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Concrete Duct Bank Cost Estimate
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Concrete duct banks play a critical role in protecting underground utility conduits for electrical wiring, fiber optic systems, telecommunications, data infrastructure, and high-voltage transmission networks. They provide durability, thermal protection, load resistance, and long-term reliability for utility infrastructure—especially in areas with heavy construction activity, vehicle traffic, or environmental exposure. Whether part of a commercial build, government project, industrial facility upgrade, or new residential development, duct banks must be accurately estimated before construction begins.
A concrete duct bank cost estimate helps determine the number of conduits needed, trench dimensions, concrete volume, reinforcement requirements, and installation labor.
While some contractors begin planning with rough numbers like dollars per linear foot, real duct bank projects require deeper detail, including site conditions, conduit type, spacing, encasement thickness, and testing requirements. Underground work is costly to repair, so accurate estimates prevent overruns and schedule delays.
Estimate Florida Consulting prepares construction cost estimates for underground utility duct bank systems based on engineered plans, Florida pricing standards, and project-specific installation factors. This guide explains how duct bank estimating works, how pricing is calculated, and what drives cost differences across projects.
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What Is a Concrete Duct Bank?
A duct bank is a system of underground conduits encased in concrete to protect electrical and communication cables. Unlike direct burial conduit, duct banks provide:
- Impact protection
- Moisture and corrosion resistance
- Controlled thermal dissipation
- Protection from load pressure (vehicles, soil movement, equipment)
- Long-term structural reliability
Duct banks are commonly installed in:
- Data centers
- Hospitals
- Airports
- Universities
- Industrial facilities
- Government infrastructure
- Substations and utility expansions
- Smart-city broadband installations
The design varies based on conduit size, voltage rating, number of circuits, and depth of installation.
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Concrete Duct Bank Cost per Linear Foot (Florida Range)
Below is the average installed duct bank cost per linear foot based on common configurations.
Duct Bank Type | Installed Cost per Linear Foot |
2-way duct bank | $165 – $385 |
4-way duct bank | $330 – $660 |
6-way duct bank | $495 – $990 |
8-way duct bank | $660 – $1,320 |
12-way duct bank | $990 – $2,200+ |
These ranges include materials, labor, concrete encasement, spacers, and typical installation conditions. Complex sites, rock excavation, or traffic-rated designs push costs higher.
Material Cost Breakdown for Concrete Duct Banks
A complete duct bank system includes multiple material components beyond the concrete alone. Each part affects pricing, performance, and installation complexity. Material pricing varies depending on conduit type, spacing requirements, reinforcement level, and encasement depth.
Below is a Florida-based cost breakdown of the primary materials used in duct bank construction.
1. Conduit Material Costs
Conduit selection depends on voltage requirements, traffic loads, soil conditions, and utility engineering standards. The most commonly used materials include PVC Schedule 40/80, HDPE (high-density polyethylene), and fiberglass.
Conduit Type | Cost per Linear Foot |
PVC Schedule 40 | $2.20 – $5.50 |
PVC Schedule 80 | $4.40 – $12.10 |
HDPE Smoothwall | $3.85 – $11.00 |
Fiberglass / Non-metallic Conduit | $8.80 – $27.50 |
PVC Schedule 80 is often required near structural load paths or traffic-rated zones where added durability is needed.
2. Spacers and Supports
Spacers ensure uniform conduit alignment and maintain separation distances required by engineers and code standards.
Material | Cost per Linear Foot |
Plastic/Polymeric Duct Spacers | $1.65 – $6.60 |
Steel or Custom Spacers (Rare) | $5.50 – $13.20 |
Larger duct banks require multiple layers of spacers and ties for stability during concrete placement.
3. Concrete Encasement Cost
Concrete encasement protects conduits from physical damage, soil movement, moisture, and freeze-thaw cycles (minimal in Florida but required by specifications).
Concrete Type | Cost per Cubic Yard |
3,000 PSI Mix | $132 – $187 |
4,000 PSI (most common for duct banks) | $154 – $220 |
High-strength Thermal / Low-Shrink Mix | $176 – $265 |
Concrete is usually calculated per linear foot based on trench dimensions and required coverage.
Example:
A 4-way duct bank may require 0.10–0.25 cubic yards per linear foot, depending on encasement thickness.
4. Reinforcement Steel
Some duct bank installs require reinforcement depending on load requirements and depth.
Reinforcement Type | Cost Range |
Standard Tie Wire & Mesh | $0.55 – $1.65 per ft. |
Rebar (#3–#6 Grid) | $0.88 – $3.30 per ft. |
Structural Cage Systems | $5.50 – $19.80 per ft. |
Projects under streets, parking lots, or industrial equipment areas often require reinforced concrete duct encasement.
5. Pull Boxes, Vaults & Manholes
Duct banks require access points typically spaced between 200 ft – 500 ft, depending on code, cable type, and pulling tension requirements.
Component | Installed Cost |
Small Pull Box | $2,200 – $6,600 |
Standard Utility Vault | $8,800 – $22,000 |
Traffic-Rated Manhole (DOT-Approved) | $22,000 – $55,000+ |
These structures significantly influence total project cost, especially on long duct runs.
Material Summary Estimate per Linear Foot
Duct Bank Size | Material Cost per Linear Foot |
2-way | $66 – $165 |
4-way | $132 – $330 |
6-way | $198 – $495 |
12-way | $385 – $1,100+ |
Labor, equipment, permitting, and restoration are separate cost categories covered in the next sections.
Labor Costs for Concrete Duct Bank Installation
Labor is one of the largest cost components in a duct bank installation because the work involves excavation, trench preparation, conduit alignment, reinforcement placement, inspections, concrete encasement, and final restoration. Labor requirements vary greatly based on project scale, installation environment, soil type, and depth specifications.
Florida labor pricing reflects underground utility work performed by licensed crews with experience in electrical and telecom infrastructure.
Average Labor Cost per Linear Foot
Duct Bank Size | Labor Cost per Linear Foot |
2-way | $110 – $275 |
4-way | $165 – $440 |
6-way | $220 – $660 |
12-way | $440 – $1,100+ |
These ranges assume normal digging conditions and standard installation practices.
Key Labor Activities Included
A typical duct bank installation requires several sequential operations:
- Surveying & Utility Location (811 compliance)
- Excavation & trenching
- Base preparation & leveling
- Spacer and conduit placement
- Rebar installation (if required)
- Inspection before concrete pour
- Concrete placement (direct or pumped)
- Backfilling and compaction
- Site restoration (pavement, sod, gravel, asphalt)
Any disruption or failed inspection may increase labor cost.
Excavation & Trenching Costs
Excavation cost depends on trench depth, width, soil hardness, and obstructions such as existing utilities or rock layers.
Condition | Cost per Linear Foot |
Standard soil | $22 – $66 |
Clay or compacted fill | $55 – $110 |
Urban utility corridor | $110 – $275 |
Rock trenching or hydro-excavation | $165 – $440+ |
Urban areas—especially downtowns, campuses, and industrial parks—usually have higher excavation difficulty and cost.
Concrete Placement & Pumping Labor
Some duct banks require direct chute placement, while others need a pump truck due to site access.
Placement Method | Additional Labor Cost |
Direct pour (easy access) | Minimal additional cost |
Line pump | $330 – $880 |
Boom pump (congested or deep trenches) | $660 – $2,200 |
Pump trucks are more common in large duct bank installations.
Backfill & Compaction Cost
Once encased and approved, the duct bank requires backfill and compaction to protect conduits and prevent settlement.
Backfill Type | Cost per Linear Foot |
Native soil reuse | $5.50 – $22 |
Sand or bedding mix | $11 – $44 |
Flowable fill | $22 – $66 |
Compaction testing (density testing) may also be required depending on engineering specs.
Restoration Costs
Restoration depends on what was disturbed during installation:
Surface Type | Cost per sq.ft. |
Soil / Soft landscaping | $1.10 – $4.40 |
Gravel or crushed base | $2.20 – $6.60 |
Asphalt patching | $8.25 – $19.80 |
Concrete sidewalk repair | $15.40 – $38.50 |
Roadway restoration (DOT-approved) | $27.50 – $82.50+ |
Restoration costs are often a hidden budgeting factor in duct bank projects.
Total Installed Cost per Linear Foot (Material + Labor)
Duct Bank Configuration | Fully Installed Cost |
2-way | $275 – $660 |
4-way | $495 – $1,210 |
6-way | $715 – $1,760 |
12-way | $1,430 – $3,300+ |
Actual pricing depends on site conditions, engineering requirements, and project scale.
Once encased and approved, the duct bank requires backfill and compaction to protect conduits and prevent settlement.
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Concrete Duct Bank Cost Examples (Florida Project Scenarios)
Concrete duct bank pricing can vary widely depending on the number of conduits, trench length, required vaults, traffic load rating, and installation environment. The examples below help illustrate realistic project budgets based on actual configurations used in Florida utility work.
2-Way Duct Bank (50–150 Linear Feet)
Typical use: Short campus connections, EV charger feed, garage supply lines, or small telecom extensions.
Cost Component | Estimated Range |
Materials (conduit, spacers, concrete) | $3,300 – $9,900 |
Excavation & Labor | $5,500 – $16,500 |
Pump Truck or Delivery | $330 – $880 |
Backfill & Surface Restoration | $1,100 – $3,300 |
Optional Pull Box or Vault | $2,200 – $8,800 |
Estimated Total Project Cost:
👉 $12,000 – $38,500+
This cost varies depending on depth, soil, and whether the duct bank crosses traffic paths.
4-Way or 6-Way Duct Bank (200–500 Linear Feet)
Typical use: Data centers, schools, hospitals, substations, and industrial upgrades.
Cost Component | Estimated Range |
Materials | $22,000 – $82,500 |
Labor & Installation | $33,000 – $154,000 |
Pump Truck & Delivery Logistics | $880 – $4,400 |
Vaults or Manholes (1–2 units) | $8,800 – $55,000 |
Traffic-Rated Restoration | $5,500 – $33,000 |
Estimated Total Project Cost:
👉 $55,000 – $330,000+
Engineered projects requiring testing, as-built documentation, and inspection approvals may increase cost.
8-Way to 12-Way Duct Bank (500–2,000 Linear Feet)
Typical use: airports, military bases, municipal upgrades, utility corridors, and major commercial developments.
Cost Component | Estimated Range |
Materials | $110,000 – $660,000 |
Labor | $165,000 – $990,000+ |
Concrete Pumping & Delivery | $2,200 – $22,000 |
Manholes / Traffic-Rated Vaults | $22,000 – $165,000+ |
Restoration & DOT Requirements | $27,500 – $165,000+ |
Estimated Total Project Cost:
👉 $330,000 – $2,200,000+
Large-scale duct banks require precise estimating to avoid costly overruns, scheduling delays, or rework.
Maintenance, Lifespan & Long-Term Cost Considerations
Concrete duct banks are designed to last decades, providing long-term protection for underground utility conduits. With proper installation and compliance with engineering standards, duct banks can often outlast surface paving, site infrastructure, and sometimes even the facility they support. However, maintenance planning and long-term considerations help ensure reliability and prevent expensive repairs.
Expected Lifespan of Concrete Duct Banks
Duct Bank Type | Expected Lifespan |
Basic PVC-only duct bank (minimal encasement) | 25–40 years |
Standard engineered concrete duct bank | 50–75 years |
Reinforced or traffic-rated duct bank | 75–100+ years |
High-voltage or fiber utility-grade network | 100+ years with upgrades |
Many failures occur not from concrete degradation, but from:
- Failed pulling tension limits
- Improper alignment
- Moisture infiltration
- Crushed conduit sections due to insufficient concrete cover
- Soil movement or settlement under traffic areas
Proper estimating and planning help prevent these long-term risks.
Maintenance Requirements
Concrete duct banks require very little maintenance once installed. Most inspections occur at pull points, vaults, or manholes—not along the encased conduit lines.
Routine maintenance includes:
- Inspecting manholes and pull boxes for water intrusion
- Checking for stress cracks or vault surface damage
- Cleaning sediment from vaults or drainage systems
- Monitoring cable strain relief fittings
- Ensuring unused conduits remain capped and dry
Systems supporting fiber optic communication or high-voltage utility lines may require periodic thermal monitoring.
Repair Costs
Repairs to duct banks can be expensive, especially if installed under pavement, concrete slabs, or highly developed sites.
Repair Scenario | Cost Impact |
Minor vault or access repair | $2,200 – $11,000 |
Partial trench exposure & conduit repair | $11,000 – $55,000+ |
Full traffic-rated reconstruct section | $55,000 – $165,000+ |
Emergency repair (night/weekend) | Costs may double |
Repairs often cost much more than initial construction—making accurate installation and estimating essential.
Future-Proofing and Expansion Planning
When designing duct banks, many owners install:
- Spare conduits (“empty ducts”)
- Future-proof space for additional data capacity
- Pull strings or mule tape for easier future cable installation
- Thermal spacers for high-voltage growth potential
Adding future provisions during initial construction is significantly less expensive than ordering trench expansion later.
Replacement vs Upgrade Considerations
Most duct banks are not replaced when cables fail—they are simply re-pulled or upgraded with new conduit inserts. Replacement is generally only required when:
- The encasement was improperly installed
- Conduits collapse
- Infrastructure routing changes
- New loads exceed thermal ratings
Planning and estimating correctly during original design minimizes future disruption.
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Final Summary
Concrete duct banks are critical infrastructure components used to protect buried electrical and communication cables. Because they require precise trenching, conduit spacing, reinforcement, concrete encasement, and inspection, estimating these systems accurately is essential before installation begins.
Concrete duct bank costs vary widely depending on conduit count, excavation difficulty, restoration requirements, concrete thickness, testing, and compliance with Florida construction standards. While online calculators provide basic material estimates, real projects require detailed estimating to avoid costly overruns, redesigns, and delays — especially on engineered, utility, commercial, industrial, or public-sector projects.
Estimate Florida Consulting provides detailed, Florida-based concrete duct bank cost estimates for contractors, engineers, developers, municipalities, and utility providers. These estimates help teams plan budgets accurately, compare bids, and ensure the project is fully scoped before breaking ground.
Question Answer
Frequently Asked Question
The cost depends on the number of conduits, depth, soil conditions, and installation environment. In Florida, the average installed cost is:
👉 $275 to $3,300+ per linear foot
Smaller 2-way banks cost much less than large 12-way or traffic-rated systems.
A complete estimate typically includes:
- Conduit type and quantity
- Concrete encasement volume
- Trenching and excavation
- Labor and crew hours
- Reinforcement steel
- Spacers and supports
- Pump truck or delivery equipment
- Backfill and site restoration
- Vaults and pull boxes (if required)
Professional estimating ensures nothing is overlooked.
Yes — almost every duct bank installation requires permits, especially if crossing:
- Roadways
- Right-of-way zones
- Utility corridors
- Municipal or state property
Engineering approval is often mandatory.
Depth depends on utility type and jurisdiction. Most duct banks are installed:
👉 24” to 60” below finished grade,
but deeper installations may be required for public roads or high-voltage lines.
Most duct banks use:
- 3,000–5,000 PSI concrete
- Low-shrink or thermal-rated mix (for high-voltage)
Engineered specs determine the exact PSI and mix requirements.
Timelines vary by scope:
Project Size | Typical Timeline |
Small duct bank (<150 ft) | 3–7 days |
Medium (200–500 ft) | 2–4 weeks |
Large multi-vault system | 1–6 months+ |
Permits, weather, and traffic control impact scheduling.
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02
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