Spanning 12,740 acres, Wasatch Peaks Ranch is a private ski and golf resort. The community required reliable infrastructure, including miles of underground electrical conduit capable of withstanding high-impact conditions and extreme temperature swings.
Challenge
Single-lane roadways, elevations ranging from 4,820 to 9,570 feet, and average annual snowfall of 400+ inches created challenging installation conditions. The project required a conduit that could reduce risk and complexity in the harsh mountain environment.
Contractors originally considered PVC conduit due to lower initial material cost in smaller sizes, but were concerned that its heavier weight and slower installation would ultimately increase total project costs.
The utility provider required that only rigid (known to be costly and heavy) or fiberglass elbows be used. Additionally, limited spacing to install 90 degree elbows required detailed planning up front and complex materials management.
Solution
Fiberglass electrical conduit was selected for the majority of the project. Its lighter weight meant less manpower and heavy equipment were needed on-site, lowering equipment rental costs and improving job site safety.
Familiar with working in extreme temperatures, the crews had confidence in the fiberglass ability to withstand the dramatic temperature shifts of the mountain. With a range for reliable performance spanning from -40° to +230°F, fiberglass retains strength and does not become brittle in freezing temperatures, and will not soften or sag in high heat.
Extensive BIM models were used to ensure that installations went smoothly, even in vaults housing 70+ elbows feeding switchgears underground and overhead. Well-known for longer, smoother pulls, fiberglass conduit’s low coefficient of friction eliminated the risk of lubricant-related damage and improved the efficiency of installation.
Prefabricated components, including duct banks and elbows, streamlined the installation process, allowing crews to safely place 60-foot sections at a time.
Results
Three years into the 15-year project, nearly seven miles of fiberglass conduit have been successfully installed mostly underground but also on bridge crossings. Installation was smooth, safe and fast, even under demanding site conditions.
A crew member from Helix noted, “Fiberglass is amazingly light; you can pick it up with one hand. With PVC, it’s a different story.”
The team was also able to realize additional project efficiencies thanks to custom labeling from Champion Fiberglass® on each length of conduit, noting the specs and voltage. Additionally, the Helix Project Manager praised the quality control process, “Everything has a quality control sticker on it, so you know you’re getting the bends that you want even if they’re custom.”
Project details
Wasatch Peaks Ranch used Champion Duct® and Champion Elbows for utilities, bridges, and commercial installations at high elevation. The lighter fiberglass material was easier to handle than alternatives, and its low friction allowed smoother cable pulls with fewer pull boxes than PVC. Custom labeling and prefabrication reduced installation time.
