Mixed-Size Power and Fiber Banks on One CNC Spacer Sheet

Data center duct sections often put large power conduits and smaller fiber or communications conduits on the same cross-section. Catalog chairs with a single hole size struggle there. A CNC-cut HDPE sheet does not. Blue Ridge Thermoforming (BRT USA) routes one board with multiple hole ODs and the engineer-specified spacing between power and communications rows.

One sheet, multiple ODs

Columns and rows follow the duct section, not a catalog grid. Hole diameter is matched to each conduit OD on the schedule. A single board can carry:

• Larger power conduits on upper rows
• Additional power or mixed sizes in middle rows
• Fiber and communications on a lower row, spaced from the power rows per the drawing

That layout is illustrative of how mixed banks appear on many packages. The actual pattern is whatever the stamped section shows. Thickness is typically 3/8 in or 1/2 in HDPE. Boards repeat along the run, typically every 4-7 ft.

Engineer-specified spacing

When power feeders and fiber share a bank, call out the center-to-center spacing the engineer wants between power and communications conduits. That gap is a design decision. It may reflect owner standards, separation preferences, or other project criteria. Put the number on the drawing or in the quote notes. BRT programs that spacing into the CNC toolpath.

What BRT will and will not decide

BRT will:

• Cut hole ODs to the conduits on the schedule
• Cut rows × columns and center-to-center spacing as drawn
• Add flow, rebar, and ground-wire holes when the print calls for them
• Ship repeating boards for long campus runs from Greenville, SC

BRT will not:

• Assign an EMI clearance for you
• Redesign the bank to fit a molded catalog module
• Invent dielectric or separation claims beyond fabricating the drawn geometry
• Call duct bank spacers thermoformed (they are CNC-routed HDPE sheet)

If the package separates power and fiber into different banks, that is fine too. Each bank gets its own board type. Mixed banks are optional, not required.

Quote inputs for mixed banks

A clean mixed-bank quote package usually includes:

• 1. Duct section showing every conduit OD and its position
• 2. Explicit center-to-center dimensions, including the power-to-fiber gap
• 3. Thickness preference (typically 3/8 in or 1/2 in HDPE)
• 4. Flow / rebar / ground requirements
• 5. Spacing interval along the run and approximate quantity
• 6. Ship-to jobsite or staging preference

Primary service, MV/HV feeders, generator ties, and fiber/comms banks can all use this same CNC approach. Generator ties especially often mix large power conduits with smaller control conduits on one sheet.

More vertical detail: data center duct bank spacers. General spacer specs: custom HDPE duct bank spacers. Hub for CNC plus thermoformed DC parts: custom plastic parts for data centers.

Prefab, thickness, and plant notes for mixed banks

Mixed-size boards are still flat HDPE sheet routed on 5-axis CNC in Greenville, SC. Typical thickness is 3/8 in or 1/2 in. Ask which virgin or reprocessed grade fits the print. Boards ship to the jobsite, with just-in-time and warehouse options when campus pours are staged.

Crews can prefabricate mixed arrays outside the trench the same way they prefabricate single-size banks: assemble on the surface using the CNC hole pattern, lower, then pour. Flow holes (when drawn) help concrete move through the sheet. Rebar and ground-wire holes appear only where specified.

ISO 9001:2015 covers the quality system at 184 Commerce Center, Greenville, SC 29615. Southeast corridor shipping includes SC, NC, GA, TN, and VA data-center work. For general spacer options beyond the mixed-bank angle, use the hub at custom HDPE duct bank spacers.

Bank types that often need mixed sheets

Generator ties frequently mix large power conduits with smaller control conduits. Primary service and feeder banks sometimes carry communications conduits on the same section. Fiber-only banks usually stay single-purpose, but when the civil package combines them, one CNC sheet can hold the combined grid. Hyperscale and AI campuses with long repeating runs benefit from locking that mixed pattern once and repeating the board every few feet along the trench.

FAQ

Can one board hold power and fiber?

Yes, when the drawing calls for a mixed bank. Tell us the center-to-center spacing between power and communications conduits. We cut that spacing; we do not assign an EMI clearance for you.

What if our fiber bank is separate from power?

Send separate sections. We will cut separate board types. Mixed sheets are only used when the drawing puts both on one cross-section.

Are mixed-size spacers molded or CNC-cut?

BRT mixed-size arrays are CNC-routed HDPE sheets cut from your schedule. They are not interlocking molded catalog chairs.

Data center duct bank spacers