RIS4015*RIS4020*IS4030IS5015IS5020IS5030IS6015IS6020IS6030

42136421424214842154421604216642172419024190842190421964220242208422144222042226

2 x 1½2 x 22 x 3

3 x 1½3 x 23 x 34 x 1

4 x 1½4 x 24 x 3

5 x 1½5 x 25 x 3

6 x 1½6 x 26 x 3

350300200225200125200140125

90100100

80100

9070

BS2015BS2020BS2030BS3015BS3020BS3030BS4010RBS4015*RBS4020*BS4030BS5015BS5020BS5030BS6015BS6020BS6030

42052420584206242070420764208242084418484185442094421004210642112421184211442130

2 x 1½2 x 22 x 3

3 x 1½3 x 23 x 34 x 1

4 x 1½4 x 24 x 3

5 x 1½5 x 25 x 3

6 x 1½6 x 26 x 3

250225200175155150175140140120120120100100100

95

Intermediate VerticalLock Spacer

* FOR DB2/PVC

* FOR DB2/PVC

Description Size in

UPCNumber

ProductNumber

Carton Quantity

Base VerticalLock Spacer

Intermediate Spacer Reference Points.

MonoBloc Spacers - Table Selection (in inches)

DescriptionProductNumber

Length(in)

DMB351122DMB351123DMB351124DMB42232DMB42233DMB42234DMB43332*DMB43332B*DMB452232DMB452233

3½” Trade Size, 2 Way3½” Trade Size, 3 Way3½” Trade Size, 4 Way4” Trade Size, 2 Way4” Trade Size, 3 Way4” Trade Size, 4 Way4” Trade Size, 2 Way4” Trade Size, 2 Way (Base)4½” Trade Size, 2 Way3½” Trade Size, 3 Way

3½3½3½444444½4½

12.516.921.514.320.527.015.015.015.522.2

130 (5.1)135 (5.3)135 (5.3)165 (6.5)165 (6.5)165 (6.5)190 (7.5)

N/A165 (6.5)175 (6.9)

118 (4.6)120 (4.7)120 (4.7)158 (6.2)158 (6.2)158 (6.2)190 (7.5)190 (7.5)173 (6.8)170 (6.7)

TradeSize (in)

Horizontal Spacing (C)mm (in)

2.02.02.03.03.03.03.03.03.03.0

Ground Clearance (D)(in)

Vertical Spacing (B)mm (in)

Base Spacer Reference Points.

11

Length

C

Length

BD

D

C

*190mm Spacing - Centre to Centre between Ducts

E_UDPF_BRV4Printed 02.2014

Our various pipe and fittings solutions have been manufactured to meet the needs of ourcustomers and their applications. Contact one of the below Sales Centres for more information:

• Municipal Pipe & Fittings Solutions• Plumbing Pipe & Fittings Solutions• Electrical Pipe & Fittings Solutions• Industrial Pipe & Fittings Solutions• Irrigation Pipe & Fittings Solutions

Sales & Distribution Centres:

Langley, BC, CanadaT/F 1.800.663.0696F 1.800.663.6564.......................................

Woodbridge, ON, CanadaT/F 1.866.769.7473F 905.856.3986.......................................

Laval, QC, CanadaT/F 1.800.465.9754F 450.688.6624.......................................

Distribution Centres:

Calgary, AB, CanadaT/F 1.800.663.0696F 1.800.663.6564.......................................

Winnipeg, MB, CanadaT/F 1.800.663.0696F 1.800.663.6564.......................................

royalelectricalca.com