Stackable Duct-Bank Stub-Up Assembly Reduces Encasing Weight
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Solution Overview
Problem
Conventional stub-up systems for underground conduit pathways face challenges such as inefficient use of encasing material, increased weight, and higher costs due to the need for extensive concrete encasement, which complicates installation and maintenance, especially in areas requiring high conduit concentration.
Innovation Solution
A stackable duct-bank stub-up assembly using pre-formed modules with curved conduits and modular encasing bodies, reducing the amount of encasing material required while allowing for efficient conduit concentration and alignment, and facilitating easier installation by minimizing the weight and complexity of the encasing structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stub-up systems use extensive concrete encasement to protect conduits, then protection against damage is improved, but weight and cost of encasing material increases
Solution Approach 1:
The encasing structure is divided into modular segments (stub-up modules) that can be assembled in stacks. Each module contains a limited number of conduits (e.g., 3x5 array) enclosed in concrete, rather than casting large monolithic encasements. This segmentation reduces the weight of individual handling units while maintaining protection through modular concrete encasements.
Solution Approach 2:
Conduits are nested within the encasing body in a structured array configuration. The conduits are positioned in predetermined patterns (e.g., 3 rows of 5 conduits) within the concrete encasement, allowing efficient use of encasing material while protecting all conduits. The nested arrangement optimizes the protection-to-weight ratio.
2Reliability
If conventional stub-up systems use extensive concrete encasement, then conduit protection is improved, but ease of installation deteriorates due to increased weight and complexity
Solution Approach 1:
The system divides the encasing structure into manageable modular segments that can be easily transported, handled, and installed. Each stub-up module is a self-contained unit with predefined conduit arrangements, allowing workers to install multiple modules by simple stacking rather than forming and pouring large concrete structures on-site.
Solution Approach 2:
Conduits are pre-positioned and pre-encased in modular units before delivery to the installation site. The spacer lattice and conduit arrays are assembled and concrete-cured in controlled manufacturing settings, then delivered as ready-to-install modules. This preliminary preparation significantly simplifies field installation operations.
3Reliability
If conventional stub-up systems use extensive concrete encasement, then conduit protection is improved, but cost increases
Solution Approach 1:
The encasing material is used efficiently in segmented modular units rather than excessive continuous encasement. Each module contains only the necessary amount of concrete to protect its specific conduit array, eliminating waste from over-encasement and reducing total material requirements while maintaining adequate protection.
Solution Approach 2:
The system changes the parameters of encasement by using standardized modular dimensions and conduit spacing (e.g., 3x5 arrays with specific pitch). This standardization allows optimized concrete usage per module, reducing the quantity of encasing material needed compared to conventional custom-formed encasements while maintaining protective functionality.
4Strength
If conventional stub-up systems use extensive concrete encasement, then structural strength is improved, but device complexity increases
Solution Approach 1:
The complex encasing structure is divided into standardized modular segments with repeating patterns. Each stub-up module has a consistent internal structure (spacer lattice, conduit array, encasing body) that simplifies manufacturing and assembly. The modular repetition reduces overall system complexity compared to custom-designed encasements.
Solution Approach 2:
The stub-up modules are designed as universal components that can be stacked in various configurations to accommodate different numbers and arrangements of conduits. The standardized mating surfaces and modular design allow the same basic module type to serve multiple installation scenarios, reducing the variety of unique components needed and simplifying the overall system.
Data Source
AI summary
A duct-bank stub-up assembly includes a first pre-formed stub-up module that comprises a first plurality of conduits and a first encasing body. For each of the first conduits, a first end of the conduit provides a mating end on a mating side of the first encasing body and a second end of the conduit provides a mating end on a top surface of the first encasing body. The assembly further includes a second pre-formed stub-up module that comprises a second plurality of conduits and a second encasing body formed to have a stub-up section and a footer section. For each of the second conduits, a first conduit end provides a mating end on a mating side of the footer section and a second conduit end provides a mating end on a top surface of the stub-up section. The first module is positioned on the footer of the second module.