Cable ducts

Extrusion technologies for technical and infrastructure ducts

Cable ducts are essential components in electrical and telecom infrastructure, used for the mechanical protection, insulation and organization of cables in civil, industrial and infrastructure installations. They are used both in underground installation and in exposed installations, where they must ensure geometric continuity, resistance to external agents and long-term stability.
Compared to other protection solutions, extruded plastic ducts offer reduced weight, corrosion resistance and easier installation. Final performance depends directly on the quality of the extrusion process, particularly on dimensional control, uniform wall thickness and internal surface quality, which facilitates cable insertion and replacement.

Dimensional requirements and extrusion challenges

In the production of cable ducts, dimensional control is a critical factor in ensuring compatibility with covers, accessories and fastening systems. The main process challenges include:

variations in profile width and height
thickness instability, especially on complex profiles
deformations during the cooling phase
loss of precision in internal geometries

Standards require tight tolerances on external dimensions and couplings, making accurate control of extrusion, calibration and cooling essential. Even small deviations can cause assembly difficulties, production scrap or non-conformity of the finished product.

Type of plastic ducts production with Extrusion lines

The cable duct market includes solutions with different geometries and structures, designed according to the type of cable, installation conditions and regulatory requirements. Relevant standards, such as EN 61386 and equivalent national standards, define requirements for mechanical strength, fire behavior, electrical insulation and dimensional precision, making a stable and repeatable extrusion process necessary.

TYPE OF CABLE DUCTS	APPLICATION	CHARACTERISTICS
Rigid PVC Ducts	Building and construction for electrical wiring	Rigid, durable, and resistant to corrosion.
Flexible PVC Ducts	Residential electrical installations	Flexibility, ease of installation, and cost-effectiveness.
HDPE (High-Density Polyethylene) Ducts	Telecommunications and energy sectors for underground cable installations.	Strong, durable, and resistant to environmental factors.
Characteristics: Fiber Optic Ducts	Specifically designed for the protection and installation of fiber optic cables.	Smooth interior for easy cable pulling, UV-resistant, and suitable for high-density installations.
Multi-Duct Systems	Ideal for situations where multiple cables need to be organized and protected	Single Screw Extruder, E-GO seriesMultiple channels within a single duct, facilitating organized cable management.
Cable Trays	Industrial and commercial buildings for overhead cable routing	Provides an open, ventilated structure for cable support and management.
Cable Conduits	Residential and commercial buildings	Tubular structure, offering protection against physical damage and environmental factors.
Corrugated Ducts	Used in various industries for flexibility and adaptability in cable routing.	Corrugated design provides flexibility while maintaining strength.

Bausano extrusion lines for cable ducts

Bausano offers extrusion lines dedicated to producing cable ducts, configured according to the product geometry and the material used. For PVC-U ducts, MD series co-rotating twin-screw extruders are used, with screw diameters from 52 to 130 mm and installed power up to 260 kW, ideal for ensuring uniform plasticization and melt stability even on complex profiles.
For production requiring greater flexibility or the use of special compounds, Bausano also offers E-ON conical twin-screw extruders, with screw diameters from 53 to 80 mm and guaranteed output of up to 300 kg/h, suitable for technical profiles and corrugated ducts.
The lines are completed with dedicated extrusion heads, vacuum calibration tables and modular cooling systems, designed to maintain geometric precision, reduce deformation and ensure consistent quality even in continuous production. The choice of the most suitable line for producing ducts therefore depends on three main factors: the material to be processed (standard PVC-U or special/recycled compounds), the geometric complexity of the profile (linear, corrugated or multi-channel), and the required output in kg/h – for standard PVC-U ducts, the MD co-rotating twin-screw configuration is the most common solution, while for corrugated profiles or special compounds, E-ON conical extruders are more suitable.

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