Beatrice Lang
Electrical conduits are tubes that protect and route electrical wires, and pulling wires through them can be a complex process. It is a fundamental skill for electricians and those installing wiring systems. There are several methods for pulling wires through a conduit, with the most suitable method depending on the length and difficulty of the conduit run. For example, shorter conduit runs are generally easier to pull than longer runs, and bends and turns can increase friction, making pulling more difficult. Some common tools used to pull wires through a conduit include a wire mouse, fish tape, string, and conduit rodders. Lubricants can also be used to reduce friction and make pulling wires through a conduit easier.
| Characteristics | Values |
|---|---|
| Electrical conduit | A tube that protects and routes multiple electrical wires throughout a house or building, keeping them together and encased |
| Conduit material | PVC |
| Conduit size | 1", 1.5", 2", 3/4" |
| Cable type | Teck cable, Romex, non-metallic cable, UF-B 10-2 cable, THHN, THWN |
| Cable size | 10-2 wire cable (3 wires) |
| Tools | Fish tape, wire mouse, string, fishing weight, shop vac, conduit rodders, mule tape, steel fish tape, fiberglass fish tape, bag and vacuum |
| Lubricant | Wire-pulling lubricants (gel, liquid, foam, wax), dish soap, petroleum jelly, talc powder, cable lube |
| Cable installation | Pulling the cable through the conduit, attaching the cable to a pulling rope or string, using electrical tape or a wire-pulling grip for a tight connection |
| Bends in conduit | No 90-degree bends, use 45-degree bends, slow bends |
| Outdoor installation | Use outdoor-rated, direct-burial rated cable to prevent moisture damage |
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What You'll Learn
Using a lubricant
When pulling electrical cable through a conduit, using a lubricant can make the process easier and faster. Cable-pulling lubricants, also known as wire-pulling compounds, are designed to reduce the friction of a cable while it is being pulled into a conduit. This reduction in friction lowers the force required to pull the cable, thereby reducing tension on the cable and lowering the risk of damage.
Lubrication is particularly useful for longer pulls, pulls with a greater total bend angle, or pulls with heavy cable. It can also be beneficial when navigating sharp bends and long runs within a conduit. However, for shorter, straight pulls with lightweight cable, lubrication may not be necessary. It is important to consider the type of lubricant used, as some products can damage wire insulation, dry out quickly, or create a mess. For example, while water can be used as a lubricant for exterior conduits, soapy products should be avoided as they may have a deteriorating effect on the wire insulation over time.
Wax-based lubricants are common and suitable for electrical wires, but they should not be used on communications cables. Polymer and silicone-based lubricants are also available and come in various forms, such as thick gel, paste, thinner gel, and liquid formulas. Liquid lubricants work well for underground pulls but are not suitable for overhead conduits due to gravity. When using a lubricant, it is important to ensure compatibility with the type of cable and conduit being used.
To use a lubricant effectively, it can be applied directly to the wire as it is fed into the conduit. For underground pulls, a liquid lubricant can be poured into a feeder tube or upturned duct. In some cases, water can be used to push the lubricant through the conduit, ensuring it reaches the desired areas. It is important to consider the cable-lubricant manufacturer's coefficient-of-friction value, which indicates how slippery the lubricant is.
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The 'fish tape' method
Fish tape, also known as mule tape, is a tool used by electricians to pull electrical wires through conduits. It is a long, stiff, flat steel wire that comes in a round, plastic casing. The tape is fed into the conduit and then pulled back through with the electrical wire attached. Here is a step-by-step guide on how to use the fish tape method to run electrical cable through a conduit:
Firstly, prepare the electrical wire by ripping the sheathing from the cable to expose several inches of wire. Then, strip the plastic casing from the ends of the wires to expose the copper wire. Twist the wires together, leaving one wire loose at the end. This wire will be attached to the fish tape.
Next, feed the fish tape into the conduit. If you are working in an attic or basement, you may need to drill a hole and insert the fish tape through the hole. Push the fish tape forward, feeding it through the conduit until a foot or two of the tape is exposed at the other end.
Once the fish tape is in place, attach the loose wire to the end of the tape. Bend the wire to form a complete loop and tamp down the wires tightly so that the bundle is smooth. Then, wrap the wires and the tape with electrical tape.
Now, it's time to pull the fish tape back through the conduit. Work slowly and patiently, and if possible, have an assistant at the other end to help unspool the electrical cable and relieve tension. As you pull the fish tape back, the electrical wire will be pulled through the conduit along with it.
Finally, once the electrical wire is in place, remove the fish tape by unwrapping the tape and untwisting the wires. Apply wire-pulling lubricant to the wire to reduce friction and make it easier to pull through the conduit.
The fish tape method is a useful technique for running electrical cable through conduits, especially in areas with limited access. It is important to take safety precautions when working with electrical wiring, such as wearing safety glasses and turning off electric circuits in the area.
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The 'string' method
The string method is a simple technique for pulling electrical wire through a conduit and is best used with short, straight conduits. It requires a strong string (called a pull string) and a long, thin, rigid rod.
First, tie the string securely to the rod. Then, push the rod into the conduit with the tied end going in first. The loose end of the string should remain at the conduit's start. Once the tied end emerges from the other end of the conduit, tie the electrical wire to the loose end of the string. Now, pull the rod out of the conduit, and the electrical wire will be pulled through to the end.
This method can be adapted for use with a partner. In this case, a pull string is tied to the loop on the wire running through a wire mouse. The mouse is inserted at the start of the conduit, followed by the string. At the opposite end, a shop vac is attached, and the vacuum is turned on when the mouse is sucked out at the end. The mouse is then removed, and the string is untied from the wire loop. One person feeds the wires straight into the conduit, while the other uses the pull string to guide the wire.
The string method can also be used in conjunction with fish tape, which is a long, flat metal wire wound inside a wheel-shaped spool. Loops are created with the string around the end of the fish tape and attached with electrical tape. The fish tape is then fed into the conduit, and the wires are pulled through by the tape.
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The 'vacuum' method
Pulling electrical cable through a conduit can be challenging, especially if the conduit is old, dry, or has severe angles. A vacuum method can be used to overcome these issues. This method involves using a vacuum to pull a string or wire through the conduit, which can then be used to pull the electrical cable.
Firstly, unwind several feet of string or kite string and feed it into one end of the pipe or conduit. Tie a small ball of paper or a plastic bag to the end of the string for added surface area. On the opposite end of the pipe, attach the hose of a vacuum and create a seal. Turn on the vacuum to pull the string or bag through the conduit.
Once the string has been pulled through, it can be used to pull the electrical wire or cable. Tie the string to the wire with electrical tape and slowly pull the wire through the pipe. Alternatively, a reel of string can be attached to a plastic bag, which is then sucked through the conduit by the vacuum. The string can then be used to pull the cable.
The vacuum method can also be used in conjunction with other tools such as a conduit mouse or piston, which is a small cylinder of foam that is slightly smaller than the interior of the conduit. The string is tied to the conduit mouse, which is then inserted into the conduit. The vacuum is applied until the mouse is sucked to the end of the conduit. The string is then attached to the wire, and the wire is pulled through the conduit. This method is useful for conduits with twists and turns but may be limited by the length of the conduit.
It is important to note that pulling wires through conduits with bends and turns can be challenging due to increased friction. In such cases, it is recommended to use a lubricant on the wiring before feeding it into the conduit. Additionally, pulling wires through conduits can be difficult to do alone, and it is often best to enlist a helper.
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The 'conduit rodder' method
The conduit rodder method is a highly effective way of running electrical cable through long conduit runs. It is a specialised tool that can cover considerable distances without requiring intermediate access points. Its flexibility allows it to navigate through bends, curves, and obstacles in the conduit with ease. Here is a step-by-step guide on using the conduit rodder method:
Firstly, it is important to inspect the conduit for any potential obstacles that could damage the cable during the pulling process. Ensure the conduit is clear of any debris. Apply a pulling lubricant to reduce friction and make the process smoother.
Next, securely attach the end of the wire you wish to pull to the end of the duct rodder. Utilise a wire pulling grip or other suitable connectors to create a tight and secure connection. Now, insert the free end of the duct rodder into the conduit from the starting point of your choice.
Keep pushing the duct rodder through the conduit until it reaches the other end. Once it has reached the desired endpoint, trim any excess length and strip the wire ends. Finally, connect the cable to the appropriate electrical boxes, outlets, or termination points as required.
It is important to verify that all connections are secure and correctly terminated. Conduct the necessary tests to ensure that the electrical system functions as intended. Conduit rodders are a highly effective tool for long conduit runs, but for even longer and larger-diameter conduits, a vacuum or compressed air system can be employed for maximum efficiency.
The conduit rodder method is a versatile and efficient way to run electrical cable through conduits, making it a popular choice for electricians and installers.
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Frequently asked questions
You will need a wire mouse, fish tape, string, or fishing weight. You will also need a lubricant to help ease the wire through the conduit.
You should use a non-conductive wire-pulling lubricant. Avoid using dish soap, petroleum jelly, or talc powder.
There are several ways to do this. One way is to tie a strong string to a long, inflexible rod and attach the string to the wire. Then, use a shop vac to suck the wire through the conduit. Another way is to use a conduit rodder, which is a specialized tool for pulling cables through ducts.
It is recommended to use outdoor-rated, direct-burial rated cable for all outdoor and below-ground conduit installations. For interior conduits, sheathed cables are an alternative to insulated wiring but are not universally allowed, so be sure to check local laws and codes.
