Selecting the right flexible conduit system can be a tricky task. Rob Sprason, Technical Sales Manager from Atkore Flexicon outlines how to get it right.

The choice of which type of flexible conduit system to use for a particular application is an important one. It is vital that the solution you opt for not only protects all areas of the cabling but provides the appropriate levels of protection for its specific environment.

However, as every electrician knows, there is so much choice available that it can be a confusing decision. One of the biggest challenges for electrical installers and contractors is time. The requirement to move onto the next task quickly will often see electricians defaulting to products they know well and have used multiple times.

Although flexible conduit might look the same visually, with similar colours and profiles, material properties can differ significantly. There are numerous products available on the market, often for a lower cost than seemingly comparable alternatives. While it can be tempting to select based on previous installation experience or personal preference, this can be a false economy, so it is essential to verify all recommended performance criteria to avoid inadvertently reducing the level of safety and increasing risk.

So, what are some of the factors you need to consider—and how can you ensure that you get it right every time?

Ongoing development

Historically, conduits and conduit fittings were only available in metal, but, over time, the development of engineered plastics saw more flexible, corrosion and water-resistant solutions enter the market.

These solutions could withstand large temperature ranges, offered improved chemical and oil resistance, and enjoyed a high level of mechanical strength. As the market acceptance for these systems grew, so nylon (polyamide) became an increasingly important material. However, metallic and composite systems also remain in demand because of their excellent mechanical strength and EMC screening possibilities.

Get the specification right

Specifying cable protection based on one property alone can be a costly mistake and the full range of environmental factors should be considered. These can include exposure to extremes of temperature, UV radiation, harsh chemicals and the likelihood of water or dust ingress.

In addition, fire performance, compression strength and impact or abrasion resistance, risk of explosion or even the resistance to build up of bacteria could need to be considered.

Nylon, metal or composite?

Where fatigue life or impact resistance is important, installers should consider nylon polyamide (PA) corrugated flexible conduits, which can offer high impact strength and recovery if crushed, combined with excellent temperature performance.

Polypropylene and PVC conduit systems are available; however, both systems are inferior to nylon polyamide (PA) when it comes to fire performance, resistance to solvents and abrasion, as well as UV properties in external applications when exposed to the damaging effects of the sun.

With no exposed metallic content, non-metallic conduits do not rust or corrode when subjected to water, thus maintaining performance and appearance over time. In addition, it is worth considering labour and installation time. Non-metallic systems are often quicker to install than metallic options as they are easier and faster to cut. Non-metallic fittings will typically be one piece and simply push on and twist to secure. This makes them easier to handle as well as providing a lighter weight system.

For installations subject to increased UV exposure, it is important when specifying non-metallic and polymer-coated metal conduit to consider that ultraviolet (UV) radiation will naturally degrade any plastic materials. Failure could result in materials cracking, an increase in brittleness, reduced flexibility and lower impact strength, thus compromising the performance of the system or equipment.

Metallic flexible conduit typically has a higher level of crush resistance, high mechanical strength and can provide excellent EMC screening properties. Metallic systems are ideal for applications that require a very high compression or pull-off strength, or where there is the need to protect cables from exposure in hazardous environments. They also offer excellent performance for extremes of temperatures, both high and low – with uncoated options such as stainless steel offering a performance range from +600°C through to -100°C.

Composite products, such as plastic sheathing on metal conduits, metal over-braiding or metal threads on plastic fittings can also offer the ideal combination of light weight and high strength.

Retrofitting with ease

In existing applications, retrofitting cable protection has, traditionally, been a more complex task, with the installer required to pull existing cabling through the open end of a conduit system.

Conduit system manufacturers are therefore developing enhanced retrofit options to make it easier and quicker to install cable protection in existing applications, such as interlocking slit conduit. The construction allows existing cabling to be inserted laterally via a slit opening, enabling the installer to wrap a flexible conduit around the cables retrospectively with minimal disruption and without the cable being exposed.

This also has the added advantage of being able to protect pre-terminated cables with connectors or plugs, which are too big to pull through a conduit system.

It is also important to consider the cable routing. Traditional slit conduit options can potentially expose cabling when bent or routed around corners, with reduced mechanical strength, whereas newer options can maintain continuous protection of the cabling irrespective of orientation or routing.

Specify a complete system

The specification process should also take into consideration the range of fittings available, especially where these can help reduce installation time.  Conventional fittings can take time to assemble and install, whereas newer designs feature innovations such as simple, one-piece push and twist conduit connection. These can offer significant time, simplicity and cost benefits, particularly where there are numerous cables to terminate.

Elsewhere, design improvements to help simplify cable management and routing over the lifetime of an installation are available. Junction boxes, such as Flexicon’s Connectabox, feature easy-to-connect entry points which can be used with non-metallic flexible conduit. These use push, twist and lock connectors to make a reliable connection in seconds, with the highest ingress protection of IP66, IP67, IP68 and IP69. This is without having to remove knockouts, drill holes, fit locknuts or even torque tighten any components.

In conclusion

When specifying the correct flexible conduit system, making the right choice is not merely a matter of convenience; it is essential for ensuring the reliability and efficiency of electrical installations. By embracing these principles, electricians can prioritise safety and performance and ensure the installation is fit for the future.

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Michael Crowther, Sales & Marketing Director at Hylec-APL, celebrates 10 years of Debox, the versatile junction box family designed to save electrical installers time and money.

Whether in domestic or commercial settings, junction boxes remain an essential component in any electrical circuit. Functioning as a central hub for wiring connections between fittings or devices and the mains power supply, these vital enclosures provide protection, isolation and easy access for maintenance or inspection. By offering mechanical strength and durable electrical continuity, they also help wiring installations comply with regulations.

However, not all junction boxes are created equal – and installers must take care to use them in a way that ensures consistently safe, reliable and compliant electrical installations. That’s exactly why Hylec-APL introduced its innovative Debox junction box a decade ago. Debox re-imagined the junction box, simplifying installation through virtually tool-free operation and saving time by including everything needed to reliably and safely connect cables.

A decade of Debox

10 years on from its introduction at LuxLive 2014, the Debox series of cable junction boxes now extends to five models to address different application use cases – and millions of units have been sold worldwide since its launch. The entire range has been designed to make installers’ lives easier and save installation time by including everything they need – from integrated terminal blocks with rapid connections and cable clamps to tool-free closure and maintenance-free operation.

Meanwhile, installers are having to deal with increasing numbers of electrical or electronic devices and fixtures – from LED up- and down-lighting to all kinds of smart home and building automation functionality. This often drives up the time, complexity and ultimately cost of installations, as well as the risk of quality and compliance issues.

So, for busy electrical installers looking to quickly and methodically wire up multiple devices or fittings on-site, Debox’s integrated design simplifies and guides them through the process, saving time and money without compromising quality – and crucially, ensuring consistently safe, reliable and compliant installations.

Debox S: the original Debox

Re-imagined and designed to speed up every installation, the original Debox S is a cost-effective, innovative all-in-one cable junction box. Complete with 4-pole 24A UL/VDE-approved terminal block as standard, Debox S conforms to EN60598-1 (GWT 650°C). Pre-fitted with external fixing lugs for fast, easy mounting, Debox S comes complete with everything needed – including in-built cable clamps and locking clip – for rapid, simple and virtually tool-free installation.

Debox SL: the 100% tool-free Debox

Debox SL introduced the first ever completely tool-free in-line electrical junction box. Now featuring a new easier-to-use, double-lever screwless terminal block, Debox SL offers maintenance-free connections. Its safe, fast and reliable 100% tool-free assembly is supplied complete with 4-pole 16A connector block, capable of accommodating 2, 3 or 4 conductors in round or flat profile cable for lighting circuits or power.

Debox SL2: the 5-pole Debox

Debox SL2 is the smallest junction box available with five poles. Each individual 32A screwless lever connector can take up to three conductors and the box features unique push-fit cable clamps. Debox SL2 saves valuable time and makes installation easier for smaller and larger internal wiring jobs, as everything needed is supplied with the box, with no need to use a screwdriver to securely join wires or mount the box itself.

Debox SM⁴⁰: the miniature Debox

Debox SM⁴⁰ is the first 4-pole in-line junction box that fits through a 40mm aperture, yet still retains generous cable management space, making Debox SM⁴⁰ ideal for use in LED lighting applications. As with all Debox junction boxes, Debox SM⁴⁰ comes ready for use, supplied with everything needed, including the terminal block, making connection simpler and easier. The miniature Debox SM⁴⁰ is only half the volume of Debox S or SL, making it the most compact 4-pole junction box available.

Debox 11: the outdoor Debox

Debox 11 is a highly versatile surface-mounted junction box for external weatherproof applications. It comes with 10 soft membrane covered cable entries, providing quick puncture-entry and self-sealing rated to IP66. Eight entries are threaded M20, ideal for cable glands, with no need for an internal locknut, offering even higher protection rating to IP67. Five 3-pole screwless connectors are supplied and the housing is made of flame retardant, impact-resistant polypropylene.

Simpler by design

Ergonomic design and convenience for electrical installers are at the heart of the entire Debox range. The design of all models aims to simplify and speed up installation, without compromising quality. All components required are supplied, with no loose screws or parts that can be easily dropped or lost – and the versatile Debox junction box family’s registered design features offer faster, more efficient and therefore cheaper installation through its simple and virtually tool-free use.

For more information, click here

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As part of its ongoing dedication to product development and innovation, Marshall-Tufflex has introduced new adjustable bends to its Sterling Curve and Sterling Compact PVC-U perimeter trunking ranges.

These high quality solutions provide electrical installers with an expert finish, avoiding unsightly gaps when fitting trunking around any corner.

Capable of accommodating building corner variances of +/-5° (85 to 95°), the new internal and external adjustable bends provide a quick, simple and neat trunking solution for corners that are not precisely 90° square.

The latest launch offers even more flexibility for installers using Sterling Curve Profile 1 dado trunking or Sterling Compact: Users can now choose between using either the existing, standard fixed bends, or the new adjustable bends for corners that aren’t perfectly square – making it really easy to achieve a good, neat finish every time.

The new products are now available and in stock for electrical wholesalers to purchase from Marshall-Tufflex.

For more information, click here

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