Electrical Conduiting Quality Check

1

Objective

To establish a comprehensive quality control procedure for electrical conduit installation, ensuring safety, durability, and proper protection of electrical wiring systems through standardized inspection methods in accordance with Indian Standards (IS Codes) and National Building Code guidelines.

2

IS Code References

Code	Description	Application
IS 9537:1983 (Part 2)	Conduits for Electrical Installations - Rigid Steel Conduits	Steel conduit specification and installation
IS 9537:1983 (Part 3)	Conduits for Electrical Installations - Rigid Non-Metallic Conduits	PVC conduit specification and installation
IS 732:2019	Code of Practice for Electrical Wiring Installations	General wiring installation requirements
IS 4648:1968	Guide for Electrical Layout in Residential Buildings	Conduit routing in residential buildings
IS 3419:1989	Fittings for Rigid Non-Metallic Conduits	PVC conduit fittings and accessories
IS 2667:1988	Fittings for Rigid Steel Conduits for Electrical Wiring	Steel conduit fittings and accessories
IS 14772:2000	Enclosures for Accessories for Household and Similar Fixed Electrical Installations	Junction boxes and accessories
NBC 2016 Part 8	National Building Code - Building Services	Electrical installation guidelines

3

International Quality Standards & Considerations

A

IEC 61386 Standard (Conduit Systems)

Widely recognized international standard for conduit systems for cable management.
Covers classification and performance requirements for conduit systems and fittings.
Addresses mechanical properties (compression, impact, bending, tensile strength) to ensure durability.
Specifies temperature ranges, electrical characteristics, and resistance to external influences (e.g., water, dust).
Includes requirements for flame propagation and fire safety to prevent spread of fire.

IEC 61386-1 (General) IEC 61386-21 (Rigid Conduits) IEC 61386-23 (Flexible Conduits)

B

Material & Dimensional Compliance

Adherence to specific material standards (e.g., UL 651 for PVC conduit, AS/NZS 2053 for electrical conduits and fittings).
Verification of conduit and fitting dimensions as per international standards (e.g., IEC 60423 for outside diameters of conduits).
Ensuring full compatibility and secure fit between conduit and fittings from different manufacturers if used.

UL 651 AS/NZS 2053 IEC 60423

C

Resistance to External Influences (IP Rating)

Proper IP (Ingress Protection) rating for specific installation environments (e.g., IP30 minimum for indoor, IP55 for outdoor/damp locations, IP67 for submersible).
Resistance to corrosion for metallic and composite conduits, especially in humid or chemical environments.
UV resistance for conduits exposed to direct sunlight to prevent degradation (especially for PVC conduits).
Temperature performance: Conduits must withstand operating and ambient temperatures without deformation or cracking.

IEC 60529 (IP Codes)

4

Materials & Equipment

A

Conduit Types

Rigid PVC Conduits (IS 9537 Part 3) - Medium/Heavy duty
Flexible PVC Conduits
Galvanized Iron (GI) Conduits (IS 9537 Part 2)
HDPE Ducts for underground applications
MS Conduits for specialized applications

IS 9537:1983 IS 4985:2000

B

Conduit Accessories

Junction boxes (circular/rectangular)
Bends and elbows (standard/inspection)
Couplers and connectors
Saddles and clips
End caps and bushings
Pull boxes and draw boxes
Conduit glands and adaptors

IS 3419:1989 IS 2667:1988

C

Tools & Equipment

Conduit pipe cutter
Pipe bender (for metal conduits)
Threading machine (for metal conduits)
Electric drill with hole saw attachments
Fish tape/draw wire
Spirit level and plumb bob
Measuring tape and marking tools
Multimeter for continuity testing

5

Pre-Installation Checks

A

Material Inspection

Check conduit material as per approved specifications
Verify conduit dimensions (diameter, thickness)
Check for manufacturer certifications and IS marking
Visual inspection for damage, cracks, or deformities
Ensure accessories match conduit type and size
Check material test certificates (MTC)

IS 9537:1983

B

Drawing Review

Review approved electrical layout drawings
Check conduit routing and integration with structural elements
Verify switch/socket points and DB locations
Confirm junction box positions and quantities
Identify potential clash points with other services
Verify conduit sizes for different circuit types

IS 732:2019 NBC 2016

C

Civil Work Coordination

Verify civil works readiness for conduit installation
Check chase dimensions and depths in walls
Ensure sleeves are provided in beams/columns
Verify cutout positions in slabs for vertical conduits
Check slab thickness for concealed conduits
Coordinate with other services to avoid interference

6

Concealed Conduit Installation

A

Wall Conduit Installation

Mark conduit routes on walls as per approved drawings
Horizontal runs: 450mm from finished floor level for switches Horizontal runs: 1050mm from finished floor level for socket outlets Vertical runs: Plumb alignment from switches/sockets to ceiling/floor
Cut chases using chase cutting machine to required depth (min. 50mm)
Ensure minimum 10mm coverage over conduit after plastering
Install junction boxes at standard heights with proper fixings
Secure conduits in chases with cement spots at 600mm intervals
Ensure conduit joints are properly sealed and waterproof

IS 732:2019 IS 4648:1968

B

Slab/Ceiling Conduit Installation

Mark conduit layout on shuttering before reinforcement
Fix conduits securely to reinforcement using GI wire
Maintain minimum 25mm clearance from bottom reinforcement
Install deep junction boxes where required
Seal all conduit ends to prevent concrete ingress
Install pull wires in all conduits for later wiring
Perform water test to verify no blockages before concrete pour

IS 732:2019

C

Bending & Joints

Limit bends to maximum 3 between junction points
Ensure minimum bending radius (8 times external diameter)
Use proper bending tools to avoid deformation
For PVC conduits:
Use solvent cement for joints as per manufacturer's guidelines Ensure full insertion into couplers/fittings Allow proper curing time before further handling
For Metal conduits:
Use threaded connections with proper threading Apply anti-corrosive paint at cut edges Ensure thread engagement length minimum 13mm

IS 9537:1983

7

Surface Conduit Installation

A

Conduit Fixing & Routing

Mark conduit routes as per approved layout
Run conduits parallel or perpendicular to walls/ceilings
Maintain alignment and aesthetics for visible conduits
Install conduit supports at specified intervals:
Horizontal runs: 600mm maximum spacing Vertical runs: 750mm maximum spacing Additional support within 300mm of junction boxes
Use appropriate saddles/clips for conduit size
Maintain minimum 150mm clearance from water pipes

IS 732:2019

B

Junction & Switch Boxes

Use metallic boxes for GI conduits and PVC boxes for PVC conduits
Install boxes flush with finished surface
Secure boxes firmly with appropriate fasteners
Ensure proper knockout openings for conduit entry
Maintain standard mounting heights for switch/socket boxes
Use brass screws for metal boxes to prevent corrosion

IS 14772:2000

C

Special Locations

For outdoor installations:
Use IP55 rated boxes and fittings Install weather-resistant seals at joints Provide drip loops at vertical-to-horizontal transitions
For wet areas (bathrooms, kitchens):
Use waterproof junction boxes Maintain minimum 1.8m height for socket outlets Seal all conduit entries with waterproof compound
For false ceiling spaces:
Secure to solid structures, not ceiling suspension system Provide adequate access points for maintenance Label conduits for circuit identification

8

Underground Conduit Installation

A

Trench Excavation

Excavate trench to minimum 750mm depth for low voltage cables
Maintain minimum 300mm width for proper working space
Ensure trench bottom is free from rocks and sharp objects
Provide 75mm sand bedding prior to conduit laying
Mark trench route with warning tape during excavation

B

Conduit Laying

Use HDPE ducts or double-walled corrugated pipes for underground application
Lay conduits on prepared sand bed with proper alignment
Maintain minimum spacing of 100mm between parallel conduits
Provide gentle bends with minimum radius (10 times diameter)
Install draw wires in all conduits for future cable pulling
Seal conduit ends to prevent ingress of dirt/water

C

Backfilling & Protection

Cover conduits with minimum 75mm sand layer
Place protective concrete tiles/bricks above sand layer
Install warning tape 300mm below ground level
Backfill with excavated soil in 150mm layers with compaction
Document exact route with measurements for future reference
Restore surface to original condition

IS 1255:1983

9

Testing & Inspection

A

Visual Inspection

Verify conduit routing as per approved drawings
Check alignment and straightness of exposed conduits
Ensure proper saddle/clip installation and spacing
Verify junction box positioning and alignment
Check for proper sealing of joints and connections
Inspect for physical damage or deformation of conduits

B

Continuity Testing

Install steel fish wire through entire conduit length
Verify smooth passage without obstructions
Test continuity between junction points
Check for proper earthing of metal conduits
Verify continuity between conduit and junction boxes
Document test results with signatures

C

Pre-Wiring Inspection

Confirm conduit capacity is suitable for intended cable quantity
Ensure all conduit ends are properly bushed
Verify accessibility of junction boxes for future maintenance
Check for proper radius of bends to allow easy wire pulling
Ensure conduits are free from debris and moisture
Obtain approvals before proceeding to wiring stage

10

Quality Checklist - Electrical Conduiting

Inspection Item	Acceptance Criteria	Reference
Conduit Material	As per approved specifications, with IS marking	IS 9537
Conduit Size	Minimum 20mm for lighting, 25mm for power circuits	IS 732:2019
Concealed Depth	Minimum 10mm coverage after plastering	IS 732:2019
Saddle Spacing	600mm (H) / 750mm (V) maximum spacing	IS 732:2019
Junction Boxes	Flush with finished surface, secure fixing	IS 14772
Bends	Maximum 3 bends between junction points	IS 732:2019
Conduit Joints	Proper sealing, no visible gaps	IS 9537
Clearance from Pipes	Minimum 150mm from water pipes	IS 732:2019
Pull Wire	18 SWG GI wire in all conduits	IS 732:2019

11

Common Defects & Remedial Measures

Defect	Possible Cause	Remedial Measure
Cracked Conduits	Improper handling, excessive bending	Replace damaged section, use proper bending tools
Loose Connections	Inadequate tightening, vibrations	Retighten connections, use thread-locking compounds
Misaligned Junction Boxes	Improper fixing, settling of plaster	Realign and secure properly before final finishes
Blocked Conduits	Debris entry, concrete ingress	Clean using compressed air or replace section if necessary
Improper Slope	Installation error, lack of support	Reinstall with proper support and slope
Exposed Conduits in Slab	Inadequate fixing, displacement during concreting	Reroute exposed sections or provide additional protection
Water Ingress	Improper sealing, damaged conduits	Seal joints properly, replace damaged sections

12

Important Notes

All electrical conduit work must comply with IS 732:2019 Code of Practice
Maintain minimum 300mm separation between power and communication conduits
Document all deviations from approved drawings with proper approvals
Obtain inspection approvals for concealed conduits before plastering/concreting
Ensure proper earthing of all metal conduit systems as per regulations
Maximum fill ratio should not exceed 40% of conduit cross-sectional area
Conduit size should be increased by one size at every 10m length for long runs

13

Safety Measures

         Use appropriate PPE (personal protective equipment) such as gloves, safety glasses, and helmet.
 Handle cutting tools with care and use proper technique to prevent injuries.
 Ensure all circuits are de-energized and locked out before working on existing conduits or wiring.
 Use insulated tools when working near live equipment or conductors.
 Verify absence of embedded electrical services or utilities before chase cutting or drilling into walls/slabs.
 Follow safety protocols for working at height when installing ceiling conduits or overhead wiring.
 Implement proper barricading and signage during underground conduit installation to warn others.
 Keep a well-stocked first aid kit accessible at the work site for immediate minor injury treatment.

      