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RDSO SPECIFICATION
OF
PERMANENTLY LUBRICATED HDPE DUCT

SPECIFICATION NO. RDSO/SPN/TC/45/2006

Revision 1.0

Number of Pages : 20

TELECOM DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW-226011

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DOCUMENT DATA SHEET

Specification Revision

RDSO/SPN/TC/65/2006 1.0
Title of Document

RDSO Specification of Permanently

Lubricated HDPE Duct

 Author 

Shri Anil Kumar Mishra

Director/ Telecom-II/ RDSO

 Approved by

Shri M. Alam

Executive Director/ Telecom/ RDSO

 Abstract

This document specifies technical specification of Permanently Lubricated

HDPE Duct.

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I. SUMMARY

This document covers the requirement of permanently lubricated high density

polythene duct (PLB-HDPE Duct) for use as underground cable conduits for 
armoured optical fibre cable.

II. SOURCE

Draft specification RDSO/ SPN/ 35-2002 has been prepared by RDSO,

Lucknow as per Railway Board letter no. 2000/ Tele/ TC/ 3/ Vol. II dated
21/02/2002 (excluding pin point requirement) and minutes of 3 rd MSG meeting
No. STT/G/MSG/89 dated 27/03/2002.

III. FOREWORD

Research Designs and Standards Organisation (RDSO) is an attached office

of Ministry of Railways, engaged in design and standardization of equipment
for use on Indian Railways.

RDSO/ SPN specification is issued as draft specification for discussion. This

specification is circulated to customers/ Railways and field inspection units for 
comments.

RDSO/ SPN along with comments received from various quarters is

discussed in Telecom Standards Committee Meeting (TCSC).
Recommendation made by TCSC is put up to Railway Board for approval.
 After approval from Railway Board, the specification is given an IRS number 
and issued as Indian Railway Standard Specification.

In the absence of IRS specification, procurement may be made as per RDSO/

SPN specification.

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TABLE OF CONTENTS

Sr. No. Item Page No.

1.0 Scope 6

2.0 Reference 6

3.0 Abbreviations 6

4.0 General Requirement 6

5.0 Technical Requirement 8

6.0 PLB HDPE-DUCT Accessories 10

7.0 Packing Requirement 11

8.0 Type tests 11

9.0 Acceptance tests 12

10.0 Inspection 12

11.0 Warranty 13

12.0 Rejection 13

13.0 Ordering Information 13

 Annexure - A 15
 Annexure - B 15
 Annexure - C 15
 Annexure - D 15
 Annexure - E 15
 Annexure - F 16
 Annexure - G 17
 Annexure - H 17
 Annexure - I 17
 Annexure - J 18
 Annexure - K 19

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1.0 SCOPE :

This document covers the requirement of Permanently Lubricated High

Density Polyethylene (PLB-HDPE duct) duct for use as underground cable
conduits for armoured optical fibre cable. It is suitable for cable installation by
blowing technique or by direct underground burial.

2.0 REFERENCES

In preparing this standard assistance has been taken from the following :

(i) DOT Specification No. G/CDS – 08/ 01 DEC. 99

(ii) IS specification No. IS 4984, 7328, 9938, 12235(Part-9)
(iii) ASTM - D – 1693, D – 1238, D-1603, D – 3895, D – 2240, 121505, 638.

3.0 ABBREVIATIONS

•  ASTM ---- American Society for Testing & Materials.

• CC ---- Cubic Centimeter.
• HDPE ---- High Density Polyethylene.
• PLB ---- Permanently Lubricated
• UV ---- Ultra Violet.
• MFI ---- Melt Flow Index.
• MFR ---- Melt flow Rate.
• SPN ---- Specification Provisional Number.
• IS ---- Indian Standard.

4.0 GENERAL REQUIREMENTS:

The PLB-HDPE duct shall consist of two concentric layers. The HDPE outer 
layer shall be co extruded with an inner layer of solid permanent lubricant to
reduce the internal co-efficient of friction (ICF). The lubricant shall be of a
solid layer of uniform thickness so formulated to provide a permanent, low
friction boundary layer between the inner surface of the duct and armoured
optical fibre cable.

4.1 Outer Layer:

The base HDPE resin used for the outer layer of the permanent lubricated
HDPE Duct shall confirm to IS 7328 or to its equivalent.

4.2 Inner Layer:

The inner layer of solid permanent lubricant shall be continuous all through
and shall not come out during storage, usage and through out the life of duct.

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The inner lubrication material shall be of friction reducing polymeric material,

which shall be integral with HDPE layer. The lubricant material shall have no
toxic or dermatic hazards for safe handling. In the finished permanent
lubricated HDPE duct, the co-extruded inner layer of solid permanent
lubricant shall be integral part with HDPE and shall be white in colour and
clearly visible in cross-section of duct.

4.3 Requirements of Raw Materials used for the Duct:

4.3.1 The anti-oxidants used shall be physiologically harmless.

4.3.2 None of the additives shall be used separately or together in quantities as to

impair long term physical and chemical properties of the duct.

4.3.3 Single pass rework material of the same composition produced from the
manufacturer’s own production shall be used and it shall not exceed 10% in
any case.

4.3.4 The raw material used for extrusion shall be dried to bring the moisture
content to less than 0.1%.

4.3.5 Suitable UV stabilisers shall be used for manufacture of the duct to protect
against UV degradation, when stored in open for a minimum period of 8
months.

4.3.6 The raw material used in the manufacture of the duct shall be such that the
service life of the duct and all its accessories can be expected to be more
than 50 years including the life of permanent lubricant.

4.4 Service Condition:

The lubricated HDPE Duct shall be able to withstand the following

environmental conditions:

(a) Ambient temperature : 00C to +550 C (50% RH Max.)

over which Specifications
are guaranteed

(b) Storage temperature (-)200C to (+)650C. However 

temporary increase in
temperature +700C should
not result in any detoriation.

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5.0 TECHNICAL REQUIREMENT:

S.No. Parameter Specified Limit Test Method

A. APPEARANCE
1. Visual appearance Smooth inside & out side surface,
free of blisters, shrink, hole, flaking,
scratches & roughness.
2. Colour The colour of the duct shall be IS : 9938
orange/green and uniform
throughout.
The colour of the inner layer shall
be white.
3. Lubricated layer Must have inner lubricant layer  
clearly visible & white in colour ,
uniform in thickness.
4. Identification marking Permanently marked with indelible
ink
• Specification No.
RDSO/SPN/45/2006
• I.R. cable duct
• Laser symbol
• Manufacturer’s name
• Name of the duct with size
•
Serial number of the duct.
• Date of manufacture
• Sequential length marking at
every meter 
B. DIMENSION AND WEIGHT
1. Wall thickness 3.50 mm + 0.20 mm Annexure – A

2. Out side diameter 40.0 mm + 0.4 mm Annexure – A

3. Standard length 1000 + 100 meter --

4. Lubricated layer   Should be min. 10% of wall  Annexure – A

thickness thickness
5. Ovality test Difference of maximum & minimum IS 4984
diameter should be less than 1.3
mm
6. Weight per coil 385 gm/ meter +/- 5 gm --

C. CHEMICAL TESTS

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1. Melt flow index 0.2 to 1.1 gm/10 min  ASTM D 1238

at 1900C, 5 Kg load
2. Ash content 0.2% max. ASTM D 1603

3. Environmental Stress No cracking ASTM D 1693

cracking resistance  Annexure – B
ESCR
4. Oxidation Induction 30 minutes (minimum) ASTM D 3895
test
5. UV stabliser content Shall not be less than 0.05% Annexure – C

D. PHYSICAL TESTS
1. Hardness 60 Shore D (min) ASTM D 2240

2. Density 0.940 to 0.958 g/cc at 270C ASTM D 1505

3. Tensile strength at Min. 20 N/mm2 ASTM 638

speed of testing 100
+ 10 mm/ minute
4. Elongation at Break Min. 600% ASTM 638

5. Heat Reversion < 3% IS 4984

6. Crush Resistance Deflection not greater than 10% and  Annexure - D
test after recovery less than 2%
7. Impact strength No crack or split IS 12235 (Part
-9)

8. Coefficient of friction < 0.06 Annexure - E

9. Mandrel Test Mandrel should easily pass  Annexure - F

between one end to other 
10. Coil test No snaking or waving having zero  Annexure - G
coil set
11. Hydraulic  At 800 C minimum holding time 165 IS 4984
characteristics hrs  Annexure - H
Induced stress 3.5 Mpa
12. Optical Fibre Cable No visible damage Annexure - I
blowing test
13. Termite test No termite effect Annexure – J

E. TESTS ON PLB HDPE DUCT ACCESSORIES

1. Coupler Leakage The coupler jointing shall meet the
Test air pressure test of 15 Kg/ cm 2 for a --
minimum period of 2 hours.
2. Pull Strength of   The pull strength of the coupler   Annexure – K
coupler  shall not be less than 408 Kg.
3. Air Tightness Test of End Plug shall be tested with a

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9.0 ACCEPTANCE TESTS:

9.1 Lot size for acceptance test shall be restricted to 100 coils of standard length
per lot.

9.2 Sampling Plan:

Clause Percentage of lot to be inspected

5.0 (A) 100%

5.0 (B) 10%

5.0 [C (1,2,3,4)] 2 samples per lot

5.0 [D (1,2,3,4,5,6,7,8,9,10,11)] 2 samples per lot

5.0[E (1,2,3,4)] 2 samples per lot

7.0 and 13.0 10%

9.3 Dimensions as per clause 5.0 B shall be checked at both top & bottom ends.
Standard length shall be verified by unrolling and rolling the coil.

9.4 Chemical and physical tests as per clause 5.0 C & 5.0 D shall be carried out
on samples taken from both top and bottom ends of the coil.

9.5 Coils for testing purposes shall be randomly selected as per the sampling
plan.

9.6 Standard format for acceptance test as circulated by RDSO, Lucknow shall
be used.
 
10.0 INSPECTION:

10.1 All the gauges/ test & measuring instruments shall be under calibration
control at the time of inspection and proof to this office shall be produced.

10.2 Inspection and testing shall be carried out by the inspecting authority
nominated by the purchaser to ensure that all the requirements of this
specification are complied with for the acceptance of the materials offered by
the supplier for inspection.

10.3 The purchaser or his nominee shall have free access to the works of the
manufacturer and to be present at all reasonable times and shall be given

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facilities by the manufacturer to inspect the manufacturing of the duct at any

stage of manufacture. He shall have the right to reject whole or part of any
work or material that does not conform to the terms of this specification or any
other specification or requirement applicable and may order the same to be
removed/replaced or altered at the expense of the manufacturer. All
reasonable/complete facilities considered necessary by the inspecting
authorities for the inspection of the cables shall be supplied by the
manufacturer free of cost.

10.4 The manufacturer shall supply the duct samples and samples of the raw
materials free of charge as required by the inspecting authority and shall at
his own cost prepare and furnish the necessary test pieces and appliances for 
such testing as may be carried out at his own premises in accordance with
this specification. Failing the existence of facilities at his own premises for the
prescribed tests, the manufacturer shall bear the cost of carrying out the tests
in an approved laboratory, workshop or test house.

11.0 WARRANTY:

The manufacturer shall warrant the material covered by this specification to

be free from defects in design, material and workmanship under ordinary use
and service, his obligation under this warranty being limited to replace free of 
cost those parts which shall be found defective within one year after delivery
to the purchaser. This warranty shall not apply to any apparatus which shall
have been repaired or altered in any way by any one other than the
manufacturer thereof so as to affect, in manufacturer’s judgment, its proper 
functioning or reliability, or which has been subjected to misuse, negligence
or accident.

12.0 REJECTION:

In case the duct tested and inspected in accordance with this specification,
fail to pass the tests or comply with the requirement of the specification, the
whole consignment shall be rejected subject to the discretion of the purchaser 
or his nominee.

13.0 ORDERING INFORMATION:

13.1 Normally the duct will be supplied as per the standard dimensions and length
as mentioned in this document. However purchaser may specify his own
dimensions/ lengths/ packing requirements etc. In such cases necessary
tolerance shall also be specified by the purchaser.

13.2 Two nos. each of end plug, cable sealing plug and end cap shall be supplied
along with each coil. Purchaser may specify additional requirement.

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13.3 Adequate no. of plastic couplers (No. of couplers to make a continuous length
of the lot + 10% extra) shall be supplied along with each lot. Purchasers may
specify additional requirement.

13.4.1 One set of Duct cutter and C spanner shall be supplied along with each lot.
Purchaser may specify additional requirement.

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Annexure – A (Dimension of the Duct)

The wall thickness and the out side diameter shall be measured with the help
of a Vernier Caliper with a least count of .01 mm.

The lubricant layer thickness shall be measured with the help of a traveling
microscope with a least count of .01 mm.

Annexure – B ( Environmental Stress Cracking Resistance Test)

ESCR test shall be carried out as per ASTM D 1693. For type approval
testing the duration of the test shall be 1000 hours. For acceptance testing
the duration of the test shall be 96 hours.

Annexure – C (UV Stabliser Content Test)

Identification of UV additive shall be done by FTIR spectra, NMR spectra and

UV spectra. UV stabiliser content of finished duct shall not be less than
0.05%.

The test shall be carried out at: National Chemical Laboratory, Dr. Homi
Bhabha Road, Pune – 411008.

Annexure – D (Crush Resistance Test)

Sample of duct of 150 mm + 2 mm in length shall be subjected to a dead load

of not less than 50 Kg for one minute and shall be allowed to recover for 5
minutes. The deflection with load on and after recovery period shall not
exceed 10% and 2% respectively.

Annexure – E (Internal coefficient of friction Test)

Scope : This procedure details the method employed to determine

internal friction properties of the duct.

 Apparatus : Extensometer machine, circular test fixture of diameter 750 mm

(capable of having secured to it), 25 Kg weight, optical fibre
cable and pulley wheel.

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Method :

(a). A suitable length of the duct, pre-conditioned at 23 + 2 0C for 2 hours

shall be secured to the text fixture such that the sample completes a
4500 deg wrap, with one end extending vertically 200 mm towards the
floor.

(b). A suitable length of armoured optical fibre cable as per IRS : TC 55-
2006 shall be inserted into the sample.

(c). The extensometer and the test fixture shall be aligned and secured
from the movement.

(d). The 25 Kg tail weight shall be attached to the optical fibre cable
extending from the 200 mm vertical extension of the sample such that
there is a minimum free travel of 150 mm for the weight.

(e). The other end of the optical fibre cable shall be attached via a pulley,
to the extensometer such that the planes of travel are in no direction
diagonal and there shall be slack remaining in the optical fibre cable.

(f). The extensometer shall be operated, and the maximum load applied,
in lifting the 25 Kg weight to a minimum travel of 150 mm shall be
noted.

(g). Extensometer conditions

Load : Kg or Newtons
Speed : 500 mm/minute
Mode : Tension

The coefficient of friction shall be calculated by the following equation :

Internal coefficient of friction (ICF) = log e ( T1 / T2 )/ Q

Where T1 = pulling force.

T2 = 25 Kg
Q = Angle of subtending arc between T1 & T2 in radians
(i.e. 450 deg = 7.85398 Radians)

Annexure – F (Mandrel Test)

 A 150 mm long mandrel of diameter, 3 mm less than the internal diameter of 
the duct shall be passed through a 5 meter length of the duct, freely
throughout the length, when the duct is bent to a radius of 5 meters.

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Annexure – G (Coil Set)

The PLB HDPE duct shall unroll off the drums without snaking or waving
having zero coil set. Thus the duct shall lay straight into the trench without re-
coiling. For this purpose, when a minimum length of 50 meters duct taken
from the coil and laid on the ground, it shall be straight without any bends or 
kinks and without deformation, except 5 meters from each end.

Annexure – H (Hydraulic Characteristics)

The duct shall be tested for internal pressure creep rupture test as per IS –
4984. For this purpose, a sample length of 10 times the outside diameter of 
the duct shall be taken. At the end of the test, the sample shall not show signs
of localized swelling or leakage and shall not burst during the test duration.
The test showing failure within a distance equivalent to the length of end cap
from the end shall be disregarded and the test repeated. The test
temperatures and the duration of the test shall be as follows:

Test Test Temp. Test Duration (Hrs.) Induced stress

0
C (Min. holding time) (Mpa)

Type Test 80 165 3.5

 Acceptance Test 80 48 3.8

Annexure – I (Optical Fibre Cable Blowing Test)

For this test an Armoured Optical Fibre Cable as per IRS : TC 55-2006 shall
be installed by blowing of the cable in a length of 1 Km of the duct. The duct
shall be laid with bends in the horizontal and vertical planes and a rise in the
middle as detailed in the figure –1. The 1 Km section shall include two
couplings at suitable locations as shown in the figure.

The OFC shall then be blown out. It shall be inspected for any visual damage.
The OFC shall then be blown in again.

It shall be possible to blow in the Optical fibre Cable through the 1 Km duct,
each time in not more than 30 minutes. There shall be no visible damage to
OFC.

The test will be conducted on two samples out of the five submitted for Type
 Approval.

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Annexure – K (Pull strength of coupler)

2 Duct samples, each 30 cms. long, are jointed with the help of the Coupler,
under test. The free ends of the 2 ducts are fitted to the two suitable grips of a
tensile testing machine. The joint is then pulled apart with the help of the
tensile testing machine at a speed 12.5 + 0.5 mm/ min. Maximum force
required to separate the joint is then measured and noted.

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