Underground Duct Bank Assembly With Prebuilt Template Framework
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Solution Overview
Problem
Modern construction of underground conduit systems involves extensive assembly in trenches, combining risks of trench work with assembly dangers and requiring significant field labor for rebar installation, side panels, and concrete pouring.
Innovation Solution
A factory-manufactured duct bank assembly with enclosed sides and minimal field work, using templates and a framework to support conduits, reduce concrete use, and allow local concrete sourcing, eliminating the need for welding and reducing assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If duct banks are assembled in trenches with rebar, side panels, and tie wire attachments, then the conduits are properly encased and protected, but the installation becomes complex, time-consuming, and dangerous
Solution Approach 1:
The template is pre-assembled in a factory setting with all necessary components (rebar, side panels, tie wire attachments) already in place before shipment to the installation site. This preliminary assembly eliminates the need for complex field assembly operations, reducing both installation time and safety risks while maintaining the required conduit encasement protection
Solution Approach 2:
The template serves as an intermediary component that combines multiple functions: it provides structural support for conduit encasement, incorporates rebar for concrete bonding, includes side panels for formwork, and has pre-attached tie wire connections. This single integrated component replaces multiple separate assembly operations
2Adaptability or versatility
If extensive field assembly work is performed in trenches, then the duct bank can be customized to site requirements, but safety risks and installation time increase significantly
Solution Approach 1:
Standardized template designs are pre-manufactured in various configurations to accommodate different conduit arrangements and site requirements. This allows the system to maintain adaptability for different applications while eliminating time-consuming field assembly operations
Solution Approach 2:
The duct bank system is divided into modular template segments that can be easily transported to the site and assembled in a simplified manner. Each template is a self-contained unit that can be adapted to different configurations without requiring extensive custom fabrication in the field
3Reliability
If rebar, side panels, and tie wire attachments are installed in the field, then proper concrete encasement is achieved, but the number of assembly steps and labor requirements increase
Solution Approach 1:
All components necessary for proper concrete encasement (rebar positioning, side panels, tie wire attachments) are pre-installed on the template during factory manufacturing. This ensures the quality and proper installation of each component while eliminating the need for multiple field assembly operations, thereby maintaining encasement reliability while significantly improving assembly productivity
Data Source
AI summary
An underground duct bank assembly includes a plurality of templates each including a longitudinal axis and a transverse axis, a central portion including a plurality of conduit apertures each configured to accommodate a conduit, and first and second outboard portions disposed adjacent the central portion and opposite each other along the transverse axis, each outboard portion including a framework aperture configured to accommodate a framework piece; a plurality of conduits each extending into a conduit aperture; and a framework configured to connect adjacent templates, the framework including a plurality of framework pieces and angle braces, wherein two adjacent angle braces meet at a framework aperture and are affixed to the template and each other.