SUBIC BAY COLLEGES (SBCI), INC.

#2&3 – 18th Street, West Bajac-Bajac, Olongapo City

Telefax: 047-6024327 Mobile: (+63) 920-9020591 Email: sbci_817@yahoo.com

COMPETENCY BASED LEARNING MATERIAL

Performing roughing-in activities, wiring and cabling works for single-phase distribution,
power, lighting and auxiliary systems

Types of Electrical Conduit

Intermediate metal conduit (IMC)

A steel threadable raceway of circular cross section designed for the physical protection and
routing of conductors and cables and for use an equipment grounding conductor when installed
with its integral or associated coupling and appropriate fittings. IMC conduit is coated with a hot
galvanized coating on the exterior and a special corrosive-resistant coating on the inside to
extend the conduit’s lifespan. Common conduit sizes range from 1/2 inch to 4 inches in
diameter. It is sold in 10-foot lengths, with or without threaded ends.

Rigid Metal Conduit (RMC)

A threadable raceway of circular cross section designed for the physical protection and routing
of conductors and cables and for use as an equipment grounding conductor when installed with
its integral or associated coupling and appropriate fittings. Steel RMC has the thickest-wall of
the steel raceways. It is available with either a straight-tapped or integral coupling. Galvanized
Steel RMC may have a primary coating of zinc on the exterior and interior of the conduit; a
combination of zinc and non-metallic coating are also permitted. Supplementary coatings can be
applied for additional corrosion protection.

Flexible Metal Conduit (FMC)

A raceway of circular cross section made of helically wound, formed, interlocked metal strip.
Flexible metal conduit (FMC) has a spiral construction that enables it to snake through walls and
other structures. FMC protects electrical wiring in commercial and industrial buildings.

Liquid tight Flexible Metal Conduit (LFMC)

A raceway of circular cross section having an outer liquid tight, nonmetallic, sunlight-resistant
jacket over an inner flexible metal core with associated couplings, connectors, and fittings for the
installation of electric conductors. Liquid tight flexible metal conduit (LFMC) is a special type of
FMC that has a plastic coating. When used with sealed fittings, it becomes watertight.

Rigid Polyvinyl Chloride Conduit (PVC)

A rigid nonmetallic raceway of circular cross section, with integral or associated couplings,
connectors, and fittings for the installation of electrical conductors and cables. is similar to
plastic plumbing pipe and is installed with plastic fittings that are glued in place. It can be bent
after being heated in a portable heater box. Because the conduit tubing and fittings are glued
together, the conduit assemblies can be watertight, making PVC suitable for direct burial in the
ground for many applications. It is also allowed in corrosive environments.

High Density Polyethylene Conduit (HDPE)

A nonmetallic raceway of circular cross section, with associated couplings, connectors, and
fittings for the installation of electrical conductors.
Nonmetallic Underground Conduit with Conductors (NUCC)

A factory assembly of conductors or cables inside a nonmetallic, smooth wall raceway with a
circular cross section.

Reinforced Thermosetting Resin Conduit (RTRC)

A rigid nonmetallic raceway of circular cross section, with integral or associated couplings,
connectors, and fittings for the installation of electrical conductors and cables.

Liquidtight Flexible Nonmetallic Conduit (LFNC)

A raceway of circular cross section of various types as follows:

1. A smooth seamless inner core and cover bonded together and having one or more
reinforcement layers between the core and covers, designated as Type LFNC-A
2. A smooth inner surface with integral reinforcement within the raceway wall, designated
as Type LFNC-B.
3. A corrugated internal and external surface without integral reinforcement within the
raceway wall, designated as LFNC-C

Electrical Metallic Tubing (EMT)

An unthreaded thinwall raceway of circular cross section designed for the physical protection
and routing of conductors and cables and for use as an equipment grounding conductor when
installed utilizing appropriate fittings. EMT is generally made of steel (ferrous) with protective
coatings or aluminum (nonferrous).
Flexible Metallic Tubing (FMT)

A raceway that is circular in cross section, flexible, metallic, and liquid tight without a nonmetallic
jacket.

Electrical Nonmetallic Tubing (ENT)

A nonmetallic, pliable, corrugated raceway of circular cross section with integral or associated
coup lings, connectors, and fittings for the installation of electrical conductors. ENT is composed
of a material that is resistant to moisture and chemical atmospheres and is flame retardant.
Proper uses and installation of conduits

Intermediate Metal Conduit (IMC) Installation

I. Uses Permitted
A. All Atmospheric Conditions and Occupancies. Use of IMC shall be permitted under
all atmospheric conditions and occupancies.
B. Corrosion Environments. IMC, elbows, couplings, and fittings shall be permitted to be
installed in concrete, in direct contact with the earth, or in areas subject to severe
corrosive influences where protected by corrosion protection and judged suitable for the
condition.
C. Cinder Fill. IMC shall be permitted to be installed in or under cinder fill where subject to
permanent moisture where protected on all sides by a layer of noncinder concrete not
less than 50 mm (2 in.) thick; where the conduit is not less than 450 mm (18 in.) under
the fill; or where protected by corrosion protection and judged suitable for the condition.
D. Wet Locations. All supports, bolts, straps, screws, and so forth, shall be of corrosion-
resistant materials or protected against corrosion by corrosion-resistant materials.
II. Securing and Supporting
A. Securely Fastened. IMC shall be secured in accordance with one of the following:
1) IMC shall be securely fastened within 900 mm (3 ft) of each outlet box, junction box,
device box, cabinet, conduit body, or other conduit termination.
2) Where structural members do not readily permit fastening within 900 mm (3 ft), fastening
shall be permitted to be increased to a distance of 1.5 m (5 ft).
3) Where approved, conduit shall not be required to be securely fastened within 900 mm (3
ft) of the service head for above-the-roof termination of a mast.

Minimum IMC fastening requirements.

B. Supports. IMC shall be supported in accordance with one of the following:

1) Conduit shall be supported at intervals not exceeding 3 m (10 ft).
2) The distance between supports for straight runs of conduit shall be permitted in
accordance with Table 1, provided the conduit is made up with threaded couplings and
such supports prevent transmission of stresses to termination where conduit is deflected
between supports.
3) Exposed vertical risers from industrial machinery or fixed equipment shall be permitted to
be supported at intervals not exceeding 6 m (20 ft) if the conduit is made up with
threaded couplings, the conduit is supported and securely fastened at the top and
bottom of the riser, and no other means of intermediate support is readily available.
4) Horizontal runs of IMC supported by openings through framing members at intervals not
exceeding 3 m (10 ft) and securely fastened within 900 mm (3 ft) of termination points
shall be permitted.
 An example of IMC supported by framing members and securely
fastened at the 3-foot distance from the box.

Table 1.: Supports for Rigid Metal Conduit

III. Couplings and Connectors

A) Thread-less. Thread-less couplings and connectors used with conduit shall be made
tight. Where buried in masonry or concrete, they shall be the concrete tight type. Where
installed in wet locations, they shall comply with 314.15. Thread-less couplings and
connectors shall not be used on threaded conduit ends unless listed for the purpose.
B) Running Threads. Running threads shall not be used on conduit for connection at
couplings.

IV. Bushings

Where a conduit enters a box, fitting, or other enclosure, a bushing shall be provided to
protect the wires from abrasion unless the box, fitting, or enclosure is designed to
provide such protection.
Rigid Metal Conduit (RMC) Installation

Uses Permitted

A. Atmospheric Conditions and Occupancies

  Galvanized St eel and Stainless-Steel RMC. Galvanized steel and stainless-steel RMC
shall be permitted under all atmospheric conditions and occupancies.
 Red Brass RMC. Red brass RMC shall be permitted to be installed for direct burial and
swimming pool applications.
 Aluminum RMC. Aluminum RMC shall be permitted to be installed where judged
suitable for the environment. Rigid aluminum conduit encased in concrete or in direct
contact with the earth shall be provided with approved supplementary corrosion
protection.
 Ferrous Raceways and Fittings. Ferrous raceways and fittings protected from
corrosion solely by enamel shall be permitted only indoors and in occupancies not
subject to severe corrosive influences.

B. Corrosive Environments
 Galvanized Steel, Stainless Steel, and Red Brass RMC, Elbows, Couplings, and
Fittings. Galvanized steel, stainless steel, and red brass RMC elbows, couplings, and
fittings shall be permitted to be installed in concrete, in direct contact with the earth, or in
areas subject to severe corrosive influences where protected by corrosion protection and
judged suitable for the condition.
 Supplementary Protection of Aluminum RMC. Aluminum RMC shall be provided with
ap proved supplementary corrosion protection where encased in concrete or in direct
contact with the earth.

C. Cinder Fill. Galvanized steel, stainless steel, and red brass RMC shall be permitted to be
installed in or under cinder fill where subject to permanent moisture where protected on all
sides by a layer of non-cinder concrete not less than 50 mm (2 in.) thick; where the conduit
is not less than 450 mm (18 in.) under the fill; or where protected by corrosion protection and
judged suitable for the condition.

D. Wet Locations. All supports, bolts, straps, screws, and so forth, shall be of corrosion-
resistant materials or protected against corrosion by corrosion-resistant materials.

Securing and Supporting

A. Securely Fastened. RMC shall be secured in accordance with one of the following:

 RMC shall be securely fastened within 900 mm (3 ft) of each outlet box, junction box,
device box, cabinet, conduit body, or other conduit termination.
 Fastening shall be permitted to be increased to a distance of 1.5 m (5 ft) where structural
members do not readily permit fastening within 900 mm (3 ft).
 Where approved, conduit shall not be required to be securely fastened within 900 mm (3
ft) of the service head for above-the-roof termination of a mast.

B. Supports. RMC shall be supported in accordance with one of the following:

 Conduit shall be supported at intervals not exceeding 3 m (10 ft).
  The distance between supports for straight runs of conduit shall be permitted in
accordance with Table 2, provided the conduit is made up with threaded couplings
and such supports prevent transmission of stresses to termination where conduit is
deflected between supports.
 Exposed vertical risers from industrial machinery or fixed equipment shall be
permitted to be supported at intervals not exceeding 6 m (20 ft) if the conduit is made
up with threaded couplings, the conduit is supported and securely fastened at the top
and bottom of the riser, and no other means of intermediate support is readily
available.
 Horizontal runs of RMC supported by openings through framing members at intervals
not exceeding 3 m (10 ft) and securely fastened within 900 mm (3 ft) of termination
points shall be permitted.

Flexible Metal Conduit (FMC) Installation

Uses Permitted

FMC shall be permitted to be used in exposed and concealed locations.

FMC 1⁄2 inch and larger may be installed in unlimited lengths, provided an EGC is installed with
the circuit conductors.

Uses Not Permitted

 FMC shall not be used in the following:

 In wet locations
 In hoist ways
 In storage battery rooms
 In any hazardous (classified) location except as permitted by other articles in this Code
 Where exposed to materials having a deteriorating effect on the installed conductors,
such as oil or gasoline
 Underground or embedded in poured concrete or aggregate
 Where subject to physical damage

Trimming

All cut ends shall be trimmed or otherwise finished to remove rough edges, except where fittings
that thread into the convolutions are used.

Securing and Supporting

FMC shall be securely fastened in place and supported in accordance with A and B.

A. Securely Fastened. FMC shall be securely fastened in place by an approved means

within 300 mm (12 in.) of each box, cabinet, conduit body, or other conduit termination
and shall be supported and secured at intervals not to exceed 1.4 m (41⁄2 ft).

Exception No. 1: Where FMC is fished between access points through concealed spaces
in finished buildings or structures and supporting is impracticable.

Exception No. 2: Where flexibility is necessary after installation, lengths from the last
point where the raceway is securely fastened shall not exceed the following:
 1) 900 mm (3 ft) for metric designators 16 through 35 (trade sizes ½ through
1¼)
2) 1200 mm (4 ft) for metric designators 41 through 53 (trade sizes 1½ through
2)
3) 1500 mm (5 ft) for metric designators 63 (trade size 2½) and larger

Exception No. 3: Lengths not exceeding 1.8 m (6 ft) from a luminaire terminal connection for tap
connections to luminaires

Exception No. 4: Lengths not exceeding 1.8 m (6 ft) from the last point where the raceway is
securely fastened for connections within an accessible ceiling to a luminaire(s) or other
equipment. For the purposes of this exception, listed flexible metal conduit fittings shall be
permitted as a means of support.

B. Supports. Horizontal runs of FMC supported by openings through framing members at

intervals not greater than 1.4 m (41⁄2 ft) and securely fastened within 300 mm (12 in.) of
termination points shall be permitted.

Grounding and Bonding

If used to connect equipment where flexibility is necessary to minimize the transmission of

vibration from equipment or to provide flexibility for equipment that requires movement after
installation, an equipment grounding conductor shall be installed.
Where flexibility is not required after installation, FMC shall be permitted to be used as an
equipment grounding conductor.

An example of acceptable and unacceptable

li ti f FMC ith t t
Rigid Polyvinyl Chloride (PVC) Installation

Uses Permitted
 Concealed. PVC conduit shall be permitted in walls, floors, and ceilings.
  Corrosive Influences. PVC conduit shall be permitted in locations subject to severe
corrosive influences as covered in (300.6 in NEC/3.0.1.6 in PEC) and where subject to
chemicals for which the materials are specifically approved.
 Cinders. PVC conduit shall be permitted in cinder fill.
 Wet Locations. PVC conduit shall be permitted in portions of dairies, laundries,
canneries, or other wet locations, and in locations where walls are frequently washed,
the entire conduit system, including boxes and fittings used therewith, shall be installed
and equipped so as to prevent water from entering the conduit. All supports, bolts,
straps, screws, and so forth, shall be of corrosion-resistant materials or be protected
against corrosion by approved corrosion-resistant materials.
 Dry and Damp Locations. PVC conduit shall be permitted for use in dry and damp
locations not prohibited by (352.12 in NEC/3.52.2.3 in PEC).
 Exposed. PVC conduit shall be permitted for exposed work. PVC conduit used exposed
in areas of physical damage shall be identified for the use.
 Underground Installations. For underground installations, PVC shall be permitted for
direct burial and underground encased in concrete.
 Support of Conduit Bodies. PVC conduit shall be permitted to support nonmetallic
conduit bodies not larger than the largest trade size of an entering raceway. These
conduit bodies shall not support luminaires or other equipment and shall not contain
devices other than splicing devices as permitted by (110.14(B) in NEC/1.10.1.14 in PEC
and 314.16(C)(2) in NEC / 3.14.2.2(C)(2) in PEC)
 Insulation Temperature Limitations. Conductors or cables rated at a temperature
higher than the listed temperature rating of PVC conduit shall be permitted to be installed
in PVC conduit, provided the conductors or cables are not operated at a temperature
higher than the listed temperature rating of the PVC conduit.

Use not Permitted

PVC conduit shall not be used under the conditions specified in (A) through (E).

 Hazardous (Classified) Locations. In any hazardous (classified) location, except as

permitted by other articles of this Code.
 Support of Luminaires. For the support of luminaires or other equipment
 Physical Damage. Where subject to physical damage unless identified for such use
 Ambient Temperatures. Where subject to ambient temperatures in excess of 50°C
(122°F) unless listed otherwise.
 Theaters and Similar Locations

Securing and Supporting

A. Securely Fastened. PVC conduit shall be securely fastened within 900 mm (3 ft) of
each outlet box, junction box, device box, conduit body, or other conduit termination.
Conduit listed for securing at other than 900 mm (3 ft) shall be permitted to be installed in
accordance with the listing.
B. Supports. PVC conduit shall be supported as required in Table 3. Conduit listed for
support at spacings other than as shown in Table 3 shall be permitted to be installed in
accordance with the listing. Horizontal runs of PVC conduit supported by openings
through framing members at intervals not exceeding those in Table 3 and securely
fastened within 900 mm (3 ft) of termination points shall be permitted.
Expansion Fittings

Expansion fittings for PVC conduit shall be provided to compensate for thermal expansion
and contraction where the length change, in accordance with Table 4, is expected to be 6
mm (1⁄4 in.) or greater in a straight run between securely mounted items such as boxes,
cabinets, elbows, or other conduit terminations.
TABLE 3. Support of Rigid Polyvinyl Chloride Conduit (PVC)

Grounding

Where equipment grounding is required, a separate equipment grounding conductor shall be

installed in the conduit.

Electrical Metallic Tubing (EMT) Installation

Uses Permitted

 Exposed and Concealed. The use of EMT shall be permitted for both exposed and
concealed work.
 Corrosion Protection. Ferrous or nonferrous EMT, elbows, couplings, and fittings shall
be permit ted to be installed in concrete, in direct contact with the earth, or in areas
subject to severe corrosive influences where protected by corrosion protection and
approved as suitable for the condition.
 Wet Locations. All supports, bolts, straps, screws, and so forth shall be of corrosion-
resistant materials or protected against corrosion by corrosion-resistant materials.

Uses Not Permitted

EMT shall not be used under the following conditions:

 Where, during installation or afterward, it will be subject to severe physical damage.

 Where protected from corrosion solely by enamel.
 In cinder concrete or cinder fill where subject to permanent moisture unless protected on
all sides by a layer of noncinder concrete at least 50 mm (2 in.) thick or unless the tubing
is at least 450 mm (18 in.) under the fill.
 In any hazardous (classified) location except as permitted by other articles in this Code.
 For the support of luminaires or other equipment except conduit bodies no larger than
the largest trade size of the tubing.
  Where practicable, dissimilar metals in contact anywhere in the system shall be avoided
to eliminate the possibility of galvanic action.

Exception: Aluminum fittings and enclosures shall be permitted to be used with steel EMT where
not subject to severe corrosive influences.

Reaming and Threading

 Reaming. All cut ends of EMT shall be reamed or otherwise finished to remove rough
edges.
 Threading. EM T shall not be threaded

Securing and Supporting

A. Securely Fastened. EMT shall be securely fastened in place at least every 3 m (10 ft).
In addition, each EMT run between termination points shall be securely fastened within
900 mm (3 ft) of each outlet box, junction box, device box, cabinet, conduit body, or other
tubing termination.

Exception No. 1: Fastening of unbroken lengths shall be permitted to be increased to a

distance of 1.5 m (5 ft) where structural members do not readily permit fastening within
900 mm (3 ft).

Exception No. 2: For concealed work in finished buildings or prefinished wall panels
where such securing is impracticable, unbroken lengths (without coupling) of EMT shall
be permitted to be fished.

B. Supports. Horizontal runs of EMT supported by openings through framing members at

intervals not greater than 3 m (10 ft) and securely fastened within 900 mm (3 ft) of
termination points shall be permitted.

Couplings and Connectors

Couplings and connectors used with EMT shall be made up tight. Where buried in
masonry or concrete, they shall be concrete tight type.

Minimum requirements for securely fastening EMT unless an exception applies.

An EMT installation in which the fastening spacing is increased to a maximum of 5 feet.

Techniques
installing and bending on conduits and fittings

Conduit Cutting and Threading

Cutting and threading steel RMC and IMC

Field threading is to be performed in accordance with the following procedures unless

manufacturer’s instructions differ. The operating and safety instructions should be read and
understood prior to operating the equipment.

 use a standard 3/4 inch per foot (1 in 16) taper National Pipe Thread (NPT) die. The
threads shall be cut full and clean using sharp dies.
 Do not use worn dies. Although ragged and torn threads or threads which are not cut
deep enough can be caused by poor threading practices.
 To adjust the dies, loosen the screws or locking collar that hold the cutting dies in the
head. When the screws or collar are loosened, the dies should move freely away from
the head.
 Screw the die head onto the threaded portion of a factory threaded nipple or factory-
threaded conduit until the die fits the factory thread. If the die head has an adjusting
lever, set the head to cut a slightly oversized thread.
 Tighten the screws or locking collar so that the dies are tightly held in the head.
 Remove the set-up piece of threaded conduit. The die is ready for use.
 After adjusting the dies as outlined above, proceed as follows:
 Cut the conduit with a saw or roll cutter. Be careful to make a straight cut.
 (See figure 1.)

Figure 1. Lower the roll cutter to the
desired length. Tighten the handle about
one quarterture per each revolution and
repeat until conduit is cut through
Figure 3: Insert the (flute) reamer into
work piece and rotate until burr is
removed
Figure 5: When proper thread length
is achieved the end of the conduit
becomes flush with the ends of the die
Figure 7: Threads should be checked
with an NPT-L1 threaded ring gauge to
ensure proper make up.
Figure 2. The roll cutter will leave a
burr on the inside diameter of the
conduit. The burr must be removed to
ensure that the wire insulation will not
be damaged during pulling.
Figure 4: A minimal amount of
pressure will remove the burr
completely and
eliminated possible flaring of the
conduit end.
Figure 6: Wire brush the threads to
remove any shavings or debris
Figure 8: A proper thread should be
free from chips or tears over the entire
length.
  NOTE: If the die is not started on the pipe squarely, crooked threads will result. When
using the wheel and roll cutter to cut pipe, the cutter must be revolved completely around
the pipe. Tighten the handle about one quarter turn after each rotation and repeat this
procedure until the pipe is cut through.)
 After cutting and prior to threading, ream the interior and remove sharp edges from the
exterior (See Figure 2, 3 and 4)
 (NOTE: Reaming the conduit after threading will stretch or flare the end of the conduit.)
 To start a universal die head, press it against the conduit end with one hand and turn the
stock with the other (see Figures 6 and 7). With a drop head die, the stock remains
stationary and the head rotates. After the dies have engaged for a thread or two, they will
feed along without pressure.
 Stop the cutting as soon as the die has taken hold and apply thread cutting oil freely to
the dies and the area to be threaded (see Figure 5).
 (NOTE: Frequent flooding of the dies with a good grade of cutting oil will further
safeguard against poor threads. The oil keeps the material lubricated and ensures a
smoother cut by reducing friction and heat. Insufficient cutting oil will also cause ragged
threads. The flow of the cutting fluid to the die head should be such that the cutting
surfaces of the die segments are flooded. As a general rule, there is no such thing as too
much oil at the die head.)
 Thread one thread short of the end of the chaser.
 Back the die head off and clean the chips from the thread (See Figure 6.)

Cutting EMT

Cut the EMT square using a hack saw or band saw. Do not use roll type tubing cutters.

(NOTE: Roll-type cutters require reaming which flares the wall of EMT, making fittings difficult to
install.)

A tool designed for the purpose is best for reaming the inside of EMT. Where side cutter pliers
or other general tools are used, take special care not to flare the ends.

Bending Guidelines

General information

 Read and understand all the bender manufacturers’ operating and safety instructions
before operating their equipment.
 It is extremely important that the bender, its components and accessories are matched to
the conduit type and size being bent because of the forces being applied. When using a
power bender, it is important that pins are in the proper pin holes for the conduit size.
 Although the National Electric Code allows up to 360 degrees between pulling points,
using as few bends as possible, and none exceeding 90 degrees, will make wire pulling
easier. The fewer total degrees between pulling points and the use of shallow bends
combine to reduce the strain created by pulling wire. For multi-conductor control cable
 and communications cable, it is recommended that runs be limited to two 90-degree
bends (a total of 180 degrees).
 Before placing the conduit in the bender, accurately measure and mark the conduit with
a thin line that goes completely around the conduit. This will assure the mark is visible if
the conduit needs to be rotated.
 The minimum radius shall comply with NEC, Chapter 9, Table 2.and the measurement
shall be made to the centreline of the bend. See EIA / TIA-569 Commercial Building
Standard for Telecommunications Pathways and Splices for guidance on bend radius for
conduit and tubing used with communication and optical fiber cables.

 Where hand benders do not have degree markings, degrees of bend shall be measured
to the inner edge of the conduit; the surface that fits in the groove.
 Where it is necessary to compensate for spring back, slightly over-bend.
 When using a hand bender, choose a solid, flat surface. Pin the conduit firmly to the
surface with steady foot pressure sufficient to keep the conduit and bender marks
aligned and the conduit nestled in the groove throughout the full arc of the bend.

Conduit Bending Basics:

Conduit come in two types, EMT and Rigid conduits and can be found in various sizes. Klein
Tools provides conduit benders for EMT in ½”, ¾”, 1” and 1-¼” conduit and ½”, ¾”, and 1” Rigid
conduit. To aid bending when performing a ground or air bend, the benders are marked with
different alignment symbols to help the operator create the bends necessary to accomplish any
project. The symbols found on the Klein Tools benders are the arrow, the teardrop, the star point
and angle markings. These markings are found on various sides of the bender head.
The 4 most common bends to know how to make are the 90° Stub-Up, Back to Back, Offset and
the 3 Point Saddle bends. It is common to use a combination of the bender markings when
making certain tube profiles. Knowing the proper technique and method of making the bends will
allow you to accomplish most projects efficiently.

Things to remember while bending:

 A proper bend is made by rolling the conduit about the bender in the conduit’s cradle
using all foot pressure.
 Use the correct size bender for the conduit size being bent.
 Some over bending may be required to allow for spring back of the conduit. The resting
condition of the conduit is to be at the final angle desired.
 Measure and properly mark your conduit using the tables and information provided.
 Floor bending: Make sure conduit is secure so it does not slide prior to bending. Apply
ample foot pressure to the benders heel while minimizing the use of the handle as a
lever but more of a guide.
 Air Bending: Make sure handle’s hilt is secure on ground and is reinforced by your foot
so it does not slide out. Make sure you are balanced and apply force close to the tool
and your body controlling the tubing as you bend it around the bender’s cradle making
sure the conduit does not slide in the bender head.
 To prevent injury, always wear protective gear and do not over exert.

90° Stub-Up Bend:

The stub-up bend is made by bending a piece of conduit into an L shape or 90° bend by placing
the free end (short end) of the tube to a predetermined length as indicated in the diagram below.
This is the most common bend and is a building block for other bends. Common uses for this
bend are: Running conduit into electrical boxes, running conduit up or down walls, running
conduit into walls through floors and ceilings and making inner and outer corner turns.

Determine the overall free end height of the conduit you want after the bend.
 1. From the overall free height, subtract the stub height listed in the Bender Take-Up Table
for the conduit size you are bending.
2. On the conduit, measure from the free end to be bent up the calculated number and
mark the conduit.

As an example, to bend 3/4” EMT conduit have a free end height of 8.5”, the table
indicates to subtract 6” from the 8.5” which leave 2.5” from the end to bend up to make
the mark.

3. Always use the proper size conduit bender for the conduit size being bent. The conduit
will not bend properly and/or will be damaged if a mismatch of bender and conduit size is
used. Place the bender onto the tubing with the hook pointed towards the free end to be
bent upwards. Make sure the conduit is resting properly in the bender’s hook and line-up
the arrow symbol with the mark you placed on the tubing.

4. Keeping the conduit flat, apply ample foot pressure to the bender’s heel minimizing the
use of the handle as a lever, rolling up the free end into the 90° position checking the
degree with a level. When done properly the free end will be at the desired height and
the arrow will be at the stub height as indicated.

Back to Back Bends:

The back to back bend is the next style of bend that is needed while running electrical conduit.
In reality the concept is formulated by the need to know the distance from the back edge of a
90° bend to a fixed point down the conduit to mark for other bend operations to meet the
installation requirement. As you will see it builds on the 90° stub bend and when done the most
common use of this bend will look like an elongated U. You will need to know this bend method
when you want to fit conduit between two parallel surfaces such as two walls or joists while
keeping the U’s outer edges of the legs touching the two surfaces. This allows for proper
anchoring and a nice clean appearance.

1. Determine the distance between the two parallel surfaces to get the dimension for back
to back bend.

2. The first bend for the back to back bend is the 90° stub-up bend. Follow the steps from
the 90° Stub - Up section to create the ideal bend for the connection on the first side.

3. From the back edge of the 90° stub-up bend, measure the distance found in step 1 and
make your mark on the conduit.
4. Place the bender on the conduit with the bender’s hook facing the free end of the tube to
be bent opposite the original bend side. Make sure the conduit is resting properly in the
bender’s cradle and line-up the Star Point Symbol with the mark you placed on the
tubing.
 Keeping the conduit flat, apply ample foot pressure to the bender’s heel, with minimal use of
the handle as a lever, rolling up the free end into the 90° position checking the degree with a
level. It is very important to keep the first 90° bend in the same plane as the new bend. If not
the two legs of the U will be skewed and will not produce the desired shape. If this happens,
some correcting can be done to properly align the legs depending on how out of shape they
are. When the bend is done properly the conduit will lay flat and will fit inside the two
surfaces measured. If the back to back distance is short (a tight U) so the bender has
problems fitting to make the second bend, you may compensate by subtracting the stub
height from the measured distance to fit the gap then follow step 3 to mark the calculated
number on the conduit. But this time you would put the bender on the conduit with the hook
facing the first bend and line up the Arrow Symbol as demonstrated in the Stub-Up section,
step 5, with the conduit mark and proceed to make the bend as in step 5 rolling up the
previously bent end up into the 90° position giving you the desired dimension.

Offset Bends

An offset bend is a style of bend that is built independently of the 90° stub and the Back to Back
bend and is an important bend to know when running conduit. It is common to shift the conduit a
certain distance while continuing to run parallel in the same direction as the pre-shift portion of
the conduit. There are many situations that call for an offset bend. The most common uses of
this bend are: staggered joists, running tight on a wall and offset into an electrical box and
changes in elevation.
 1. Determine/measure the offset distance necessary to clear the obstacle and how far away
the offset will need to be bent from the end of the conduit.
2. Decide what angle you wish to make the offset bend and determine the proper values
from the Offset Formula Table. Calculate the proper values to mark on the conduit to
clear the obstacle and fit in the gap measured.

As an example, the offset distance of the obstacle is 6” and the distance to obstacle is 20”. The
installation allows for a 45° X 45° offset bend. Note: The choice of degree is usually the
installer’s choice and most of the time the installation location will determine what degree will fit.

3. From the table use the 45° X 45° offset row for the values to calculate the series of
markings necessary to make the proper bend. To find out where to place the first mark
on the conduit, multiply the measured Offset Distance to clear the obstacle by the tables
Shrink/Inch that will occur to the conduit after all the bends are made due to that offset
distance or:

(Offset Distance) X (Shrink/Inch) = Total Shrink.

Example: 6” X .375 = 2.25” of total shrink.

This value is then added to the measured Distance to Obstacle number or:

(Distance to Obstacle) + (Total Shrink) = First Mark Distance.

Example: 20” + 2.25” = 22.25” to make first mark.

To calculate the second mark needed on the conduit, multiply the measured Offset Distance by
the Constant Multiplier of the table or:

(Offset Distance) X (Constant Multiplier) = Second Mark Distance (Distance between

Marks).
This calculated value is how far apart to make your marks from each other on the conduit and
where to make your 45° bends.

4. Using the technique to align the bender on the conduit as described under the Stub-Up
Section 5, Place the bender on the conduit with the hook facing away from the second
mark and line up the Arrow Symbol up with the first mark.

5. Keeping the conduit flat, apply ample foot pressure to the bender’s heel minimizing the
use of the handle as a lever, smoothly rolling up the free end until the 45° mark is
reached. When done properly the free end will be at a 45° angle from the original plane.

Note: Some over bending may be required to allow for spring back of the conduit. The resting
condition of the conduit is to be at the final angle desired.

6. Keeping the bender and conduit together flip the two parts upsides down and put the
bender’s handle hilt on the floor, balancing the conduit in the air, allow the conduit to rotate
180° in the cradle. Slide the conduit down so the first bend is moving away from the bender
head, aligning the second mark as outlined before using the Arrow Symbols (See Stub-Up
section, note 5).
7. The second bend of the offset is accomplished by performing an air-bend. Make sure the
handle hilt is secure on ground and is reinforced by your foot so it does not slide out. Make
sure you are balanced and apply force close to the tool and your body controlling the tubing
as you bend it around the bender’s cradle. Bend the free end until the 45° mark is reached. It
is very important to keep the first 45° bend in the same plane as the new bend will be. If not,
the two legs of the offset will be skewed and will not produce the desired shape. If this
happens, some correcting can be done to properly align the legs depending on how out of
shape they are. When the bend is done properly the conduit will lay flat and fit inside the
measured distance to and clear the obstacle.

Three Point Saddle Bend:

The three-point saddle bend is a variant of the offset bend since it is an offset bend that returns
to the original in-line run after clearing an obstacle. This bend is intended to bridge over
obstacles such as existing conduit or plumbing running perpendicular to the intended conduit
installation.

1. Determine/measure the offset distance necessary to clear the obstacle and how far away
the saddle bend will need to be from the edge of the conduit. Unlike the offset bend you
must measure to the center of the obstacle to bridge over.
2. Choose the angle that will be used for the center bend. The other two return bends will be
½ the center angle chosen. If the center angle is 45°, the two-return bends will be 22.5°.
Use the table to calculate the distance between bends and how much shrink is to occur to
the conduit due to the bends.
3. Calculate the value needed to place your first mark on the conduit. This number is
determined by the Measured Distance to Center Point of the obstacle plus the Shrink from
the 3 Point Saddle Bend Table that will occur.

(Measured Distance to Center Point) + (Shrink) = Center Mark

Example: 20” + 3/8” = 20-3/8”
 4. Using the Distance off Center Mark values found in the table to clear a 2” obstacle, simply
mark that distance from the center line in both directions or subtract this number from the
center
mark value for the first return bend mark and add that number to the center mark value to obtain
the second return bend mark distance.

(Center Mark) – (Distance off Center Mark) = 1st Return Bend Mark
Example: (20-3/8”) – 5” = 15-3/8”

(Center Mark) + (Distance off Center Mark) = 2nd Return Bend Mark
Example: (20-3/8”) + 5” = 25-3/8”

5. Mark the conduit accordingly.

6. Place the bender on the conduit and position the appropriate Center of Bend Rim Notch on the
enter mark in the orientation shown.

7. Keeping the conduit flat, apply ample foot pressure to the bender’s heel minimizing the use
of the handle as a lever, smoothly rolling up the free end until the 45° mark is reached.
 8. Keeping the bender and conduit together, flip the two parts upsides down and put the
bender’s handle hilt on the floor, balancing the conduit in the air, allow the conduit to rotate
180° in the cradle. Slide the conduit down so the first bend is moving away from the bender
head, aligning the 1st return bend mark with the Arrow Symbol (See Stub-Up section, note
5).
9. The second bend of the saddle bend is accomplished by performing an air-bend. Make sure

handle hilt is secure on ground and is reinforced by your foot so it does not slide out. Make
sure you are balanced and apply force close to the tool and your body controlling the tubing
as you bend it around the bender’s cradle. Bend the free end until the 22.5° mark is
reached.
10. Remove bender and place it back on the conduit on the other side of the center bend with the
hook facing the center bend as before aligning Arrow Symbol (See Stub-Up section, note 5).
On the 2nd return bend mark.
11. The last bend of the saddle bend is made again by performing an air bend. Make sure
handle hilt is secure on ground and is reinforced by your foot so it does not slide out. Make
sure you are balanced and apply force close to the tool and your body controlling the tubing
as you bend it around the bender’s cradle. Bend the free end until the 22.5° mark is
reached.

Fittings For use With Steel RMC, IMC, and EMT

Size and raceway type

Before installing a fitting or a raceway support, review the packaging labels containing
specific applications for which the fitting or raceway support is recommended and / or listed.
(NOTE: Do not take applications for granted. Many fitting designs look the same but may
contain subtle construction differences designed to enhance performance in particular
applications. Listed fittings contain required, informative markings and any specific conditions for
use. For specific selection and installation guidelines, consult NEMA FB2.10, “Selection and
Installation Guidelines for Fittings for Use with Nonflexible Metallic Conduit and Tubing”.)

Fittings and raceway support shall be used only with conduit of the trade size indicated
on the fitting or raceway support or its smallest unit shipping container.

Fittings for Special Applications

Threadless fittings intended for use in wet locations are marked “Wet locations” on the
fitting or its smallest unit shipping container. Fittings marked “Raintight” are suitable for use in
“Wet Locations”. “Wet Location” fittings are sometimes referred to as “Raintight”.

A Threadless fitting designed for use in wet locations that requires a gasket or sealing
ring installed between the fitting and a box shall be installed only with the specific component
marked on the fitting’s smallest unit shipping container.

(NOTE: “Wet Locations” or “Liquidtight” fittings are not necessarily suitable for use in
applications where submersion in water is expected. “Wet Locations” fittings are not necessarily
considered “Liquidtight. “Liquidtight” fittings are intended for use in typical wet locations and also
in “wet” industrial environments which may contain machine oils and coolants.)

RMC and IMC fittings for use in industrial applications involving sprayed mineral oils and
coolants are marked “Liquidtight” on the fitting or its smallest unit shipping container. Threadless
fittings intended for embedment in poured concrete are marked “Concrete-tight” or “Concrete-
tight when taped” or “Wet Locations” on the fitting’s smallest unit shipping container.

Installing fittings

Threadless fittings

Threadless fittings shall not be assembled to threaded RMC or IMC unless specifically
recommended by the fitting manufacturer. Where threadless fittings are to be assembled to steel
RMC, IMC and EMT, conduit ends shall:

a) have squarely cut ends, free of internal and external burrs, and circular form as provided
from the factory.
b) Be free from dirt or foreign matter on the surface of the conduit to be inserted into the
fitting, and
c) Have the ends of the conduit or tubing assembled flush against the fitting’s end stop.
Careful consideration shall be given to the torque applied to the fitting’s securement
means.

(NOTE: Listed fittings are tested under prescribed torque which represents normal, not
excessive force. Performance is not enhanced, and can be reduced, by over- torqueing the
fitting’s securement means.)

Set-screw type

The length of screws provided with set-screw type fittings varies. The appropriate torque
for some designs is reached when the head of the screw touches a screw boss on the fitting.
This cannot be universally relied upon, however. Screws on certain fitting designs, particularly
larger trade sizes, can offer more than one tightening option including screwdriver (Slot, Phillips,
or Robertson-square drive) and bolt head for wrench application (hex or square). Greater
mechanical advantage and torque can generally be achieved with a wrench. Where tightening
options for both screwdriver and wrench application are offered, torque should be limited to that
which can be applied by the screwdriver.
Compression (gland) type

Generally, most compression gland nuts achieve maximum securement after hand tightening
and then wrench tightening one or two additional turns.

Prior to embedment in poured concrete, all threadless fittings, including those marked
“Concrete-tight,” shall be taped adequately to prevent the entrance of concrete aggregate where
they will be embedded more than 24 inches or where the pour area will be subjected to a
concrete vibrator. Tape shall be applied after the fitting is assembled and secured to the conduit.

Threaded fittings

Threaded joints, both fitting to conduit and fitting to threaded integral box entries, shall be made
up wrench tight.

(NOTE: Avoid excessive force. Generally, a force equivalent to hand tight plus one full turn with
an appropriate tool is recommended. This should assure engagement of at least three full
threads.)

Conduit bodies generally have an integral bushing to provide a smooth surface for conductors
when pulled. This bushing is often mistaken for a conduit end stop. It is not necessary that the
conduit be inserted flush against this bushing to assure a secure joint.

Attachment to Boxes and Support

Prior to attachment to a box, enclosure or a thread-less coupling, RMC, IMC and EMT shall be
supported at intervals required by the NEC/PEC, using raceway supports intended for the
purpose and secured by hardware acceptable to the local jurisdiction.

Properly align the raceway, fittings, and knockouts to provide secure mechanical and electrical
connections. Allow sufficient conduit length to complete engagement of the conduit and fittings
at joints and entries.

Conduit bushings shall not be used to secure threaded RMC or IMC to a box or enclosure. A
locknut shall always be assembled between a conduit bushing and the inside of the box or
enclosure.

EMT connectors are permitted to be assembled into threaded entries of boxes, conduit bodies
or internally threaded fittings having tapered threads (NPT). EMT fittings designed to NEMA FB
1 “Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and Cable Assemblies,” have
straight threads (NPS). Threaded openings where these fittings are intended to be used are
permitted to have either tapered (NPT) or straight (NPS) threads. Care should be taken to
ensure that the threaded entry will accommodate a minimum of 3 full engaged threads of the
fitting.

I. Fire stopping and Fire Blocking

Steel RMC, IMC, and EMT do not require fire resistance ratings. Fire resistance ratings apply
only to assemblies in their entirety. Building codes consider steel conduit and tubing to be non-
combustible. Fire testing is not required by the UL standard to which these products are listed,
however, steel RMC, IMC and EMT have been exposed at UL to the ASTM E119 time
temperature curve for up to four hours in duration.

Penetration of fire-resistance-rated assemblies

The raceway installer shall determine if the walls, floors, or ceilings are fire-rated prior to
installing raceway systems. Penetration openings shall be properly filled for fire safety, using
approved materials. The NEC and building codes require that openings around raceways which
penetrate a fire-resistance-rated assembly be sealed to prevent the spread of fire and smoke
from one area migrating into another.

Penetration of non-fire-rated assemblies

In non-fire-rated assemblies, when non-combustible penetrating items such as steel conduit and
EMT connect not more than three stories, the space around the penetration must be filled with
an approved non-combustible material to resist the passage of flames and products of
combustion. This is called fire blocking If the penetrant connects not more than two stories, the
annular space filler does not have to be non-combustible, but it must be an approved material
that resists the page of flame the products of combustion.

Thermal protection of steel raceways

The NEC and local or state code requirements for fire protection of emergency systems and fire-
pump circuits be reviewed prior to installing these circuits. Local codes sometimes vary from the
NEC. Steel raceways withstand fire; however, ordinary conductor insulation melts when
exposed to elevated temperatures and a short circuit can be created. This is the reason for
special protection of emergency and fire-pump circuits. Methods of thermal protection include
putting the conduit / tubing in a fire-rated enclosure such as a chase (horizontal or vertical),
embedding in concrete, using a listed wrap system for protection from fire or using circuit
integrity cables within conduit as part of a listed Electrical Circuit Protective System.

(NOTE: Fire wraps can affect the temperature of the conductors and the need for ampacity de-
rating must be determined. It is also important to determine that the support system is protected
and will withstand the fire exposure.)

Corrosion Protection

Steel RMC, IMC and EMT are typically galvanized to provide excellent corrosion protection.
Sometimes supplementary corrosion protection is required if the installation is in a “severely
corrosive” environment. See Sections1 through 4 below for information on these types of
environments and recommended supplementary protection methods. Specifics on installing
steel conduit with a factory-applied PVC coating are contained in Section 6 of these Guidelines.

1. Installed in soil

Where installed in contact with soil, steel RMC and IMC do not generally require supplementary
corrosion protection unless.

a. Soil resistivity is less than 2000 ohm-centimeter or

b. Local experience has confirmed that the soil is extremely corrosive. The authority having
jurisdiction has the authority to determine the need for additional protection.

(NOTE: Soils producing severe corrosive effects have low electrical resistivity, expressed in ohm
centimeters. Local electric utilities commonly measure the resistivity of soils. The authority
having jurisdiction has the authority to determine the necessity for additional protection.)

2. Transition from concrete to soil

Where steel RMC, IMC, and EMT emerge from concrete into soil, it is recommended that
protection be provided a minimum of 4 inches on each side of the point where the raceway
emerges. In areas such as coastal regions, use the same method of protection for EMT
emerging from concrete into salt air to lengthen the service life. Examples of protection include
paint, tape, and shrink tubing.

3. Installed in concrete slab

Where installed in a concrete slab below grade, determine if EMT requires supplementary
protection for that location. RMC and IMC do not require supplementary corrosion protection in
this application.

4. Supplementary protection methods

Where supplementary corrosion protection is required for the conduit or EMT, the authority
having jurisdiction must preapprove the method selected. Following are typical methods of
providing supplementary corrosion protection:
 A factory-applied coating which is additional to the primary coating for conduit or tubing.
 A coating of bitumen.
 Paints approved for the purpose. Zinc-rich paints or acrylic, urethane or weather stable
epoxy-based resins are frequently used. Oil-based or alkyd paints should not be used.
Surface preparation is important for proper adherence. For best results, the conduit /
 EMT should be washed, rinsed and dried. It should not be abraded, scratched or blasted
since these processes could compromise the protective zinc layer. A compatible paint
primer or two coats of paint adds protection.
 Tape wraps approved for the application. Wraps must overlap and cover the entire
surface of the conduit / EMT and all associated fittings. Shrink wraps are available that
will protect the conduit and fittings without requiring a heat source.
 Couplings and fittings can also be shrink-wrapped

Equipment Grounding Using Steel Conduit

I. Steel conduit as equipment grounding conductor

Steel RMC, IMC and EMT are recognized by the NEC as equipment grounding conductors.
Using a supplemental equipment grounding conductor in the form of a copper, aluminum, or
copper-clad aluminum conductor in addition to the raceway is a design decision, except where
the NEC requires it in some specific installations such as patient care areas in NEC 517.13.
Steel conduit is the main equipment grounding conductor regardless of whether a supplemental
equipment grounding conductor is installed. In the event of a fault, the raceway will carry most of
the current and therefore must be continuous. For this reason, each raceway must be installed
securely and with tight joints to provide mechanical and electrical continuity.

II. Continuity of grounding path

The NEC states that the path to ground in circuits, equipment and metal enclosures for
conductors shall be permanent and continuous. Using less than the NEC required supports or
failing to properly tighten joints can cause discontinuity in a raceway system, which would result
in the failure to carry a ground fault. Good installation workmanship is critical.

The NEC further requires that the path to ground have the capacity to safely conduct any fault
current likely to be imposed and have sufficiently low impedance to limit the voltage to ground to
cause operation of the circuit protective device. Steel RMC, IMC and EMT are “conductors”
permitted to carry current in the event of a ground fault. All three have been tested and they all
meet the NEC requirements when properly designed and installed (see Annex B).

III. Maximum length of steel conduit / EMT

Copper, aluminum and copper clad aluminum equipment grounding conductors must be sized
according to NEC Table 250.122. Just as with these types of” wire” equipment grounding
conductor, conduit runs and couplings must be properly sized. The installed length of any wiring
method will impact the operation of the overcurrent device. In the event of a phase to neutral or
phase to conduit ground fault, the length of the particular conduit run determines safe operation,
assuming proper overcurrent protection has been provided. For a phase to phase fault, it is the
conductor length which determines safe operation. See Annex B for Tables that show examples
of the maximum run lengths for steel RMC, IMC and EMT.

IV. Clean threads

Threads must be clean to ensure electrical continuity of the assembled raceway system. Leave
the thread protectors on the conduit until ready to use. Wipe field-cut threads with a clean cloth
to remove excess oil and apply an electrically conductive rust resistant coating.

V. Continuity of the raceway system

The NEC does not permit certain circuits to be grounded. However, steel raceways and all metal
parts likely to become energized must still have assured continuity and be bonded together and
run to a grounding electrode to prevent electric shock.

VI. Bonding

Bonding is used to provide electrical continuity so that overcurrent devices will operate and
shock hazards will not be present. This is the “finishing touch” for a metallic raceway system and
close attention is to be paid to detail. All fittings, lugs, etc., shall be securely made up.

Bonding around steel raceway joints / couplings is not necessary when EMT, IMC, and RMC are
properly made up as recommended in this installation guideline. A secure joint provides
excellent low impedance continuity. Bonding is not required because this joint already meets the
NEC definition of bonding.

Metal raceways for feeder and branch circuits operating at less than 250 volts to ground shall be
bonded to the box or cabinet. Do one or more of the following:

 Use listed fittings.

 For steel RMC or IMC, use two locknuts one inside and one outside of boxes and
cabinets.
 Use fittings, such as EMT connectors, with shoulders that seat firmly against the box or
cabinet, with one locknut on the inside of boxes and cabinets.

(NOTE: Remove paint in locknut areas to assure a continuous ground path. Repaint or cover
any exposed area after installation is completed.)

VII. Service raceway system bonding

A service raceway system includes service equipment enclosures, meter fittings, boxes, etc.,
and requires special consideration for bonding the enclosures to the raceways where the
connection relies on locknuts only. Service equipment must be connected with threaded bosses
and fittings such as locknuts, wedges, and bushings of the bonding type.

Standard locknuts are not to be used on circuits over 250 volts to ground where the raceway is
terminated at concentric or eccentric knockouts. The raceway must be bonded to the enclosure
using the same methods as noted above for service raceway systems; or boxes and enclosures
listed for bonding are to be used.

VIII. Additional bonding considerations

Expansion fittings and telescoping sections of metal raceways shall be listed for grounding or
shall be made electrically continuous by the use of equipment bonding jumpers or other suitable
means.

Proper use of safety harness (PPE)

A safety harness is a form of protective equipment designed to protect a person, animal, or

object from injury or damage. The harness is an attachment between a stationary and non-
stationary object and is usually fabricated from rope, cable or webbing and locking hardware.

Classifications

 Fall Protection Systems

 Listed below are different types of fall safety equipment and their
recommended usage.
 Class 1 Body belts (single or double D-ring) are designed to restrain a person in a
hazardous work position to prevent fall or to arrest a fall completely within 3 foot of
movement (OSHA). Amends must be made to keep the line rigid at all times. A
harness should also be used.
 Class 2 Chest harnesses are used when there are only limited fall hazards (no
vertical free fall hazard), or for retrieving persons such as removal of persons from a
tank or a bin.
 Class 3 Full body harnesses are designed to arrest the most severe free falls.
 Class 4 Suspension belts are independent work supports used to suspend a worker,
such as boatswain's chairs or raising or lowering harnesses.

Types

 Safety harness types include:

 Seat belts
 Child safety seats
 Over the shoulder restraints used in roller coaster trains
 A seat with a full-body harness such as used by fighter pilots.
 Diving harnesses as used by professional divers

Uses


 Window cleaner  Construction worker
 Theatrical fly crew member  Crane operator
 Bridge painter
 Lineman
 Rock climber
 Motorsport
 Scaffolder
 Sailing
 High ropes
 Bungee jumping
 Professional diver
How to Inspect a Harness Before Using It

1. Pick up the harness by its D-ring in the back.

2. Gently shake the harness to let the straps fall in to place.
3. Make sure the buckles are unfastened.
4. Look for any damage, such as worn, frayed or missing
threads, cracked webbing, or foreign material on the harness.
5. Check the metal strap fasteners and d-ring to make sure they
aren’t cracked or deformed.
6. If your harness uses grommets, make sure they are firmly
attached and are not deformed or otherwise damaged.
7. Make sure buckle tongues are firmly attached and not bent.

How to Put on a Fall Arrest Harness

1. Slip the harness over your shoulders like a vest.

2. Make sure the D-ring is in the middle of your back, directly between your
shoulder blades.
3. Pull each leg strap up and fasten the buckles together.
4. Stand up straight and adjust the length of the side body straps as needed
to make sure there is no slack.
5. Fasten the chest strap about mid-chest high.
6. Adjust the chest strap as necessary to remove any slack.
7. Make sure the shoulder straps and leg straps are snug, while still allowing
full range of motion.
8. Eliminate any excess slack by tightening the straps in the buckle.
9. Make sure the loose ends of the straps are tucked into the strap retainers.
10. With your hand held flat, you should be able to fit your fingers underneath
your leg straps.

PPE Safety

Personal Protective Equipment (PPE) is clothing or equipment designed to protect

workers from physical hazards when on a worksite. PPE should only be considered as a last
line of defense between a hazard and the worker. Attempts to control workplace risks and
hazards should always be addressed first.

Workplace safety should begin with a hazard assessment. Once the hazards and risks have
been identified, a plan can be put forward to prioritize and reduce risk of injury. Useful
systems and tools to perform hazard assessments include performing a Risk Assessment
and a Job Safety Analysis.

Basic Types of PPE

Head Protection
PPE includes hard hats and headgears and should be required for tasks than can cause any
force or object falling to the head. When performing head protection safety checks, ensure
that there are no dents or deformities on the shell and connections are tightened inside. Do
not store in direct sunlight and always replace a hard hat if it was used for any kind of
impact, even if damage is unnoticeable.

Face and Eye Protection

PPE includes safety goggles and face shields and should be used for tasks that can cause
loss of vision and an eye, burns, splashes, sprays of toxic liquids etc. When conducting
equipment safety checks, ensure that there are no cracks or deformities on the lenses,
ensure the strap is in good working order and is firmly sealed to the cheek and forehead.

Foot Protection

PPE includes knee pads and safety boots and should be used for tasks that can cause
serious foot and leg injuries from falling or rolling objects, hot substances, electrical hazards
and slippery surfaces. Use boots with slip-resistant soles that protect against compression
and impact.

Hands Protection
PPE includes safety gloves and should be used for tasks that can cause hand and skin
burns, absorption of harmful substances, cuts, fractures or amputations. When inspecting
hand protection equipment, ensure that they fit perfectly with no spaces and are free from
cuts, burns and chemical residue. Always replace them if any sign of contamination was
observed.

Body Protection

PPE includes safety vests and suits and should be used for tasks that can cause body
injuries from extreme temperatures, flames and sparks, toxic chemicals, insect bites and
radiation. Ensure that they are clean and free from cuts and burns. Always get a good fit to
ensure full body protection.

Hearing ProtectionPPE includes ear muffs and plugs and should be used for tasks than
can cause hearing problems and loss of hearing. When ensuring hearing safety, the
equipment must fit the ear canal perfectly. Recommended types include formable earplugs
to fit on different sizes of ear canals.
Fall Protection

PPE includes safety harnesses and lanyards and should be strictly used for task that can
cause falling from heights and serious injury or death. When inspecting equipment, ensure
that the straps are free from tears, deformities and burn marks and buckles are connected
securely and tightly. It is very important to dispose them if used after a falling incident.

Respiratory Protection

PPE includes respirators and should be used for task that can cause inhalation of harmful
materials to enter the body. When conducting respiratory protection safety, ensure that the
equipment is fit-tested and the employee has undergone proper training before wearing one.

Proper uses and installation of wire ways and cable trays

Wire-ways are troughs with hinged or removable covers for housing and protecting electric
wires and cable. Conductors are laid into the wire-way after the wire-way has been installed
as a complete system.

Uses

The use of wire-ways are permitted as follows:

1. For exposed work in dry locations. For outdoor or wet locations, use Type 3R wire-
way.
2. If installed in inaccessible spaces, the use of wire-way is permitted only for use with
audio signal conductors.
3. In hazardous locations
4. For extensions through walls, if the length passing through the wall is unbroken and
access to conductors can be maintained from both sides.

The use of wire-ways is not permitted where a risk of severe physical damage or corrosive
vapor is present.

Size of Conductors

Table 1 show maximum allowable cable sizes for varying wire-way sizes. (Based on UL 870
Table 7.1)

Conductors entering the wire-way only at the ends of runs are limited in size only by the 20
percent fill requirement of the NEC®. However, it is recommended that wire sizes not
exceed those in Table I above.

Number of Conductors

Wire-ways which contain no more than 30 current-carrying conductors at any cross section,
and for which the sum of the cross-sectional areas of all contained conductors at any cross
section does not exceed 20% of the interior cross-sectional area of the wire-way, require no
de-rating of cables. (Refer to Table II below).
Splices and Taps

Splices and taps are permitted within a wire-way, provided they are accessible. The
conductors, including splices and taps, shall not fill the wire-way to more than 75 percent of
its area at the point of a splice or tap.

Wire-way Selection

Sample Calculation

Wire-way dimensions are obtained as follows:

1. List cables by size and types.

2. List cable cross sectional areas.
3. List the number of each size of cable.
4. Multiply cable cross sectional areas by number of each cable.
5. Sum the total cross-sectional areas of each cable type to obtain the total cross-
sectional areas for the conductors.
 List Cable List Cable List Multiply (A) x (N) =
Sizes and Cross Sectional Number Total Cross-Sectional Area for Each Size
Types Areassq.
(A)in. of Cables
(N) sq. in.
2 AWG-XXHW 0.1182 x 4 = 0.4728
2/0-TW 0.2290 x 2 = 0.4580
750 kcmil-RHH 1.1300 x 2 = 2.2600
Sum of the total cross-sectional = 3.1908
areas
6. The wire-way must first meet the dimensional requirements for the largest conductor.
In the example above, the largest conductor is 750 kmil. The minimum wire-way
cross section based on the largest conductor size requirements is 8” x 8”.
7. The wire-way dimensions must meet 20% fill requirements. Based on the sum of the
total conductor cross sectional areas (3.19 sq. in.), the minimum wire-way cross
section, based on the 20% fill requirements is 4” x 4”.
8. In this example, the wire-way dimensions must be the larger of the two cross
sections obtained in steps 6 and 7. In this case, 8” x 8” wire-way is required.

Cross Sectional Area of Conductors

Single Conductor Cable 600V

Cross Sectional Area of Conductors (sq. in.)

SIZE AWG XXHW, XXHW-2, XHH THHN, THWN THWN-2 THW, THW-2, THHW RHH*, RHW* RHW-2*
kcml Diameter Area Diameter Area Diameter Area Diameter Area
in. in.2 in. in.2 in. in.2 in. in.2

14 0.1330 1.0139 0.1110 0.0097 0.1630 0.0209 0.1930 0.0293

12 0.1520 1.0181 0.1300 0.0133 0.1820 0.0260 0.2120 0.0353
10 0.1760 0.0243 0.1640 0.0211 0.2060 0.0333 0.2360 0.0437
8 0.2360 0.0437 0.2160 0.0366 0.2660 0.0556 0.3260 0.0835
6 0.2740 0.0590 0.2540 0.0507 0.3040 0.0726 0.3640 0.1041
4 0.3220 0.0814 0.3240 0.0824 0.3520 0.0973 0.4120 0.1333
3 0.3500 0.0962 0.3520 0.0973 0.3800 0.1134 0.4400 0.1521
2 0.3820 0.1146 0.3840 0.1158 0.4120 0.1333 0.4720 0.1750
1 0.4420 0.1534 0.4460 0.1562 0.4920 0.1901 0.5850 0.2688
1/0 0.4820 0.1825 0.4860 0.1855 0.5320 0.2223 0.6220 0.3039
2/0 0.5280 0.2190 0.5320 0.2223 0.5780 0.2624 0.6680 0.3505
3/0 0.5800 0.2642 0.5840 0.2679 0.6300 0.3117 0.7200 0.4072
4/0 0.6380 0.3197 0.6420 0.3237 0.6880 0.3718 0.7780 0.4754
250 0.7050 0.3904 0.7110 0.3970 0.7650 0.4596 0.8950 0.6291
300 0.7600 0.4536 0.7660 0.4608 0.8200 0.5281 0.9500 0.7088
350 0.8110 0.5166 0.8170 0.5242 0.8710 0.5958 1.0010 0.7870
400 0.8580 0.5782 0.8640 0.5863 0.9180 0.6619 1.0480 0.8626
500 0.9430 0.6984 0.9490 0.7073 1.0030 0.7901 1.1330 1.0082
600 1.0530 0.8790 1.0510 0.8676 1.1130 0.9729 1.2430 1.2135
700 1.1240 0.9923 1.1220 0.9887 1.1840 1.1010 1.3140 1.3561
750 1.1580 1.0532 1.1560 1.0496 1.2180 1.1652 1.3480 1.4272
800 1.1900 1.1122 1.1880 1.1085 1.2500 1.2272 1.3800 1.4957
900 1.2540 1.2351 1.2520 1.2311 1.3140 1.3561 1.4440 1.6377
1000 1.3120 1.3519 1.3100 1.3478 1.3720 1.4784 1.5020 1.7719
1250 1.4790 1.7180 - - 1.5390 1.8602 1.7290 2.3479
1500 1.6020 2.0156 - - 1.6620 2.1695 1.8520 2.6938
1750 1.7160 2.3127 - - 1.7760 2.4773 1.9660 3.0357
2000 1.8220 2.6073 - - 1.8820 2.7818 2.0720 3.3719
A wire-way is typically produced as a metallic or non-metallic trough with hinged or
removable covers, so that the cables contained are well-protected but still accessible. The
high cost of manufacturing and installing wire-ways limits their use to small sections of cable
management systems, while most systems primarily consist of cable trays, conduit, and
other types of raceway. When connected, wire-ways must be reinforced using special fittings
and gaskets between sections.

The layout of a cable management system, consisting of various connected wire-way

shapes, is shown below.

Cable Tray

A cable tray system is used to support insulated electrical cables used for power distribution,
control, and communication. Cable trays are used as an alternative to open wiring or
electrical conduit systems, and are commonly used for cable management in commercial
and industrial construction.
What is a cable tray System?

As per the national electrical code, a cable tray system is “a unit or assembly of units or
sections and associated fittings forming a rigid structural system used to securely fasten or
support cable s and raceways.

What does this mean?

cable trays support cable the way that roadway bridges support traffic.

A bridge is a structure that provides safe passage for traffic across open spans

Cable tray bridge that allows for safe transport of wires across open spans.

Types of cable tray

1. Ladder Cable Tray

2. Solid Bottom Cable Tray
3. Trough (Ventilated) Cable Tray
4. Channel (Perforated) Cable Tray
5. Wire Mesh Cable Tray
6. Single Rail Cable Tray

Ladder Cable Tray

 Solid side rail protection and system strength with smooth radius fittings and a
wide selection of materials and finishes.
 Maximum strength for long span applications standard widths of 150, 300, 450,
600, 750 and 900 millimeters
 Standard depths of 50, 75, 100, 125 and 150 millimeters
 Standard lengths of 3 to 6 meters
 Rung space spacing of 150, 225, 300 and 450 millimeters
 Ladder cable tray is generally used in applications with intermediate to long
support spans 3 meters to 6 meters.

I - Beam Channel Flange In Channel Flange Out

Solid Bottom Cable Tray

 Non ventilated continuous support for dedicate cables with added cable
protection available in metallic and fiberglass.
 Solid bottom metallic with solid metal covers for non-plenum rated cable in
environmental air areas
  Standard width of 150, 300, 450, 600, 750 and 900 millimeters
 Standard depths of 75, 100, 125 and 150 inches
 Standard lengths of 3, 6 meters
 Solid bottom cable tray is generally used for minimal heat generating electrical or
telecommunication applications with short to intermediate

Example of Solid Bottom Cable Tray

Pan Flange In Corrugated bottom

Use of wire and cables

Different Types of Electrical Wires and Cables

Labelling of Cables

The labelling of the cables is very important and it provides a lot of information regarding its
insulation types, numbers of wires and the gauge of the wires. Take a look at some of labels
written on the wires commonly used in home wiring.

 14-2G: The cable contains two insulated wires and a ground wire; individual wire
is 14-gauge.
 14-3G: The cable contains three insulated wires and a ground wire; individual
wires are 14-gauge.
 12-2 w/G: The cable contains two insulated wires with a ground wire; individual
wires are 12-gauge.
 12-3 w/G: The cable contains three insulated wires with a ground wire; individual
wires are 12-gauge.
 600 V: This Cable is rated for a maximum of 600 volts; commonly used NM cable
for home wiring.
 TYPE NM-B: NM stands for Non-metallic; it is a non-metallic sheathed cable of
type-B; this is the commonly used cable for wiring appliances and devices in
home.

The most important label of them is about the insulation or the plastic coating around the
conducting wires. Here are some of the common labels written on wires.

 THHN
 THWN
  THW
 XHHN

The meaning of each letter used in the labels above is given below:

T- Thermoplastic insulation, a fire-resistant material

H- Heat resistant able to withstand temperatures up to 167 F.
HH - Highly heat-resistant; able to withstand temperatures up to 194 F.
W- “Wet” or approved for damp and wet locations; this wire is also suitable for
dry locations
X - Insulation made of a synthetic polymer that is flame-retardant
N - Nylon coated for resistance to oil and gasoline

Residential Wiring Cables

The residential wiring from the utility pole to the appliances or devices inside the home is
divided into mainly five types.

1. Service Drop Cable:

It is the cable between the utility pole and the consumer’s premises or building. The
service drop cable is an overhead electrical line from the pole to the service weather
head of a house. The service drop cable can be of many types given below:

Duplex Cable: The duplex service drop cable is a two-core conductor i.e. it has

two conductors; an insulated conductor for phase line and a bare conductor for
neutral line. It is used for supplying a single-phase power to the building.

Triplex Cable: The Triplex service drop cable is a three-core conductor. It has two
insulated conductors for phase line and a bare conductor for neutral line.

Quadruplex Cable: The Quadruplex service drop cable is a quad or four core
conductors. It has 4 conductors; three of them are insulated conductors for phase
lines and a bare conductor for neutral line. It is used for supplying a 3-phase
power supply from the utility pole to the building.
 The phase conductor is an AAC cable while the neutral conductor is available in
AAC/AAAC/ACSR. The insulation used on these cables is XLPE that protects
these conductors from moisture, heat etc.

2. Main Feeder Wires:

The main feeder cables & wires supply the power from the service weather head to
the building. The cables used for this purpose are 600v THHN, solid or stranded with
the rating of 25% more than the maximum required load.

3. Panel Feed Wires:

The panel feed wires supply power to the main distribution junction box. It is usually
black insulted THHN cables with rating of 25% more than maximum load current.

4. Non-Metallic Sheathed Wires:

The non-metallic or NM sheathed wires are used for in-house wiring. It may consist of
2 or more than 2 insulated conductors with an insulated or bare ground conductor.
There is another layer of plastic XLPE sheathing for more protection. The latest
version NM type-B is currently used by electricians for interior installation. The
conductors could be solid or stranded. The stranded conductors are easier to route
through conduits.
5. Single Conductor Wire

Single Conductor wire is the most popular choice for electrical layout inside a home.
It is available in multiple gauges, colour (for phase, neutral and ground identification)
and solid or stranded conductors. A single solid wire provides better connections but
single stranded wires are easier to route through conduits. Both of them are available
in THW and THHN insulation.

6. Communications Cable

The types of cables and wires that are used for communication or signal transmission
purposes are called communication cable. There sole purpose is to transmit
information. Here are 3 types of communications cables:

7. Coaxial Cable

Coax or coaxial cable is type of electrical cable made from four layers, forming
coaxial shape (having common axis or center). The central part of coaxial cable is a
conductor covered by an insulating plastic layer which is surrounded by a metallic
shield. On top that is a fourth layer of plastic insulation.

The coaxial cable is used for transmission of high frequency signal. This is why the
metallic shield is used for blocking noise interference. It is commonly used for cable
television signal distribution, signal transmission between antennas, transmitter and
receiver.

a. Hard line Coaxial or Heliax Cable

Hardline coaxial or mostly known by its trademark name Heliax cable is a

thick coaxial cable with its center solid conductor made from copper and the
shield made from copper or silver tubing. It is specifically used for high

frequency broadcast transmission. It can carry hundreds of channels and is

usually installed between a transmitter on ground and aerial antenna.
b. Radiating or Leaky Coaxial Cable

Radiating or leaky coaxial cable is another type of coaxial cable where the
shield is deliberately designed in such way to radiate RF waves. The shield is
made with slots tuned for specific RF wavelength that provide bi directional
leakage effect between transmitter and receiver. This type of coaxial cable is
used in places where antenna is not feasible such as underground tunnels,
elevator shafts etc.

c. RG-6 Coaxial Cable

RG-6 is the most common type of coaxial cable used for signal transmission
in residential and commercial applications. It is made from a solid copper wire
with plastic insulation covered by an aluminum foil and a braided shield for
protection against interference. It is used for audio and video signal
transmission in application such as cable TV, Satellite TV signal and radio etc.

d. Triaxial or Triax Cable

Triaxial is another type of coaxial cable which includes another layer of

insulation and shield over the top of existing shield. The second or outer
shield is grounded to protect the inner shield from electromagnetic
interference.
 e. Twin-axial or Twinax Cable

Twinax cable is type of coaxial cable similar to RG-6 but with two inner
conductors instead of one. The two insulated inner conductors are twisted
together surrounded by a braided shield. It is used for high-speed short-range
signal communication usually for 10 Gigabit Ethernet Network.

f. Semi-rigid Coaxial Cable

Semi-rigid coax cable is another type of coax cable where the outer sheath is
from solid copper with an inner conductor. The outer shield provides better
interference protection. Due to the tube-like structure of the shield, it is not
very flexible and is not meant to bent after initial forming.

g. Rigid Line Coaxial Cable

The rigid line coax cable is a modified form of semi-rigid cable made from two
concentric tubes (shield) that provides extra protection for high power signal.
Such cables are not meant to be bent which is why elbow and interconnects
are used for bending. They are used for high power signal transmission
between RF components of a transmitter and antenna.

8. Twisted Pair Cable

This type of communication cable is made from two insulated wires twisted together
to form a twisted pair. The purpose of twisting is to reduce the electromagnetic
interference or noise. They are used in Ethernet network and telephone
communication.

They are further divided into two types based on their noise protection.
 a. Unshielded Twisted Pair (UTP) Cable

The UTP cables do not have any extra shield for protection against noise. They
twisted pairs may reduce the noise but it still affects it. Various categories of
UTP cables are used in residential and commercial building with various
bandwidth e.g. CAT1, CAT2 etc.

b. Shielded Twisted Pair (STP) Cable

The STP cable has an extra layer of foil that protects the wires from
electromagnetic interferences. They are used for high-end applications where
the cables may get affected by external environmental interferences.

9. Fiber Optic Cables

Fiber optic or optical fiber cable is a type of communication cable made of flexible,
transparent glass fibers known as optical fibers that transmit data in the form of light.
The fiber’s thickness is approximately equal to human hair and each individual fiber is
covered with plastic insulation. There is another external protection layer that protects
the fibers from interference.

The fiber optics cable is classified into two main types;

a. Single Mode or Mono-mode Fiber Optics Cable:

This cable allows only one mode of light to transmit. It is made of a very thin
single strand of fiber that allows only single light wave to propagate. This
decreases the number of light reflections which reduces the attenuation in
signal. It provides high transmission rate at long distance with very low
attenuation but at high cost.

b. Multi-Mode Fiber Optics Cable:

This type of fiber optic cable is made of relatively thicker fibers that allow more
than one light wave so it can transmit relatively more data. But the number of
 light reflections due to large number of waves at large distance causes
attenuation and distort the signal at the receiving end. This is why it is used
for relatively short distance transmission such as LAN, security system etc.

10. Direct-Buried Cable (DBC)

It is a type of cable used for communication and power transmission. It is specifically

designed to be buried directly underground without the need of extra insulation,
sheathing or piping. It is made of bundles of fiber optic cables with a thick metal core
for stiffness. It has multiple layers of protection such as plastic insulation layer,
waterproof layer as well as shock absorbing gel etc. to protect it from heat, moisture
and other underground factors.

11. Non-Metallic Sheathed Cable (NM, NM-B)

The non-metallic or NM sheathed cable or known by its trademark name “romex”

cable is a type of electrical cable whose outer sheath is made of plastic that protect
the inside conductors. It is commonly used for residential electrical wiring.

There are two types of NM sheathed cable based on number of conductors;

a. Two wires NM sheathed cable: This type of cables has two separately insulated
conductors with a bare conductor for ground connection that makes a total of 3
conductors. It comes in various gauges for various ratings and it is labeled as
“<gauge> – 2 WG”. It means this cable contains 2 wires plus a grounding wire.
b. Three wires NM sheathed cable: this type of cable contains 3 insulated wires

with a bare grounding wire. It is used for three phase application this is why the
individual conductor is marked with different phase color for identification.
12. Metallic Sheathed Cable (Armored Cable, AC or BX, MC)

Metallic sheathed cable, as the name suggest is a type of armored electrical cable
with a metallic protection over the insulated conductors. The conductors are
separately insulated with plastic layer which is surrounded by a metallic sheath for
extra protection. The metal sheath can be braided or twisted that surrounds individual
or all conductors or it could a solid pipe like structure.

The metallic sheathed cables are mostly known by AC (armored cable) or BX cable
and MC (metal clad) cable. BX is the registered trade name for AC cables.

a. Armored Cable (AC)

Such type of metallic sheathed cables has a protective twisted or braided

metallic layer usually made of steel over its conductor. The external sheath is
made of plastic. The metallic layer provides extra mechanical strength against
any sort of damage and can also be used for grounding connections. Thus, they
are not used in damp or wet location as well as underground. The armoured
layer can be wire braid, steel wire or steel tape. The steel wire armored (SWA)
cable is most common type of armored cable used for power transmission.

b. Metal Clad (MC) Cable

The difference between AC and MC cables is that MC Cable’s metallic sheath

cannot be used as grounding wire. It has an extra green colored insulated wire for
ground connection. Thus, they can be used as direct burial type and in wet
locations but if they have their protective PVC outer sheath.
13. Multi-Conductor or Multicore Cable:

Multi-core or multi-conductor cable has multiple conductors with insulated sheaths

that are rolled into one jacketed cable. Its job is to avoid the messy connection by
having one single cable instead of 10 or 20 separate wires and save time by
connecting them one by one.

The individual conductors have insulation sheath with a common housing made from
insulating material. But in some cases, there is an aluminum layer for protection
against EMI (electromagnetic interference) or an extra armored layer for more
protection. The multiple core cables usually end in a multi-pin connector.
The cores are the number of useful connections; a simple 3-phase cable cannot be called a
multi-core cable but a cable having 2 or more than 2 separate 3-phase conductors is a
multicore cable. For example, an audio mixer has multiple input cables from microphones,
the cables are joined together to form a multi-core cable which is easier to plug in instead of
plugging each cable in its own spot.

They are mostly used in electronics for data transmission in application such as:

 Transmitting audio signal to audio mixer.

 Sending audio and video signal in gaming consoles.
 Sending camera signal to CCU (camera control unit) in TV studios
 Sending audio and video signal using a single cable from camera.
 in networking.
14. Paired Cable

Paired cables are type of electrical cable made from a pair of two insulated conductor
covered by an insulation sheath. They are mostly used for DC application and also in
low frequency AC applications.

a. Portable or Extension Cord

It is a flexible electrical cable with connectors on both ends to provide a

temporary AC power supply. it is usually used as extension of power source
for powering portable equipment, machines and devices.

15. Ribbon Cable

 This type of cable is made from multiple small grade insulated wires parallel to each
other in a flat shape that resemble a piece of ribbon thus the name ribbon cable.
They are flexible and they can handle very low voltages.

They are mostly used in electronic devices and computers to connect different
internal peripheral that require data buses like hard drives, CD drives, printers etc.
Due to their flat shape, they block the airflow inside computer which affects the
cooling system. Nowadays, they are mostly replaced by round cables.

16. Submersible Cable

As the name suggest, this type of electrical cable is designed to be used in wet
locations or submersed in a liquid. The insulation used for such cables is very
rugged, abrasion-resilient and extremely durable and reliable to meet the challenges
present in the installation environment. They are designed to be used as direct buried
cable.

They are available in single as well as multiple conductor design having flat or round
structure to meet its applications. The conductors are color coded to identify phase
and earth connections as well as the control wires that runs along the power
conductors.

They are used in location that is physically restrictive and inaccessible. The most
common use of submersible cable is to supply power to submersible motors and
pumps underwater, in agriculture industries, underground mining or drilling purposes.

17. Twin-lead
 Twin lead cable is a two-conductor flat cable used as a balanced line to carry radio
frequency RF signal. The conductors are held apart and uniformly space by a plastic
layer between them. The equal spacing is very important because it keeps the signal
from distortion. The conductors are mostly stranded to avoid skin effects and they are
insulated using the same plastic material.

They are more susceptible to external noise interference and weather conditions that
is why these factors are kept in mind during installation. Of course, the coaxial cable
has better noise protection but twin lead cable is preferred due to its low power
losses.

18. Ladder Line

Sometimes, due to wet condition such as rain, wind etc. the water drop gets
accumulated on top of the plastic between the conductors. This causes interference
in the signal. In order to avoid such condition, a window like slots is cut into the
plastic layer. The resulting wire resembles a ladder like structure, thus the name
ladder Line.

The twin lead is available in 600, 450, 300, and 75-ohm characteristics impedance.
The most common type is known by 300-ohm twin lead cable used for television sets.
They are mainly used to connect the transmitter or receiver with RF antennas in TV
and Radios etc.

19. Underground Feeder (UF) Cable:

It is a type of non-metallic sheathed cable designed for use in wet location such as
supplying power to lamp post or street light. NM cables have a loose wrap of plastic
sheath around it whereas the conductors in UF cables are individually surrounded by
a solid layer of thermoplastic that provide flexibility and extra protection. The water-
resistant insulation material allows them to be used in damp locations such as
supplying power to garden shed, lamp post. They are mostly available in gray color
outer sheath. They are the best choice for avoiding poles and exposed wire by simply
running them underground.
Flexible Cables

Flexible cables are a type of electrical cables that can withstand continues bending in
moving applications. The flexibility is achieved by using stranded conductors. They
are used in automation industries where the machines are continuously moving such
as pick and place machines and CNC based machines such engraving, milling
machines etc.

The flexible cables are of two types;

a. Stranding in Layer

This type of cable is made from multiple layers of strands of conductor. The
cores of this cables are designed to be firm and the surrounding layers are made
long. Because the outer layer stretches during bending while the center core
compresses. This type of cable is easier to manufacture and is cheaper. The
material used for such cable is flexible but too much bending might deform the
cable.

b. Stranding in Bundles

This type of cable is achieved by braiding the conductor around each other so
that the conductor stretches uniformly when the cable bends. This type of cable
is more durable because of its tension proof core but a little stiffer than the
stranded cable.

20. Overhead Power Line:

Overhead power lines are conductors suspended from electrical towers or poles to
transmit power over long distance. The conductors used are completely bare and
made from aluminum. The electrical and mechanical properties of the conductor
depend on its construction. Here are some of the cables used for power
transmission.

a. All Aluminum Conductor (AAC)

AAC transmission cable, also known as aluminum stranded conductor is

made from multiple strands of hard drawn 1350 aluminum alloy which is 99 %
pure with a little bit of silicon, iron etc. it has very high conductivity and
resistive to corrosion but very poor strength to weight ratio. That is why it is
preferred short distances in the stations not for rural power transmission over
long distance.

b. All Aluminum Alloy Conductor (AAAC)

In order to increase the mechanical strength of the AAC cable, a special

aluminum alloy is used made with magnesium and Silicium. It increases the
strength to weight ratio while maintaining the corrosion resistivity. However,
the conductivity falls a bit.

c. Aluminum Conductor Steel-Reinforced (ACSR) Cable

ACSR is also a stranded aluminum cable whose inner strands are made from
galvanized steel surrounded by strands of pure aluminum conductors. The
steel core increases the tensile strength of cable while the aluminum provides
good conductivity and low weight. They are used in long distance
transmission line because we can alter the strength of its steel core to meet
the requirement.

d. Aluminum Conductor Aluminum-alloy Reinforced (ACAR)

 It is made of pure aluminum conductors surrounding an aluminum core. The
structure of ACAR resembles ACSR but instead of its core made from
galvanized steel, it is made of aluminum alloy which increase the overall
conductivity (ampacity) while maintaining the tensile strength if ACSR.

e. Bundled Conductors:

Due to high voltage transmission of above 132KV over long distances, a

phenomenon occurs in the conductors known as corona discharge. High
voltage ionizes the air around it which causes power loss as well as
interference in the communication lines nearby. To reduce this effect 2 or
more than 2 conductors are used per phase also known as bundled
conductor. These conductors are made from same materials and are equally
separated by a spacer.
Proper Procedure in Installation of Auxiliary Terminal Cabinet and Distribution Panels.

Installing an Electrical Distribution Sub-Panel

There are two basic types of electrical distribution sub-panels.

1. Those that are designed to supply power to a single appliance or device such as an
air conditioner and are termed a Disconnect Switch. For an air conditioner it would be
an air conditioner (AC) disconnect switch. These primarily act as location specific
electrical disconnects for that specific appliance or device.
2. Those that are designed with a number of circuits to power numerous electrical
receptacles appliances or other devices.

This article covers the 2nd item - Those sub-panels that are designed with a number of
circuits to power numerous electrical receptacles appliances or other devices.

The primary purpose of an electrical sub-panel is to provide you with additional electrical
circuits. It does not change the total amount of power available to the home. In other words,
adding an extra eight 15-amp circuit positions does not mean that your home can draw an
additional 120 amps of power.

The total amount of power that your home can draw from the electrical utility is based on the
electrical service (the size (wire gauge) of the wires connecting your home and the main
disconnect circuit breaker or fuses.

The primary difference between a main electrical distribution panel and a sub-panel is in the
main disconnect. Modern electrical distribution panels have a main disconnect circuit
breaker built into them, see Figure 1.

Figure 1 - Home electrical service before the addition of a

distribution sub-panel.
Whereas the sub-panel is generally powered from a circuit breaker within the load center or
main distribution panel and does not have its own disconnect associated with it.

There are two primary reasons to consider the installation of an electrical distribution sub-
panel.

 Your current electrical distribution panel (load center) does not have any vacant
spaces for the addition of more circuit breakers.
 You need multiple circuits in a distant location, such as a garage, greenhouse or
workroom.

The installation method for both of the aforementioned variations is the same, the only
difference is the length of the wires from the main distribution panel to the electrical sub-
panel, see Figure 2.

Figure 2 - Home electrical service after the addition of

a distribution sub-panel.
Principles Applied in Installing Panel Board

1. The approach shall be accessible and more convenient.

2. The panel board is centrally located to shorten the home wiring runs.
3. It must be installed near the load center, as in most cases panel boards are mounted
near the kitchen and the laundry where heavy loads are expected.
4. To limit voltage, drop on the branch circuit, the panel board shall be located in such a
manner that no circuit (wiring connections) exceed 35 meters long.
5. In the event that circuit more than 35 meters long cannot b avoided, no. 10AWG wire
shall be used for funs up to 50meters long and No. 8 AWG wire for longer circuits.
 Figure 3 - Panel Board
Installation of the Panel Board

a. Panel Board with 100 cm. high or less shoud be located 135 cm. form the floor to the
center line of the box.
b. Panel board with boxes over 100 cm. high should ba located 75 cm. form to the

bottom of the box, except that the highest branch circuit unit should not be more than
195 cm. from the floor.
c. If necessary, the box maybe lowered to a distance not less than 45 cm. from the floor
to the bottom of the box. However, where a maximum height of 195 cm above the

floor to the upper circuit or a minimum distance of 45 cm. above the floor cannot be
divided into two sections.
d. If two or more boxes are adjacent on the same wall, they should be installed with the
horizontal center line of each box equidistance from the floor. The center line
distance of higher box controlling the boxes should be installed with a minimum
spacing of 10 cm. apart.
Cable Pulling and Installation Requirements

PRE-INSTALLATION
To ensure safety during cable installation and reliability once the cable is installed, you
should confirm the following prior to installation.

 The cable selected is proper for your application

 The cable has not been damaged in transit or storage
1. CABLE INSPECTION

Inspect every reel of cable for damage before accepting the shipment. Be
particularly alert for cable damage if:

 A reel is lying flat on its flange side

 Several reels are stacked on top of each other
 Other freight is stacked on top of a reel
 Nails have been driven into reel flanges to secure shipping blocks
 A reel flange is damaged
 A cable covering has been removed, or is stained or damaged
 A cable end seal has been removed or is damaged
 A reel has been dropped (hidden damage likely)

NOTE: All damages must be noted on the waybill upon receipt of the
cable.
CABLE HANDLING

YES NO
Do not lift by top flange. Cable or reel
Cradle both reel flanges between forks
will be damaged.

Reels can be hoisted with a shaft Use a spreader bar to prevent

extended through both flanges. bending the reel flanges and mashing
the cable.

Place spacers under the bottom

flange and between reels to create a Upended heavy reels will often arrive
space to insert the forks. damaged. Refuse or receive subject
to inspection for hidden damage.

Lower reels from truck using

hydraulic gate, hoist or fork lift. Never allow forks to touch cable
LOWER CAREFULLY surface or reel wrap.

Always load with flanges on edge and Never drop reels.

chock and block securely.
Remove all nails and staples from the reel flanges before moving a reel, and avoid all
objects that could crush, gouge or impact the cable while it is being moved. NEVER use the
cable as a means to move a reel. When unreeling, observe recommended bending radii, use
swivels to prevent twisting, and avoid overruns.

CABLE STORAGE

Cables should be stored on hard surfaces so that reel flanges cannot sink. Small reels may
weigh several hundred pounds while large reels can exceed several thousand pounds.

 Impact damage can be prevented by the following precautions:

 Aligning reels flange to flange
 Using guards across flanges when different reel sizes are stored together
 Maintaining adequate aisles and barricades to prevent equipment from hitting the
cable

Seal the ends of all cable stored outdoors, and re-seal both ends when a length is cut from
the reel.

INSTALLATION

A high percentage of cable failures are due to mechanical damage, which typically occurs
during transportation, handling and installation.

In fact, most cables are subjected to more mechanical stress during installation than they
ever experience in actual operation. Needless to say, handling and installing the cable
according to the manufacturer’s recommendations is extremely important.

When cables are installed in a raceway, underground electrical duct or cable tray, the
following factors must be considered.

 Conductor configuration
 Raceway or cable tray fill
 Physical limitations of cables
 Installation equipment
 Ambient temperature and conditions

INSTALLATION TEMPERATURE

Low temperatures are a cause for concern when installing cable. Cable should not be
installed when temperatures are less than the cold bend temperature rating of the
cable product plus 15°C (i.e., minimum installation temperature = cold bend
temperature rating + 15°C). For example, when installing a cable with a cold bend
temperature rating of -25°C, the minimum recommended installation temperature is -
10°C.

The cold bend temperature ratings are indicated on the catalog spec sheets.

Prior to performing a low temperature (less than 10°F or -12°C) cable installation,
cable should be pre-conditioned by storing it for a minimum of 24 hours at a
temperature of 55°F (13°C) or higher.
 Cable should be pulled more slowly and trained in place the same day it is removed
from storage. Do not impact, drop, kink or bend cable sharply in low temperatures.

Cable Pulling

 Raceway Cleanout – Provide clean smooth concentric inner surface; test with a
mandrel for obstructions and swab to remove any debris.
 Bending – Bends during pulling must be larger than those permitted for final training,
especially the last bend, which may be temporary for installation. If possible, it is
recommended that bends should be at the beginning of the pull to minimize the
Sidewall Bearing Pressure.
 Edges – Install temporary guides, tubes, sheaves, etc., as necessary to prevent
cutting the cable on sharp edges, such as at panelboards.
 Maximum Tension –
o Keep sidewall loads below specified maximum limits.
o Check maximum allowable pulling tension. Monitor with the use of a
dynamometer.
o Check limitation for type of pulling attachment used. A swivel should be
employed to avoid twisting.
 Lubrication –
o Use pulling compound liberally.
o Be sure it is compatible with the particular cable being installed.
o Pre-lube just before making a pull.
 Temperature – Check for minimum allowable installation temperature. Allow for
change of the coefficient of friction with temperature.
 End Seals – Keep moisture out of cable.
 Special Instructions – Check shipping container for special instructions.

Cable Lay Out and Installation

Laying Out Cables

Basic Rules

 Different types of cables such as power cables, signal cables, and ground cables
must be laid out and bound separately. Cables of the same type are laid out in the
same direction. Cables at a small distance can be laid out in crossover mode. When
laying out cables in parallel, the distance between power cables and signal cables
must be longer than or equal to 30 mm (1.18 in.).
 If cables cannot be identified by labels, attach engineering labels to distinguish
different types of cables.
 Cables must be protected from burrs, heat sinks, and active accessories, which may
damage the insulation layers of the cables.
 Cable ties are used for binding cables. Do not tie two or more cable ties together for
binding cables. After cables are bound using cable ties, cut off the excess part and
ensure that the cuts are neat and smooth.
 Cables must be properly laid out, supported, or fixed in cable troughs inside a rack.
This is to prevent excessive stress on the cables or wiring terminals, loose
connections, and damage to the cable insulation layer.
 Surplus parts of cables are coiled and bound in a proper position of the rack.
  Cables are routed straightly and bound neatly in a rack. The bending radius of a
cable varies according to the bending position.
o If you need to bend a cable in the middle, the bending radius must be at least
twice the cable diameter.
o If you want to bend a cable at the output terminal of a connector, the bending
radius must be at least five times the cable diameter, and the cable must be
bound before it is bent.
o Do not use cable ties at positions where the cables are bent. Otherwise, the
core wires of the cables may break.

Common Methods

The methods of laying out cables inside a rack are described as follows:

 Lay out power cables at the rear of the rack along the left side. Choose overhead or
underfloor cabling based on equipment room conditions, such as the positions of the
AC power distribution cabinet, surge protection device (SPD), and terminal block.
 Route service data cables at the rear of the rack and bind them to the right cable
trough, or route them at the front of the rack and bind them to the cable troughs on
both sides. Choose overhead or underfloor cabling for service data cables based on
equipment room conditions, for example, the cabling mode (overhead or underfloor
cabling) used by signal cables.
 Place the connectors of all service data cables at the bottom of the rack in order so
that the connectors cannot be easily reached.
 Ensure that high-density cables are not routed in crossover mode. This helps identify
connectors and remove and install server nodes.

DOLE Department order No. 13 s. 1998 Guidelines Governing Occupational Safety and
Health in the Construction Industry

Objectives

 To ensure the protection and welfare of workers employed in the construction

industry.
 To ensure protection and welfare of the general public within and around the
immediate vicinity of any construction worksite as well as the promotion of
harmonious employer-employee relationships
  To take into consideration industry practices and applicable gov’t. requirements

Definitions of Terms

 Construction SH Committee - the general SH committee for a construction project

site that shall be the overall coordinator in implementing OSH program
 Construction SH Officer - any employee/worker trained and, in addition to the
regular duties and responsibilities, tasked by his employer to implement OSH
programs in accordance with the provisions of the OSH Standards
 Construction SH Program - a set of detailed rules to cover the processes and
practices that shall be utilized in a specific construction site in conformity with the
OSHS including the personnel responsible and the penalties for violation thereof.
 Emergency Health Provider - any person or organization who is certified or
recognized by DOH and who can provide the same or equivalent emergency health
services as an emergency h0ospital, including emergency treatment of workers on
site, emergency transport and care of injured workers to the nearest hospital, with
adequate personnel, supplies and facilities for the complete immediate treatment of
injuries or illnesses.

Section 4: Coverage

The guidelines shall apply to all construction activities, including demolition, whether owned
by the private or the government sector.

Section 5: Construction Safety and Health Program

Before the start of the actual construction, the construction project manager shall prepare
and submit to DOLE Regional Office a comprehensive construction safety and health
program.

Construction Safety and Health Programs


 Safety and Health Committee
 Safety Policies
 Penalties and Sanction
 Orientation, Instruction and
Training
 Waste Disposal
CORE1 COMPETENCIES EIM NCII
Construction SH Programs

 Executed and verified by the construction project manager or project manager.

 Shall be submitted to Regional Offices for approval or modification.
 cost shall be integrated into the project cost, provided it shall be a separate pay item.

Section 6: Personal Protective Equipment

All employers must provide personal protective equipment for all employees needing such equipment. All
other persons entering the construction site must wear the necessary protective equipment. The equivalent
cost for the provision of PPE shall be an integral part of the project cost.

Personal Protective Equipment

 For Specialty Construction Workers

 For all other persons authorized or allowed within the construction site.
 Free of charge

Section 7: Safety Personnel

A means of coordination was established wherein the main or general contractor shall have overall
management and coordination of all safety and health officers /personnel working within the construction
site. All full-time safety and health personnel must be accredited by DOLE.

Safety Personnel

 General constructor must provide for a full-time general construction safety and health officer
 Additional construction SH Officer depending on the number of workers
 Subcontractor’s safety officer

Safety Personnel Requirement DO 16 & DO 13

Hazardous Workplaces
No. of Workers Safety Personnel

1 – 50 1 Part-time Safety Man

51 – 200 1 Full-time Safety Man
201 – 250 1 Full-time & 1 Part-time Safety Man
251 – 500 2 Full-time Safety Man
Every additional 500 or fraction thereof 1 Additional full-time safety man
1 Safetyman for every 10 units of heavy equipment

Section 9: Construction Safety Signages

Mandatory provision of safety and warning signs are reiterated not only for the protection of workers, but
also the public in general. Signs should conform with the standard requirements of the OSHS.

 Usage of PPE
72 JOHN JOHN O. GATCHITORENA
TRAINER/ASSESSOR EIM NCII
CORE1 COMPETENCIES EIM NCII
 Falling/ falling objects
 Explosives and flammable substances
 Tripping or slipping hazards
 Toxic or irritant airborne contaminants/substances
 Electrical facility
 Dangerous moving parts of machines
 Fire alarms/ fire fighting
 Instructional signs/ Update of man-hours lost

Section 10: Safety on Construction Heavy Equipment

 Pre-Construction
o Operators tested and certified by TESDA
o Heavy equipment tested and certified by DOLE or its recognized organizations
 During Construction
o Mobilization or transport of heavy equipment
o Standard procedure in erection and dismantling
o Routine inspection

Construction Safety and Health Committee

Composition

Chairperson: Project Manager

Secretary: Gen. Construction Safety Officer

Construction Safety Officers
Safety Reps. From Sub-con
Members:
Health Personnel
Worker’s Representatives

Duties

 Direct accident prevention efforts in accordance with rules/ program

 Conducts toolbox meetings everyday
 Review inspections and accident investigation reports
 Prepare and submit to DOLE minutes of committee meetings, work accidents and illnesses, and
other reporting requirements
 Assist government inspectors
 Initiate/ supervise safety and health training for employees
 Develop and maintain a disaster contingency plan

Safety Inspection

 Safety Inspection is a systematic way of identifying potential workplace hazards before they cause a
health and safety problem.

“An inspection is a service to an organization and its workforce; NOT a burden”

73 JOHN JOHN O. GATCHITORENA

TRAINER/ASSESSOR EIM NCII
CORE1 COMPETENCIES EIM NCII
Inspections are needed because nothing is completely risk-free...

 Things wear out

 Conditions change
 People are not perfect

Purposes of Safety Inspection

 Eliminate Hazards
 Assess Effectiveness of OSH Program
 Display Visible Management Commitment to Safety
 Establish Accountability
 Identify Training Needs
 Fulfill Legal Obligations

Section 12: Safety and Health Information

A detailed safety and health information system is included in the guidelines. These include orientation,
instructions, and training for workers; means of conveying safety related information to all workers and
specialized instructions and trainings for specialty workers and operators.

General Safety and Health Measures

 Basic rights and duties of workers

 Emergency procedures
 Good housekeeping
 Welfare and first-aid facilities
 Care and use of PPE
 Personal hygiene and health protection
 Safety and health rules and regulations

Tool Box Meeting (TBM)

 a 10-15-minute on-the-job safety and health awareness meeting focusing usually on the current
activities of the group to keep everybody informed and alert on work-related accidents and illnesses
and their causes.

Benefits of a TBM

 It addresses actual safety and health concerns on the job or in the site.
 It provides good opportunity for supervisors to know the mental and physical conditions of workers.
 It also provides good opportunity for management to communicate its commitment to safety

Who conducts the TBM?

Usually the supervisor, foreman or leadman (the project manager, safety officer, nurse may serve as
guests)

Section 13: Construction Safety and Health Training

74 JOHN JOHN O. GATCHITORENA

TRAINER/ASSESSOR EIM NCII
CORE1 COMPETENCIES EIM NCII
All safety personnel assigned within the construction site are required to undergo the basic construction
safety training course prescribed by the Bureau of Working Conditions. Continuing training (minimum of 16
hours per year) for all full-time safety personnel shall also be a responsibility of each constructor.

Safety and Health Training

 Basic Construction Safety and Health Training (BOSH)

 Continuing Training (minimum of 16 hours per year)

Specialized Instruction and Training

 Operation of construction equipment

 Erection or dismantling of scaffold
 Excavation works
 Workers engaged in pile-driving
 Erection of steel structural frames and tall chimneys
 Handling hazardous substances and materials
 Rigging and signaling

Section 14: Construction Safety and Health Reports

 The monthly submission of summary reports to DOLE is required. The summary reports shall
include safety committee meeting agreements, accident investigation reports, and hazard
assessments with corresponding remedial action/measures required.
 Notification of major accidents to DOLE within 24 hours

Section 15: Construction Worker’s Skills

A Skills certificate shall be required for construction related occupations which have been classified as
“Critical Occupations” by TESDA.

An occupational shall be considered as critical

– When it may affect and endanger people’s lives and limbs.

– When it involves the handling of hazardous tools, equipment, supplies.
– When it requires a relatively long period of education and training.
– When the performance of the job may compromise the safety, health and environment concerns
within the immediate vicinity of the construction site.

TESDA shall:

 establish national skills standards for critical construction occupations

 prepare guidelines on skills testing and certification
 accredit construction sector organizations in the area of skill training and trade testing
 extend relevant assistance to construction sector organizations
Section 16: Worker’s Welfare Facilities

The employer shall provide for adequate supply of safe drinking water, adequate sanitary and washing
facilities in order to ensure humane conditions of work.

75 JOHN JOHN O. GATCHITORENA

TRAINER/ASSESSOR EIM NCII
CORE1 COMPETENCIES EIM NCII
Section 17: Cost of Construction Safety and Health Program

The total cost of the Construction Safety and Health Program Shall be a mandatory integral part of the
construction project. It shall be treated as a separate pay item and reflected in the project’s bid tender
documents.

Section 19: Violations and Penalties

Violations committed by constructors as determined by DOLE after due process shall be considered as
prima facie case of a construction mal-performance of grave consequence under RA 4566 (Constructors’
Licensing Law) as amended and pertinent IRR.

In cases of imminent danger situations, the procedures/requirements of the OSHS and DOLE regulations
shall be applied.

Section 20: Effectivity

The Guidelines shall be immediately effective, that is, 15 days after publication in newspapers of general
circulation, as provided in Article 5 of the Labor Code.

Wiring Procedure such as Cable Lay-out, pulling splicing and termination of wire

The common methods of cable laying are:

 Direct in the ground in trenches (underground cables).
 In cable trenches in outdoors switchyards.
 In cable trays or cable ducts
 Fixed with clamps (usually at walls and ceilings).
 In conduits

CABLE LAYING ARRANGEMENT

Multicore cables are laid in “flat formation” arrangement and single core cables may be laid in “trefoil”
arrangement or in “flat formation” arrangement.

SEGREGATION OF CABLES

No matter what method is used for laying, cables must be segregate taking into account the voltage level
and function, in order to avoid possible electromagnetic interferences that can disturb the networks and the
signals cables are carrying on.

Segregation means that cables with different voltage levels and/or different functions must not be laid at the
same physical support and must be separated.

Segregation of cables must be done in accordance with standards and regulations, as well as local
authorities’ recommendations and must consider the following situations:

 Power cables (by voltage level).

 Control cables.
 Communication cables.

76 JOHN JOHN O. GATCHITORENA

TRAINER/ASSESSOR EIM NCII
CORE1 COMPETENCIES EIM NCII
CABLE MARKING

Cables must be identified along cable runs, using cable markers or labels, showing the reference of each
cable.

This identification shall be according to the following principles:

 Every 150 m.
 Changes in direction
 Both ends

For underground cables splices must be marked and along the cable run wood or concrete markers shall
be installed to identify cable run.

CABLE LAYING

Cables for power transmission and distribution networks and cables for major communications networks
within city areas are usually installed in trenches, directly buried in the ground.

In most countries LV and MV distribution networks, mainly in rural areas are overhead lines.

Also, HV transmission network are overhead lines.

However overhead lines present some disadvantages:

 Occupy more area.

 Have more visual impact
 Emanate electric fields that can affect people
 Are affected by storms, namely lighting phenomena.

By these reasons’ electrical distribution companies and some electric transmission companies have made
an option for underground cables, although it is a more expensive solution.

Underground cables present a set of advantages in relation to overhead lines:

 It provides the missing cross border link to urban or near to rural areas
 Underground cables are not susceptible to storm damage
 Underground cables are “invisible", so no visual intrusion
 Lower losses
 No electric field emanates from underground cables
 Magnetic field from underground can be managed, by use of trefoil arrangement and shielding

Underground cables must be mechanically protected – power cables are required to be armored - and
communications cables must be protected by conduits – plastic or metallic.

Also, power cables may be protected by plastic conduits, namely when crossing roads and other traffic
routes; according to the recommendations of local authorities’ conduits may be concrete enclosed.

The depth of the trench depends on local regulations and trenches must be provided with a cable tile and a
warning tape.

77 JOHN JOHN O. GATCHITORENA

TRAINER/ASSESSOR EIM NCII
CORE1 COMPETENCIES EIM NCII
Manholes for inspection shall be provided.

In outdoors switchyards cables are installed in concrete trenches (pre-fabricated or site fabricated) with
covers.

These trenches must have drains and a suitable inclination to avoid rain water to accumulate; they also
must be provided with metallic supports for cable laying.

Cables may also install in cable trays.

Cable trays must be chosen according to environmental conditions, like strong chemical corrosion and may
be made of:

 Galvanized steel
 Stainless steel
 Aluminum
 Glass-fiber reinforced plastic

Cable trays may be provided with a cover and cables must be tight with cable ties. Cables may also be
installed with clamps fixed on ceilings and walls, mainly LV cables. Mainly in residential installations cables
may be installed in conduits (plastic or metallic), usually recessed. Communications cables usually are
installed in conduits, for mechanical protection. However, in industry and in substations it may be required
to install power cables in metallic conduits for mechanical protection. When metallic conduits are used for
single core cables, those conduits must be of a non-magnetic material, in order to avoid induced current in
the conduit and the consequent heating of the conduit.

CABLE PULLING

Cable pulling if it is not done properly may cause damages to the outer sheath of the cables, this leading,
sooner or later, to a fault in the cable. Pulling tension must be in accordance with the type of cable and the
instructions of the manufacturer must be followed. Also, maximum bending radii indicated by the
manufacturers must not be excited. For long runs, when installing cables in trenches and cable trays
special equipment’s and tools must be used:

 Cable pulling winch (mechanical drive)

 Cable feeders for reels
 Cable rollers
 Tirfors

When installing cables in conduits approved lubricants of type compatible with cable jacket must be used to
reduce pulling tension. If more than one cable is to be installed in the same conduit they must be installed
simultaneously. A “fish tape” shall be used.

78 JOHN JOHN O. GATCHITORENA

TRAINER/ASSESSOR EIM NCII