Plastic HDPE ducts
Plastic Prestressed Corrugated Duct Product Introduction
Plastic prestressed corrugated ducts are flexible conduits specially designed for post-tensioning systems, widely used to protect prestressing tendons (strands or bars) and form grouting channels after concrete pouring. Compared to traditional metal corrugated ducts, plastic ducts offer advantages such as lightweight, corrosion resistance, and electrical insulation, making them ideal for bridge construction, building slabs, and infrastructure projects.
Material Composition
Plastic corrugated ducts are manufactured from high-performance engineering plastics, including:
High-Density Polyethylene (HDPE)
Resistant to acids, alkalis, and impact, suitable for general environments.
Polypropylene (PP)
Heat-resistant (up to 100°C), ideal for high-temperature applications.
Modified Nylon (PA)
High strength and toughness, used in high-stress structures.
Recycled Plastics
Eco-friendly options for sustainable construction.
Additives
UV stabilizers, flame retardants, and antioxidants enhance durability.
Manufacturing Process
Extrusion Molding
Plastic pellets are melted and formed into a tube via an extruder.
Corrugation Shaping
The tube passes through a mold to create spiral or ring-shaped corrugations.
Cooling & Solidification
Rapid cooling ensures dimensional stability.
Cutting & Quality Control
Ducts are cut to required lengths and tested for pressure resistance and flexibility.
Key Quality Checks
- Uniform wall thickness (±0.1mm)
- Consistent corrugation pitch (affects crush resistance)
- Smooth inner surface (reduces friction during tendon installation)
Applications in Prestressed Construction
Installation Process
- Embedding & Positioning – Secured to rebar cages as per design.
- Concrete Pouring – Protected from vibration damage.
- Tendon Stressing – After curing, prestressing strands are threaded and tensioned.
- Grouting – Cement grout is injected to protect tendons from corrosion.
Key Functions
- Tendon Protection – Prevents concrete intrusion, ensuring free movement during post-tensioning.
- Grout Channel – Ensures full encapsulation of strands for bond strength.
- Electrical Insulation – Critical for electrified rail and subway projects.
Why Choose Plastic Corrugated Ducts?
Feature | Plastic Ducts | Metal Ducts |
Corrosion Resistance | Excellent (no rust) | Requires galvanizing/epoxy coating |
Weight | Lightweight (~0.95g/cm³) | Heavy (steel: 7.85g/cm³) |
Cost | Lower (stable material prices) | Higher (subject to steel prices) |
Installation | Flexible, easy to cut | Requires special tools |
Insulation | Non-conductive (ideal for electrical environments) | Conductive (needs extra protec |
Common Applications
- Bridge Girders – Longitudinal ducts for post-tensioned box girders.
- Floor Slabs – Flat-profile ducts (20-30mm thick) for unbonded post-tensioning.
- Utility Tunnels – Resistant to groundwater corrosion.
- Nuclear Plants – Radiation-resistant modified nylon ducts.
- Offshore Structures – HDPE ducts for chloride resistance.
Quality Standards
Mechanical Performance
Leakproofness
No leakage at 0.1MPa water pressure.
Environmental Adaptability
No cracking at -30°C.
No deformation at 80°C.
Eco-Certifications
RoHS, REACH compliance.
Future Trends
Smart Ducts
Embedded fiber-optic sensors for prestress monitoring.
Bio-Based Plastics
PLA materials for reduced carbon footprint.
3D-Printed Customization
Complex joint integration.
Conclusion
Plastic prestressed corrugated ducts are increasingly replacing metal ducts due to their corrosion resistance, lightweight design, and cost efficiency—especially in harsh environments and precision-engineered structures. Selection depends on material (HDPE/PP/PA) and corrugation type (spiral/ring).
Specification
L (mm) | W (mm) | Thickness (mm) | Fit PT slab system |
46 | 20 | 2 | BM15-2 |
60 | 20 | 2 | BM15-3 |
72 | 20 | 2 | BM15-4 |
90 | 23 | 2 | BM15-5 |
ID (mm) | OD (mm) | Thickness (mm) | Fit Post tension system |
φ50 | φ61 | 2 | YJM15-3~5 |
φ70 | φ81 | 2 | YJM15-6~9 |
φ85 | φ99 | 2 | YJM15-310~12 |
φ100 | φ114 | 2 | YJM15-13~19 |
φ120 | φ136 | 2.5 | YJM15-20~22 |
φ130 | 146 | 2.5 | YJM15-23~31 |
φ140 | φ157 | 3 | YJM15-32~37 |
φ160 | φ177 | 3 | YJM15-38~55 |
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- ISO 9001, ASTM A109, JIS G 3141 Certified
- Competitive pricing with bulk order discounts
- Just-in-time delivery & global shipping options