Conduit is used in aircraft installations for the mechanical protection of wires and cables. It is available in metallic and nonmetallic materials and in both rigid and flexible form.

When selecting conduit size for a specific cable bundle application, it is common practice to allow for ease in maintenance and possible future circuit expansion by specifying the conduit inner diameter about 25 percent larger than the maximum diameter of the conductor bundle. The nominal diameter of a rigid metallic conduit is the outside diameter. Therefore, to obtain the inside diameter, subtract twice the tube wall thickness.


From the abrasion standpoint, the conductor is vulnerable at the ends of the conduit. Suitable fittings are affixed to conduit ends in such a manner that a smooth surface comes in contact with the conductor within the conduit. When fittings are not used, the conduit end should be flared to prevent wire insulation damage. The conduit is supported by clamps along the conduit run.

Many of the common conduit installation problems can be avoided by proper attention to the following details:

  1. Do not locate conduit where it can be used as a handhold or footstep.
  2. Provide drain holes at the lowest point in a conduit run. Drilling burrs should be carefully removed from the drain holes.
  3. Support the conduit to prevent chafing against the structure and to avoid stressing its end fittings.

Damaged conduit sections should be repaired to prevent injury to the wires or wire bundle. The minimum acceptable tube bend radii for rigid conduit as prescribed by the manufacturer’s instructions should be carefully followed. Kinked or wrinkled bends in a rigid conduit are normally not considered acceptable.

Flexible aluminum conduit is widely available in two types: bare flexible and rubber-covered conduit. Flexible brass conduit is normally used instead of flexible aluminum where it is necessary to minimize radio interference. Flexible conduit may be used where it is impractical to use rigid conduit, such as areas that have motion between conduit ends or where complex bends are necessary. Transparent adhesive tape is recommended when cutting flexible conduit with a hacksaw to minimize fraying of the braid.