Underground Utilities: Key Practices for Electricians and Distributors

In the United States alone, utilities depend on over 20 million miles of underground infrastructure — and that number may be an extreme underestimate.

Each year, the infrastructure grows, and the trend is unlikely to change in the near future. Solar installations, EV chargers, and fiber internet will all require new buried utility lines. Underground installations are more resilient against inclement weather, safer, and more aesthetically appealing.

For the extended future, underground installation will remain a part of the job for construction electricians. However, it’s also a potential pain point: Without an appropriate workflow, line installation can lead to productivity bottlenecks and serious ergonomic hazards. 

In this article, we’ll discuss several tried-and-true principles for underground (UD) utility installation. We’ll also explain how BHS electrical installation equipment can help you maintain efficiency during greenfield projects — regardless of the size or complexity of the job. 

Planning Undergrounding for Utilities

While undergrounding is advantageous for a variety of reasons, the process carries high upfront costs. Planning can reduce those expenses: If ducts arrive prefabricated — and the site has been appropriately assessed — workers will be able to follow a fairly predictable installation schedule.  

BIM (Building Information Modeling) technologies can quickly create highly accurate layouts that allow ducts to be prefabricated and “dropped in" to trenches. Professional modeling reduces waste significantly, cutting the cost of the project while supporting an efficient installation. To minimize unexpected challenges, engineers should also use radar and other technologies to inspect the installation site and select an appropriate route for trenches. 

Cables should be installed below the seasonal frost line. Repeated freezing and thawing can put tremendous mechanical stress on the cables, raising the chances of a fault. The thermal qualities and the general condition of the soil may also determine whether additional protections (such as concrete barriers or concrete-encased duct banks) are necessary.

Limiting Cable and Wire Waste During Underground Installation

Experienced electricians understand that underground systems require high-quality materials and components. After all, refurbishing the system won’t be cheap — and operational issues will cause enormous headaches for the occupants (not to mention their contractors). 

UD primary cables must be adequately insulated and jacketed. Of course, when you’re working with high-quality components, you’re paying much more for each foot of the system; product loss must be avoided wherever possible. 

Professional modeling certainly helps, but no installation is perfect. Some amount of product loss is inevitable, and work practices certainly play a major role.

To that end, electricians should: 

• Keep duct ends plugged prior to pulling cable to prevent debris from causing damage.
• Store cable and wire in product-safe conditions. Avoid storing UD materials in direct sunlight.
• Pre-parallel reels with an appropriate amount of product (discussed below).
• Alternatively, you can work with a distributor that provides pre-paralleling as a delivered solution.
• Set reasonable overage amounts to keep sufficient materials on hand. Remember, the cost of installation will be determined by two factors: Availability and planning. 

Improving Ergonomics with Cable Payout Equipment

Depending on the project, you may be installing multiple primaries along with secondaries. You might be running 10 AWG conductors along with 2 AWG. Pulling each product individually will take time — and will probably lead to quite a bit of reaching, grabbing, and awkward positioning. 

That can be problematic for workers. Pulling cable isn’t easy, even in the best of conditions; forcing long runs through underground ducting and conduit will require manual effort, and poor work habits can lead to injuries and lost time (not to mention product damage). 

Product to Consider: Parallel Reel Payout (PRP)

Parallel Reel Payout	Spool Winding Trolley

The BHS Parallel Reel Payout (PRP) system can simplify cable pulls by accommodating a variety of types of wires and cables on a single piece of equipment. Its free-spinning, multi-compartment reels provide a reliably even payout and an ideal solution for at-scale undergrounding. 

Available in several models and in custom configurations, the PRP features: 

• Individual hub locks, which prevent unwanted payout.
• Shaft safety locks with a locking pin.  
• A four-way fork pocket design that allows for efficient transport and positioning via pallet truck or forklift.
• Heavy-duty construction for reliable service, even when used regularly for UD installations.
• Optional casters for manual maneuverability. 

Utilizing Delivered Solutions for Pre-Paralleled Cable

Delivered solutions can simplify installations, particularly when distributors provide custom paralleling. Multiple reels can be loaded to order, then transferred to the installation site along with ducting and conduit — and in some cases, unused product can be returned to the distributor at the end of the project. 

To facilitate this approach, BHS provides the Spool Winding Trolley and the Parallel Reel Payout Trailer. 

Product to Consider: Spool Winding Trolley (SWT-LITE)

The SWT-LITE is a standalone payout engine that enables electricians and electrical suppliers to efficiently load reels with multiple cables, reducing ergonomic concerns (and potential product waste). The innovative design enables respooling on a wide variety of configurations without removing reels from stands.

The SWT is also available as an Industrial Internet of Things (IIoT) model, complete with its own software package and ready for integration with other IIoT systems.

Product to Consider: Parallel Reel Payout Trailer (PRP-TRL)

The PRP-TRL offers a turnkey solution for cable dispensing at installation sites. Each unit consists of two to three rotating PRP units mounted on a single trailer. Load the required cable or wire, haul the PRP-TRL to a worksite, and begin the installation. 

The turntable bases allow electricians to pull cable in any desired direction without moving or repositioning the trailer, maximizing productivity and minimizing downtime. Custom reel designs allow the equipment to be configured for specific jobs, and the 360-degree turntables are ideal for undergrounding. 

Explore Custom Electrical Material Handlings Solutions from BHS

At BHS, Inc., we understand that high-quality material handling equipment is essential for a successful underground installation. Our engineers can help you find the perfect solution, whether that means customizing an off-the-shelf-solution or designing something entirely new. 

With close collaboration between our engineers and your team, we leverage state-of-the-art equipment and our extensive 148,000 square-foot production facility to turn your ideas into reality. To get started, call 1.800.247.9500 to speak with a member of our sales team or fill out our online form.