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Wa0006.

Chapter One discusses the installation of wiring enclosures, focusing on conduits that protect electrical cables from damage. It covers various types of conduits, including rigid steel, EMT, PVC, and flexible conduits, along with their advantages and disadvantages. The chapter also outlines installation techniques, conduit fittings, and general regulations for proper conduit use.

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0% found this document useful (0 votes)
25 views61 pages

Wa0006.

Chapter One discusses the installation of wiring enclosures, focusing on conduits that protect electrical cables from damage. It covers various types of conduits, including rigid steel, EMT, PVC, and flexible conduits, along with their advantages and disadvantages. The chapter also outlines installation techniques, conduit fittings, and general regulations for proper conduit use.

Uploaded by

iddymbawala983
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 61

CHAPTER ONE

1.0 INSTALLING WIRING ENCLOSURES

1.1 Introduction
The conductors and insulation of cables are protected from external agencies (mechanical
damage and chemical attack) either by an integral protective sheath enclosing the cable or
by a protective enclosure forming part of the wiring system into which the cable is drawn
or laid, for example, a pipe-work system (conduit) or trunking and a ductwork system.
Wiring enclosures are structures consisting of an area in which insulated electrical
conductors (cables) are contained. The main purpose of cable enclosures application are
to provide a mechanical protection of electrical cable, easy for rewiring or modification of
circuit, flexibility and tidy looking.
This chapter discusses and elaborates more about conduits, their types, sizes, advantages
and disadvantages, installation techniques and finally some learning outcome review
questions.

1.2 Conduit wiring system


A conduit is a tube, or pipe in which insulated conductors are contained. The conduit, in
effect, replaces the PVC outer sheath of a cable, providing mechanical protection for the
insulated conductors. A conduit installation is preferred because of its flexibility that it can be
rewired easily or altered at any time, and this flexibility, coupled with mechanical protection,
makes conduit installations popular for commercial and industrial applications.These piping
systems are commonly referred to as cable raceways.
Conduit Classification
There are namely:
a) Rigid steel conduits,
b) Rigid no-metallic (PVC) conduits and,
c) Flexible metallic and non-metallic conduits

1.2.1 Rigid Steel Conduits


Rigid-steel conduit is a heavy-duty pipe that is similar in appearance to metal water pipe.
Rigid-steel conduit provides the best protection from physical abuse because of its
strength. They are either heavy gauge welded or solid drawn. Heavy gauge is made from
a sheet of steel welded along the seam to form a tube and is used for most installation
work. Solid drawn conduit is a seamless tube which is much more expensive and only
used for special gas-tight, explosion-proof or flameproof installations. Rigid conduits are
threaded at both ends (figure 1.1)
Figure 1.1 Heavy gauge conduit (screwed joints)

1.2.2 Electrical metallic tubing (EMT)


The EMTs are solid and they are used in both house and commercial to protect electrical
cables and wiring. EMT conduit is a light-gauge pipe often referred to as thin-wall conduit
(Figure 1.2) The wall thickness of EMT conduit is about 40 percent less than that of rigid-
steel conduit, and because of this thickness EMT conduit can be easily bent. Light gauge
conduits cannot be threaded (because of its thin wall) so special pressure fittings are used to
couple the conduit to the outlet box or during extending the length.

Figure 1.2 Light gauge conduit (plain ended with lug-grip fittings)

Figure 1.3 Comparison of Rigid Metal conduit and EMT conduit


Conduit is supplied in 3.75 m lengths and typical sizes are 16, 20, 25 and 32 mm. Conduit
tubing and fittings are supplied in a black enamel finish for internal use or hot galvanized
finish for use on external or damp installations. The conduit size designator, internal
diameter and its corresponding cross-sectional area is as shown in table 1.1. Common sizes of
EMT conduit in inches are: 1/2, 3/4, 1, 1 1/2, 2, 2 1/2, 3, 3 1/2, and 4.
Table 1.1 conduit sizes
Conduit trade size designator Conduit internal diameter Cross-sectional area
Imperial Metric Inches mm Inches mm2
½ 16 0.62 15.7 0.30 195
¾ 21 0.82 20.9 0.53 345
1 27 1.05 26.6 0.87 559
1¼ 35 1.38 35.1 1.51 973
1½ 41 1.61 40.9 2.05 1,322
2 53 2.07 42.5 3.39 2,177
2½ 63 2.47 62.7 4.82 3,106
3 78 3.07 77.9 7.45 4,794
3½ 91 3.55 90.1 9.96 6,413
4 103 4.03 1.2.3 12.83 8,268
5 129 5.05 128.2 20.15 12,984
6 155 6.07 154.1 29.11 18,760

Some Advantage of metallic conduits


i. Easy for installation and rewired.
ii. Can be utilized as the Circuit Protective Conductor.
iii. Affords cables good mechanical protection.
iv. Minimizes fire risks.
Some Disadvantage of metallic conduits
i. Under certain conditions moisture is liable to form on the inside wall of the conduit.
ii. Expensive compared with some other wiring systems.
iii. Liable to corrosion where subject to acids, alkalis and corrosive fumes.

1.2.3 Rigid Non- metallic (PVC) conduits


Rigid non-metallic conduits are Polyvinyl Chloride (PVC) made from a combination
(a polymer) of both plastic and vinyl. PVC pipes can be installed above ground,
underground or encased in cement. PVCs are most commonly used underground.
These pipes are light weight, flexible, impact resistant, non-conductive, ultraviolet
resistant and corrosion resistant.
PVC conduits are popular because it is impervious to acids, alkalis, oil, aggressive
soils, fungi and bacteria and is unaffected by sea, and air. It withstands all pests and
does not attract rodents. PVC conduit may be buried in lime, concrete or plaster
without harmful effects.)The conduit size and range of fittings are the same as those
available for metal conduit.
PVC conduit is used for concealed (direct burial or concrete encasement) installation.
Figure 1.4PVC conduits

Advantages of PVC Conduits


i. Very long life
ii. Lighter in weight and easy to handle
iii. Anti-corrosive
iv. Can be buried in lime, plaster and concrete
v. Easy to join, they telescope into one another.
vi. Easy to form and bend
vii. Does not require painting
viii. Minimal condensation due to low thermal conductivity in wall of conduit.
ix. Excellent electrical and fire resistant properties
x. Easy to cut and deburr
Disadvantages of PVC conduits
i. Does not provide greater mechanical protection as steel
ii. A separate Circuit Protective Conductor must be run inside the conduit
iii. If insufficient adhesive is used the joints may not be waterproof
IEE regulations require that all non-metallic conduits shall be non-flammable, non-
hygroscopic, damp-proof, mechanically continuous and strong.PVC conduit is not suitable
for installations subject to temperatures below -5 0C or above 65 0C.
1.2.4 Flexible conduits
Flexible conduit is made of interlinked metal or PVC spirals. Flexible metal conduits is
often covered with a PVCsleeving. The tubing must not be relied upon to provide a
continuous earth path and, consequently, a separate current protective conductor (CPC) must
be run either inside or outside the flexible tube (Regulation 543–02–01).
Flexible conduit is used for the final connection to motors so that the vibrations of the motor
are not transmitted throughout the electrical installation and to allow for modifications to be
made to the final motor position and drive belt adjustments (see figure 1.5 (a) and (b)

Figure 1.5 (a) flexible metallic conduit and (b) Flexible non-metallic conduit

1.2.5 Conduit fittings and support


A wide range of fittings are available and the conduit is fixed using saddles or pipe
hooks, (as shown in Fig. 1.6) metal conduits are threaded with. Fittings such as
elbows, bushes, joint boxes, and tee are required to enable continuous run of conduit
following curves, varied path and also to overcome the necessity of separate runs of
conduits for each circuit.

Figure 1.6PVC conduit fitting and support


Figure 1.7 Metallic conduit fittings and support

Figure 1.8 Flexible metal conduit fittings


Conduit boxes
Conduit boxes are used to help the drawing of wired at sharp bends. They come into four
shapes and may have a number of patterns such as two ways “through”, two way “angle”,
three way, four way, back outlet, etc. (see figure 1.9)
i. Circular
ii. Octagonal
iii. Square and,
iv. Rectangular

Figure 1.9Circular conduit boxes


Bends, elbows and Tees
These may be used in place of conduit boxes. There are two types, (a) solid and (b)
inspection.
Solid bend are used instead of bending conduits. They have either external thread or internal
thread.
Inspection bend are internally threaded and fitted with a lid, which when removed enables the
bend to be used as a drawing in/out point for cables.
Elbows are small 900bends. Inspection elbows and tees may be also be used as drawing in/out
point for cables.
Couplings
This is an internally screwed metal tube for joining two conduits together in condition where
neither part can be rotated.
Nipples
Nipples are used to convert internal thread of one size conduit and an internal thread of a
smaller conduit.
Lock rings or lock nut
They are used to stop conduit fitting from becoming loose.
Bush
These are of two types: externally threaded smooth bore bush and internally threaded ring
bushes. They are used to protect cables emerging from conduits.
Stopping plugs
It is used to prevent the conduit from becoming filled with unwanted materials.
Adaptor
It is used to adapt other system to the conduit system such as flexible conduit to non-flexible
conduit, lead sheathed to conduit adaptors etc.
Saddle and earthing clips
Saddle are used to fix conduits to the surface of the wall and earthing clip is used to hold the
earthing wire running along the conduit surface.

Fig. 1.10 Conduit support


1.2.6 Metallic Conduit Finishes
Conduit tubing and fittings are painted with special coat of a clear finish to prevent
the formation of rust. There are three types of finish available for metal conduits:
a) Enamel finish
The conduit and conduit accessories are coated internally and externally
usually with black enamel paint.
b) Galvanizing
This is an internal and external zinc covering applied on conduits during
manufacturing for the purpose of preventing conduits from the formation of
rust.
c) Sherardizing
Sherardizing is a special process by which zinc alloy is embedded in the
surface of the metal, making it rust-proof.

1.2.7 General IEE Requirements regarding conduits


i. The conduit installation must be erected first before any cables are drawn
in(IEE Regulation 522–080–02)
ii. Conduit runs should be separate from other services such as water pipes, gas
pipes, bell alarms, radio and communication circuits, or other metal work,,
unless intentionally bonded, to prevent arcing occurring from a faulty circuit
within the conduit, which might cause the pipe of another service to become
punctured (IEE Regulation D10 and D14; Protection against earth-leakage
currents)
iii. Boxes of fairly large capacity should be included at all places where cables
should be joined.
iv. Metal conduits containing alternating current (ac) circuits must contain all
phases and neutral conductor (if any) in the same conduit to prevent eddy
currents flowing, which would result in the metal conduit becoming hot
(Regulation 521–02–01).
v. The radius of all bends in conduit must not cause the cables to suffer damage,
and therefore the minimum radius of bends must not be less than 2.5 times the
outside diameter of the conduit.
vi. The ends of the conduit must be reamed of filed to prevent damage to the
cable when drawing in.
vii. Conduits installed in damp or wet conditions must have a water and rust
resistant finish.
viii. Extra low voltage and low voltage cables must be run into the same conduit.
ix. All metal conduits must be earthed and all joints must be electrically and
mechanically continuous
x. Drainage points should be provided at the lowest point in a conduit installation
where moisture is likely to collect.

1.3 Installing conduits


Conduit wiring system is best for both domestic and commercial installations. The cables
used in this system is either V.I.R or PVC insulated. Conduits carrying the insulated wires
can be installed on the surface of the walls or concealed in the walls and the ceiling. For the
purpose of good looking appearance conduits installed on the wall surfaces are normally
fixed either vertically or horizontally not at an angle. Modern practice is to conceal the
conduit in the plaster of the wall, so that the appearance of the house remains unaffected.
Once the routes of all conduits length s have been decided, the conduit can be prepared.
1.3.1Conduit Preparation
Conduits are usually brought in length of about 3.5m and will therefore need to be
cut or shapped to make it fit the installation requirements. This section discusses
on how to determine conduit size, Cut, thread, bending, install,perform
calculations, and how to install conductors into the conduit.
i. Conduit size
Conduit is supplied in 3.75 m lengths and typical sizes are 16, 20, 25 and 32 mm.

ii. Cutting the conduit


All conduits should be cut at a 90° angle. Rigid-steel conduit can be cut with either
a hacksaw or a pipe cutter. Although a vise is not absolutely necessary, it makes
cutting with either tool much easier.

Tools and materials required:


a. Fine-teeth hacksaw or pipe cutter
b. Pipe vise
c. Metallic and PVC conduits
d. Reamer
e. Cutting oil (oil can)
Figure 1.11 Conduit cutting tools and material
When cutting any conduit with a hacksaw, use a blade with 18 to 32 teeth per inch. A blade
with fewer teeth hangs up, binds, or even breaks.
Put the blade in the hacksaw frame (with the teeth pointing forward) so that the teeth cut
when you push the saw forward.

Figure 1.12 hacksaw teeth direction


Place the pipe in the vise so that there is ample room between the vise and the cut. This lets
you saw without hitting your hands on the vise and allows enough room for threading
purposes after the cut is made.

Figure 1.13 Fixing a conduit in the pipe vise


Remember, let the saw work for you, do not force it. Use a steady forward cutting stroke with
light to medium pressure.
Figure 1.14 cutting the conduit

Cutting Procedure
1. Secure the material to be cut in a vise or other holding devise to avoid vibration
whichmay snap the blade (see figure 1.15)

Figure 1.15 securing a workpiece in a vise

2. To make an accurate cut, use a triangular file to make a notch for guiding the first
strokes of the saw. (figure 1.16)
Figure 1.16 conduit marking out

3. Steady the saw by holding the handle with the right/left hand and the frame with
the left/right.
4. Hold the blade parallel to the work surface and cut on the push stroke, being
careful not to bear down too hard.
5. Draw the blade back using no pressure each time.
6. Saw at a rate not to exceed 40 to 50 strokes perminute.

Care Of Saws
1. Store blades in a dry place and apply a light coat of oil when not in use. This will
keep theblades from rusting.
2. Never use a metal cutting saw to cut through woods.
3. Do not force the saw if it binds. Use a wedge to spread the cut.
4. Replace damaged saw handles with new ones immediately when needed.
5. To keep saw teeth in top condition, touch up the teeth with a file occasionally.
6. Always loosen the blade tension on a hacksaw when not in use.
7. Always remove the nested saw blade from the handle for storage.

A pipe cutter is also used to cut metallic conduit.

Figure 1.17 Pipe cutter

To use a pipe cutter, place the conduit in the vise as described above for cutting with a
hacksaw. Put the cutter over the conduit and adjust it until the cutting wheel makes
contact at the point of the cut (Figure 1.17)
Tighten the cutter just enough to score the pipe on the first turn. Then, screw the
handle in about one-fourth of a turn for each turn around the conduit until the cut is
complete. Cutting oil can be used to ease the cutting action. Rigid-steel conduit is cut
the same way.
Cutting PVC Conduits
PVC conduit is easily cut using a junior hack saw (figure 1.18) because pipe cutters
may flatten the end of the pipe. Pipe cutters also leave a ridge on the inside of the pipe
that is very hard to remove. Any roughness of cut and burrs should be removed with
the aid of knife blade or simply by wiping with a cloth.

Figure 1.18junior hacksaw

Flexible metallic and nonmetallic conduit should also be cut with a hacksaw at a 90°
angle. Cutting any type of conduit leaves a sharp edge or burrs on the inside of it that
must be removed by reaming.

Reaming conduits
To ream rigid-steel conduit, use the reamer shown in Figure 1.19. A rat-tail file does a
good job on any type of conduit. Use pliers, such as needle-nose or side-cutting pliers,
to ream EMT that has been cut with a hacksaw.

Figure 1.19 reaming a conduit

The important thing is to remove any sharp edge or burrs inside the conduit that might
cut the insulation when the conductors are pulled into it.

Threading Conduit
Once rigid-steel conduit is cut, it must be threaded for use with threaded couplings,
locknuts, and bushings. The thread is cut using stocks and dies rotating them in the
clockwise direction while pushing against the end of the conduit.
The dies used for threading smaller sizes of conduit are usually hand-driven (Figure
1.20). The handle may be solidly attached to the die, or the die assembly may be a
ratchet-type.
Figure 1.20Stocks and dies

Threading Procedure
Before threading the conduit, inspect the dies to see that they are sharp and free from
nicks and wear. Next, insert the conduit into the vise, place the guide end of the pipe
threader on the conduit, and push the threading dies against the conduit with the heel
of your hand (Figure 1.21).

Figure 1.21. Threading conduit

With pressure against the threader, take three or four short, clockwise strokes
downward to start the threads. Continue the threading with clockwise strokes, mixed
with a reverse stroke every now and then, until two or three threads extend beyond the
die. To reverse the threader, pull the ratchet lock out and turn it a half turn. The
reverse turns keep the threads and dies clean and free of bits of metal.

Figure 1.22 threaded coupling


A full thread must be cut so that the ends of the conduit come together in the coupling
(Figure 1.22).
Cutting oil applied during the threading helps the cutting process be easier by
reducing friction. Once the threads has been made the ends must be cleanrd and the
inside of the conduitshould be filed to remove any sharp edges. To remove the
threader, release the ratchet lock and turn the die by hand counterclockwise. Removal
of the die also cleans the threads.
Bending Conduits
When installing conduit, you will need to make bends to go over or around obstacles. These
bends must be made without reducing the inside diameter of the conduit at the bend.
Since most of the bending are done with manual benders, the bending procedures will be
made with aid of bending block or bending machine. If a bending block is used a bending
spring must be placed into the conduit to avoid the conduit from kinking. A bendig machine
is designed to bend a cnduit to the angle required (betwee 00 to 900) without kinking it.
Conduit Sets
Sets are produced by bending theconduit at different points to produce offset bend, three bend
saddle, 900 stub-up bend, or four bend saddle. Bending require some thought, simple math
calculations, and a lot of practice. The angle of simillar set should be parallel to one another.
(see figure 1.23)

Figure 1.23Conduit bend sets


Bending Steel Conduit
The most common method of bending steel conduit is to use a bending machine. However,
for bending 32mm diameter or larger conduits it is recommended to use a portable ratchet
bender.
Figure 1.24 . Metallic conduit bending machines
The following are the main steps to be taken when using a bending machine.
a) Insert the conduit under the stop and into the groove in the former.
b) Pull down the handle, allowing the roller to bend the conduit around the former.
c) Use a template to compare the angle of the bend formed with the desired angle.
Remember; bends should be formed to an internal radius of not less than 2.5 times the
conduit diameter.
Making a 900 Bend in Steel Conduit
If a piece of 20cm conduit measuring 50cm from the back of the end of the conduit is desired;

Figure 1.25 Taking measurement


The first step is to measure and mark off 50mm from the end of the conduit figure 1.21
Figure. 1.26 . Marking out
i. Place the conduit in the bending machine former with thread and most of the
70cm sticking out of the back of the bending machine.
ii. . Position the conduit so that a try-square, held against the mark touches and forms
a tangent to the edge of the former as illustrated in Figure 1.26

Figure 1.26 positioning of a conduit and try square in the bending machine

iii. Using a set square, line up the 70cm mark with the front edge of the bending
machine former making sure that the conduit is touching and parallel with the set
square.

Figure 1.27 Testing the edge and marking out

iv. Bend the conduit to 90 degree by pulling the bender handle toward you. Use a
firm and steady motion to avoid kinks or crimps in the conduit.
Figure .1.28. Bending a conduit
Check to make sure your bend is the right angle (90 0) by either holding it up to the wall, door
frame, window frame, work bench or by using a set square. You can also hold it to a surface
you know is level to check it.

Figure 1.29 A complete perfect 900 bend

Making an offset bend


Offset bends are used to move a run of conduit from one plane to another. An offset is
normally used to bend the conduit around an obstruction, or to relocate the conduit close to a
structural member to make it easier to fasten the conduit. Figure 1.30 shows an example of
an offset bend.
Figure 1.30 an offset bend
Normally offsets should be formed at either 30° or 45°. A 30° offset is preferred for two
reasons:
i. Ease of measurement.
ii. Ease of drawing-in cables.

Forming of a 30° Offset


A rule of thumb for right angle triangle (30 0, 600 and 900) states that the realationship
between the three sides is in the ratio 1:2:√ 3 as shown in figure 1.31

Figure 1.31 A right angled triange rule


After knowing the dimmentions of the offset (100mm in this case) it is time to calculate and
mark off the distance between the two ends. At this point take the straight piece of conduit
and mark on it where you want the first bend to start from, then measure 200mm from that
point to where the second bend starts, as shown in figure 1.32

Figure 1.32 conduit marking out


Now go to the bending machine. Mark a point on the former as shown in Figure 1.33(a).
Place the conduit in the former matching the first mark on the conduit with the mark on the
former and bend to 30° as shown in Figure 1.33(b). Now remove the conduit and check the
offset angle against a 30° template.
Figure 1.33 bending machine former preparation
Place the conduit back in the machine pointing in the same direction as before but inverted
and match the second mark on the conduit with the mark on the former, see Figure 1.33. The
second offset is now formed until it is in parallel with the first offset.
Alternative offset bending method

Figure 1.34 Marking out


Suppose it is required to bend an off set of 50mm set position as in figure 1.34mark off the
distance of one end. Then with the help of a straight edge such as a work bench or floor,
place the conduit parallel along to its length as shown in figure 1.35 and mark out distance X
equal to 50mm.Then, mark at poit C where the conduit crosses the straight line. This is the
second bending point. Place the conduit back in the bending machine and complete the offset
bend.

Figure 1.35Bending the offset bend

Making a Saddle Set (Jump) in Steel Conduit


Saddle bends are used to route conduit around an obstruction (figure 1.36 (a) and (b)

Figure 1.36 (a) three point saddle. (b) Four point saddle

Figure 1.37 example of conduit obstacles


Position the conduit over the obstacle, marking it where it crosses the straight line on the
floor.
Place the conduit back in the bending machine and when the outside edge of the conduit lines
up with one of the marks on the conduit then start bending.
Figure1.38Bending a saddle set
Turn the conduit round and do the same as above until the conduit is parallel.

Alternative method: (by Calculations)

Figure 1.39 450 marking out


The following formula is used to calculate the position of the next two bend which must be
formed in order to attain the 30mm clearance required.

Opposite
Sine= … … … … … … … … … … … … … … …(1.1)
hypotenuse
In this case:

30 30
Sine= Hypotenuse=
hypotenuse sine 22.5

Hypotenuse=78 mm
Figure 1.40 (a) to (d) illustrates the application of the formula.

Figure 1.40 (a) Pythagoras theory


Figure 1.40(b) Conduit marking out

Fig 1.40 (c) Conduit bending


Reverse the conduit in the former and match mark 3 with the existing former mark. Bend
down until the edges of the conduit are in line, see Figure 1.33.

Figure 1.40 (d) complete saddle set

Bending PVC Conduit


Cold bending of PVC conduit may be carried out on conduit sizes up to 25mm diameter using
a bending spring, see Figure 1.41. It is essential to use the correct size bending spring.
It is important that the spring is not damaged or kinked. A faulty spring can cause the conduit
to kink and fracture. The spring can also jam inside the bend.
The radius of the bends should be as near as possible to that of a similar bend formed in steel
conduit of a similar size. Having inserted the spring into the conduit, grip the conduit on
either side of the proposed bend and bend the conduit slowly, as illustrated in fig. 1.41.

Figure 1.41 Bending PVC Conduit using a bending spring


The conduit should be bent to a more acute angle than the angle finally desired because of the
tendency of PVC to “recover” after bending. This tendency lessens as the temperature
decreases.
In very cold weather it is recommended that the conduit is warmed slightly by rubbing with a
cloth held in the hand. If the conduit is bent too quickly there is a risk of kinking and / or
fracturing of the conduit and possible damage to the bending spring.
If the conduit is intended for surface work it should be saddled and fixed as soon as possible
after bending. Once a bend has been formed it should not be forced backwards as this can
damage both the conduit and the spring.
To remove the spring, twist it in an anti-clockwise direction. This will reduce the diameter of
the spring and make it possible to pull the conduit and spring apart. If the spring jams during
this operation do not pull hard on it, otherwise the spring will be damaged.
Hot Bending of PVC Conduit
Hot bending of conduit should be carried out on sizes over 25mm diameter. A bending spring
of the correct size should be used. Apply a gentle heat preferably with a hot air torch, electric
heating element or hot water. Bend the conduit in accordance with above instructions and
Fig. 1.41.
Care should be taken to avoid the direct application of flame to the conduit. When the conduit
is in a pliable state it should be slowly bent around a suitable former and held in position for
about one minute until set. After setting, the bending spring may be twisted anti-clockwise
and removed.
Termination of Steel Conduit to Enclosures
Two methods of terminating steel conduit are commonly used.
a. The coupling and male bush method, see Figure 6A (Usually used and preferred)
b. The locknut and female bush method, see Figure 6B (Used where space is tight)

Coupling and Male bush Method


The coupling and male bush method is slightly more expensive than the locknut and female
bush method but it allows more wiring space and is a stronger form of termination. Using this
method a coupling is screwed securely on to a standard threaded conduit end and then butted
against the accessory box. A male bush is passed through the box entry and screwed tightly
into the coupling using an open-ended spanner or a bushing spanner.

Figure. 1.42 Terminating steel conduit withcoupler and male bush

Locknut and Female Brass Bush Method


Using this method a locknut is screwed tightly onto a standard threaded conduit end and the
thread passed through the hole in the accessory box. A second locknut is screwed onto the
conduit effectively sandwiching the wall of the box. To prevent damage to cables, from the
exposed end of the conduit, a female bush is then screwed onto the conduit thread. One
disadvantage in using this method of terminating a conduit to a switch or socket box is that
the conduit protrudes into the box and may inhibit the fixing of the switch or socket.
Figure. 1.43 Terminating steel conduit withlocknut and femalebrass bush

Figure. 1.44 Conduit fittings and support

Figure 1.45 EMT fittings


Conduit capacities and Space factor
Single PVC insulated conductors are usually drawn into the installed conduit to complete the
installation. Having decided upon the type, size and number of cables required for a final
circuit, it is then necessary to select the appropriate size of conduit to accommodate those
cables.
The tables in Appendix 5 of the IEE Regulations describe a ‘factor system’ for determining
the size of conduit required to enclose a number of conductors.
The tables are shown in Tables 1.2 and 1.3 of thischapter. The method is as follows:
i. Identify the cable factor for the particular size of conductor.(This is given in Table
12A for straight conduitruns and Table 12C for cables run in conduits
whichincorporate bends, see Table 1.2 of this chapter.)
Table 1.2 Conduit cable factors. Reproduced from the IEE Regulations. (Institution of
Electrical Engineers)
Table 12C Cable factors for use in conduit in long straight runs over 3 m, or runs of any
length incorporating bends
Type of Conductor Conductor cross-sectional area mm2 Cable factor

Solid 1 16
or 1.5 22
Stranded 2.5 30
4 43
6 58
10 105
16 145
25 217
16 145

Note: The inner radius of a conduit bend should be not less than 2.5 times the outside
diameter of the conduit.
ii. Multiply the cable factor by the number of conductors, to give the sum of the cable
factors.
iii. Identify the appropriate part of the conduit factor table given by the length of run and
number of bends. (For straight runs of conduit less than 3m in length, the conduit
factors are given in Table 12C. For conduit runs in excess of 3 m or incorporating
bends, the conduit factors are given in Table 12D, see Table 1.3 of this chapter.)
iv. The correct size of conduit to accommodate the cables is that conduit which has a
factor equal to or greater than the sum of the cable factors.
Example 1.2.1
Six 2.5mm2PVC insulated cables are to be run in a conduit containing two bends between
boxes 10 m apart. Determine the minimum size of conduit to contain these cables.
Solution:
From Table 12C, shown in Table 1.2of this chapter:-
The factor for one 2.5mm2 cable = 30
The sum of the cable factors = 6 x 30 = 180
From Table 12D shown in Table 1.3:-
A 25 mm conduit, 10 m long andcontaining two bends, has a factor of 260.
A 20 mm conduit containingtwo bends only has a factor of 141 which is less than 180, the
sum ofthe cable factors, therefore, 25 mm conduit is the minimum size tocontain these cables.
Example 1.2.2
Ten 1.0mm2PVC insulated cables are to be drawn into a plastic conduitwhich is 6 m long
between boxes and contains one bend. A 4.0 mm PVCinsulated CPC is also included.
Determine the minimum size of conduit tocontain these conductors.
Solution:
From Table 12C, and shown in Table 1.4The factor for one 1.0 mm cable = 16
The factor for one 4.0 mm cable = 43
The sum of the cable factors = (10 x 16) + (1 x 43) = 203
From Table 12D shown in Table 4.6, a 20 mm conduit, 6 m long and containingone bend, has
a factor of 233. A 16 mm conduit containing onebend only has a factor of 143 which is less
than 203, the sum of thecable factors and, therefore, 20 mm conduit is the minimum size to
containthese cables.
Table 1.3 Conduit cable factors for runs incorporating bends.
Table 12D Cable factors for runs incorporating bends and long straight runs
Conduit diameter, mm
Length 16 20 25 32 16 20 25 32 16 20 25 32 16 20 25 32 16 20 25 32
Of
Run
(m) Straight One bend Two bends Three bends Four bends

1                
Covered
1.5                
by
2                
2.5 Tables                
3            
A and B

3.5                
4                
4.5                
5                
6            
7            
8            
9            
10            

Aditional factors:
For 38mmϕ use …………1.4 x (32mm factor)
For 58mmϕ use ………… 2.6 x (32mm factor)
For 63mmϕ use ………… 4.2 x (32mm factor)
Space factor
This is the ration (in percentage) of the sum of the overral cross-sectional area of all cables
(including insulation) to the internal cross-sectional area of the conduit where,
(csa of all cables)
Space factor = ×100 % … … … … … … … … ..(1.2)
(Internal csa of conduit )
The maximum permissible conduit space factor is 40%. In other words, the area of the cables
must not exceed 40% of the internal cross-sectional area of a conduit. The 60% empty-space
requirement is intended to enable the dissipation of the heat produced by the current-carrying
conductors grouped inside the conduit.
Apendix 12 of the IEE Regulations gives tables showing how to calculate the maxmum
number of cables allowed in certain size of conduit.
Table 12A and 12B of the IEE Regulations, refers to straight conduit length of 3m of less.
Table 12A and 12D refers to longer runs including bends and sets.
Table 1.4 Straight Conduit cable factors.
Table 12A straight conduit length of 3m or less
Type of conductor Conductor Cross-sectional Factor
2
area (mm )
Solid 1 22
1.5 27
2.5 39
Stranded 1.5 31
2.5 43
4 58
6 88
10 149

Table 12B
Conduit diameter (mm) Cable factor
16 290
20 460
25 800
32 1400

Example;
Calculate a suitable conduit size which can be used to accommodate the following cables;
4 x 1.5 mm2 solid cables
4 x 1.5mm2 stranded cables
2 x 2.5mm2 stranded cables
Solution:
i. Find the cable factors and multiply by the number of cables:

(a) The factor for one 1.5mm2 solid cable = 27


The sum of the cable factors = 4 x 27 = 108
(b) The factor for one 1.5mm2 stranded cable = 31
The sum of the cable factors = 4 x 31 = 124, and

(c) The factor for one 2.5mm2 stranded cable = 43


The sum of the cable factors = 2 x 43 = 86

Next add together to get the sum of the cable factor:

The sum of the cable factors = 108 + 124 + 86 = 318


From Table 12B shown in Table 4.6:-
A suitable conduit diameter is one with a cable factor of not less than 318, in this case 20mm
straight conduit.

Installing Conductors
Nearly all types of wire may be used in conduit installation; however, the most common type
used is moisture-resistant thermoplastic. To determine the length of wire to be installed, add
the length of conduit and the length of wire to be left in the boxes for connections (usually 10
to 15cm for each outgoing wire). If the conductors are to be connected into the breaker panel
add conductor lengths, in cm, equal to the length and width of the breaker panel.
The general procedure for installing conductors in conduit is the same for all types of conduit.
Conductors are installed by pulling them through the conduit. The pulling is done with a
special tool called a fish tape (Figure1.46).A fish tape is a thin, flexible metal tape with a
hook on one end. The tape is usually packaged on some type of reel. The tape is used to pull
wires through conduit or through openings in walls. For conduit use, the tape is inserted in
one conduit opening and worked through to the next opening. The wires to be drawn through
the conduit are bent around the hook on the fish tape.
Figure 1.46 Fish wires
All conduit installations must be erected first beforeany wiring is installed (IEE
Regulation 522–080–02).

Figure 1.47 conduit installation


Cables should be fed into the conduit in a mannerwhich prevents any cable crossing over
and becomingtwisted inside the conduit. The cable insulation mustnot be damaged on the
metal edges of the draw-inbox. Cables can be pulled in on a draw wireif the runis a long
one. The draw wire itself may be drawn in ona fish tape, which is a thin spring steel or
plastic tape.
Figure.1.48connecting conductors to the fish tape (staggered)
A limit must be placed on the number of bendsbetween boxes in a conduit run and the
number ofcables which may be drawn into a conduit to preventthe cables being strained
during wiring. Table 12Dof the IEE Regulations gives a guide to the cable capacitiesof
conduits and trunking.

Figure 1.49 attachment of conductors to fishing line tapped over


When more than one conductor is to be pulled, the connection to the fish tape should be
staggered to avoid a bulky connection that would make pulling difficult (Figure 1.48)The
attachment may also be tapped over with suitable slippery tape to avoid friction. (figure 1.49)
Chapter review questions
1. What is meant by conduit?
2. Why must a conduit system be erected before wires are drawn in?
3. List three types of conduit used in electrical installation work.
4. Four 1 mm cables and four 2.5 mm cables are to be run in a metal conduit which
contains one right-angle bend and one double set. The distance between the boxes is 8
m. find the size of conduit required to enclose these cables.
5. Calculate the number of 1.0 mm cables which may be drawn into a 5 m straight run of
20mm conduit.
6. What is the difference between heavy gauge metallic conduit and light gauge metallic
conduit?
7. Mention two methods of bending PVC conduit
8. A space factor for conduit is
a. 450
b. 350
c. 400
d. 600
9. Conduit threads are cut by means of ______________________________
10. What is reamer?

CHAPTER 2
2.0 CABLE TRUNKING
2.1Introduction
A trunk is a rectangular section enclosure usually made of plastic, polyvinyl chloride (PVC.)
or metal sheet having one removable side.Where large number of cables follow the same
route or where cable sizes are large a trunking system will be used instead of a very large
conduit or multiple run of smaller conduits. It is available in two ranges, ordinary wiring
trunking and bus-bar trunking. The ordinary system is further available in either metal or
PVC. Trunking is usually supplied in length of 3 to 4 metres but longer length is available.
A cable tray is also a cable carrier that is used at some situations such ascommercial and
industrial constructione.g when making power distributions at a power room etc. In this
chapter we shall therefore discuss both trunking and tray systems of cable carriage.
2.2.0 Erecting PVC trunking
The main areas in which PVC trunking is used are domestic and office premises. All
necessary fitting are available to complete any shape of run with little difficulty. The
accessories are usually secured to the lengths of Trunking with a PVC solvent adhesive or
screwing.PVC. Trunking is available in categories that are mini-trunking (mainly for use in
domestic or small and special installation), Multi-compartment trunking and skirting
trunking.
PVC mini- Trunking
This isvery smallPVCtrunking,ideal for surface wiring in commercial installations such as
offices for carrying small cables such as computer cables,internal telephone cables etc.The
trunking can also be used in domestic when it seems to be convenient.The trunking is
screwed directly to a wall and there are various trunking sizes up toa minimum size of 16mm
by 10mm denoted as16x10mm.
When a trunking needs to pass through a corner,say,90 ° a smart cutting design should be
made.
Preparation and installation procedures
The preparationprocess involves the following stages:
a. Identify the required size of the mini-trunking piece(s)
b. Anticipate the number and nature of corners each trunking should pass
c. Gether useful tools,equipments and materials required in the whole process
d. Indicate markings on the trunking for bending or cutting purposes.Be very precise to
avoid undesirable material destruction
e. Cut or bend the trunking in the required shapes and corners e.g. 90° angle of bend etc
f. Collect the processed trunking pieces for fitting or installing on wall or
board.However,you must have drilled the board or wall before installlation starts.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,drilling machine,set of screw
drivers,fischers and screws

Safety measures to observe


During the practical performance you must be wearing overall and safety boots.Make
sure you maintain best practice and good workmanship.
Figure 2.1show typical mini-trunking sizes and a place of application.

Fig.2.1
Multi-Compartment Trunking
Where an installation comprises a mixture of low-voltage and very low voltage circuits such
as mains lighting and power, fire alarm and telecommunication circuits, they must be
separated or segregated to preventelectrical contact (IEE Regulation 528.1). For the purpose
of these regulations various circuits are identified by one of two bands as follows:
Band one cables which are for telephone, radio, bell, call and intruder alarm circuits,
emergency circuits for fire alarm and emergency lighting.
Band two cables which are for mains voltage circuits.
Preparation and installation procedures
The preparationprocess involves the following stages:
a. Identify the required size of the multi compartment trunking piece(s).Be concious of
the cable bands you have
b. Anticipate the number and nature of corners each trunking should pass
c. Gether useful tools,equipments and materials required in the whole process
d. Indicate markings on the trunking for bending or cutting purposes.Be very precise to
avoid undesirable material destruction
e. Cut or bend the trunking in the required shapes and corners e.g. 90° angle of bend etc
f. Collect the processed trunking pieces for fitting or installing on wall or
board.However,you must have drilled the board or wall before installlation starts.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,drilling machine,set of screw
drivers,fischers and screws

Safety measures to observe


During the practical performance you must be wearing overall and safety boots.Make
sure you maintain best practice and good workmanship.

Figure 2.2 shows a typical multi-compartment trunking

Fig.2.2
Skirting Trunking
This is widely used in offices where a lot of socket outlets are required. The trunking is run
around the bottom of the wall and socket outlets accessories can be placed at various intervals
along the trunking.
Preparation and installation procedures
The preparationprocess involves the following stages:
a. Identify the required size of the multi compartment trunking piece(s).Be concious of
the socket outlets to incorporate
b. Anticipate the number and nature of corners each trunking should pass
c. Gether useful tools,equipments and materials required in the whole process
d. Indicate markings on the trunking for bending or cutting purposes.Be very precise to
avoid undesirable material destruction
e. Cut or bend the trunking in the required shapes and corners e.g. 90° angle of bend etc
f. Collect the processed trunking pieces for fitting or installing on wall or
board.However,you must have drilled the board or wall before installlation starts.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,drilling machine,set of screw
drivers,switched-sockets,fischers and screws.Cable laying and termination should
automatically be the last stape in the task.

Safety measures to observe


During the practical performance you must be wearing overall and safety boots.Make
sure you maintain best practice and good workmanship.
Figure 2.3 shows a typical skirting trunking fitted on a wall.

Fig.2.3

2.2.1Erecting metallic trunking


Metallic trunking is available in different finishes the most popular being grey painted and
sheradized.When installed in a factory trunking should be painted orange to indicate that it
contains electrical conductors. Trunking is available in different gauges (thickness) i.e. light
gauge and heavy gauge. With metallic trunking, since the trunking forms part of the circuit
protective conductor (c.p.c.) i.e. the earthing system, the length of the trunking and fitting all
need to be bounded together (see figure 2.4)
Preparation and installation procedures
The preparationprocesses of istalling light gauge and heavy gauge metallic trunking are
almost the same.They involve the following stages:
a. Identify the required size of the metal trunking piece(s).
b. Anticipate the number and nature of corners each trunking should pass
c. Gether useful tools,equipments and materials required in the whole process
d. Indicate markings on the trunking for bending or cutting purposes.Be very precise to
avoid undesirable material destruction
e. Cut or bend the trunking in the required shapes and corners e.g. 90° angle of bend etc
f. Collect the processed trunking pieces for fitting or installing on wall or
board.However,you must have drilled the board or wall before the trunking
installlation starts.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,drilling machine,set of screw
drivers,measuring tape,fischers and screws.Cable laying and termination should
automatically be the last stape in the task.

Safety measures to observe


During the practical performance you must be wearing overall and safety boots.Make
sure you maintain best practice and good workmanship.

Figure 2.4 Typical trunking pieces

Busbar Trunking
This system of trunking has solid conductors of Copper or Aluminium fixed inside it.This
type of trunking is basically devided into two types namely :
i.Rising mains busbar trunking and
ii.Overhead or Tap-On basbar trunking
The rising mains busbar trunking
The rising mains busbar trunking is normally for supplying mains to each floor of a multi
storey building and is usually mounted vertically as shown in figure 2.5.

Figure 2.5 Typical rising main bus bar trunking installation

Preparation and installation procedures


The preparationprocess involves the following stages:
a. Identify the required size of the basbar piece(s).

b. Gether useful tools,equipments and materials required in the whole process


c. Indicate markings on the basbar for any required process.Be very precise to avoid
undesirable material destruction
d. Collect the processed basbar pieces for fitting or installing with the trusses or wall
support etc.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,set of spanners,screw drivers,bolts and nuts, supporting
brackets,portable drill machine,step ladder,cold chisel,club hammer,spirit level, and
screws.Cable termination should automatically be the last stape in the task.

Safety measures to observe


During the practical performance you must be wearing overall and safety boots.Make sure
you maintain best practice and good workmanship.
The Overhead or Tap-On basbar trunking
The Overhead or Tap-On basbar trunking is commonly used in factories or other industrial
installation.This type of trunking is constructed so that tap-on boxes may be plugged in at
regular intervals .The tap-on box contains a set of contacts for plugging into the busbar and
fuses for outgoing circuit. Figure 2.6 shows a typical Overhead or Tap-On basbar
trunking.Overhead bus-bar trunking is ideal for distribution in factories. It is run at high level
and the tap-off boxes enable machinery to be moved easily. When connected in the form of a
ring and incorporating section switches, this system enables parts of the trunking to be
isolated when necessary, without all machines losing supply.

.
Figure 2.6 A typical Overhead busbar trunking.
Preparation and installation procedures
The preparationprocess involves the following stages:
e. Identify the required size of the basbar piece(s).
f. Anticipate the number and nature of tap-on points required
g. Gether useful tools,equipments and materials required in the whole process
h. Indicate markings on the basbar for any required process.Be very precise to avoid
undesirable material destruction
i. Collect the processed basbar pieces for fitting or installing with the trusses support etc
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,tray,set of spanners,screw drivers,bolts and nuts,
supporting brackets and screws.Cable laying and termination should automatically be
the last stape in the task.

Safety measures to observe


During the practical performance you must be wearing overall and safety boots.Make sure
you maintain best practice and good workmanship

Trunking Fittings
These are trunking joinery parts available in various shapes and sizes.The fittings are for
making conduit corners, lengthening conduits, providing multi outlets etc.Typical trunking
fittings are tee piece, four way box, bend etc.Both PVC and metallic conduit fittings are
available and are normally not mixed of their category in their application.This means that
PVC fittings should be used for PVC trunking and metallic fittings for metallic trunking
only.Some of these fittings are straight piece,flat bend piece,flat tee piece,flat four way
piece,reducer piece,straight couple piece,etc. as shown inFigure 2.7

Fig 2.7 Trunking fittings

Cable ladder
This is another cable carrier channel. Cable ladders are manufactured for
installation of power cable in the heavy cable distributions at power stations, and
main power system of buildings,as shown in figure 2.8. This type of ladder is
produced in 2.5 metres of length. The ladders are in most cases made of stainless
steel, steel or galvanized steel. They are found in white, grey or orange in colour.
Ladder fittings available are flat bend piece, straightpiece, flat tee piece, flat four
way piece, reducerpiece, straight couple piece, etc.
Figure 2.8 Cabble ladder

TRUNKING SPACE FACTOR


Space factor (s.f.) is the ratio between sums of cross-sectional area of cable (including
insulation) to the internal cross-sectional area of trunking. The ratio percentage of this factor
should not exceed 45% according to IEEE Regulation.

Mathematically , s . f =
∑ of cross−sectional areaof cables ×100 % …. (2.1)
Internal cross−sectional area of trunking

Practically we are asked to lay cables that should not cover more than 45% of the conduit
cross-sectional area.Normally cable manufacturers give diameter and even cross-sectional
area of cables (including insulation).The cross-sectional area of a single cable can therefore
be multiplied by a number of conductors to obtain the area of the trunking to be occupied
which should not be more than 45% of the entire trunking space.IEEE has given specific
tables to compute for suitable trunking size with given cable size.Table 12E and 12F are
used for this purpose.

Table 2.1 Cable factor


Table 12E
Cable conductortype ConductorCross-sectional Area (mm2) factor

Solid and single 1.5 7.1


Solid and single 2.5 10.2
Solid and single 1.5 8.1
Solid and single 2.5 11.4
Solid and single 4.0 15.2
Solid and single 6.0 22.9
Solid and single 10 36.3

Table 2.2 Trunking size


Table 12F
Dimension of trunking(mm) Factor
50×37.5 767
50×50 1037
75×25 738
75×37.5 1146
75×50 1556
75×15 2371
100×25 993
100×37.5 1542
100×50 2091
100×75 3189
100×100 4252

Example 1
A trunking is required to carry the following:
40 conductors of 2.5 sq.mm solid core cables
10 conductors of 4.0 sq.mm single core cables and
5 conductors of 6.0 sq.mm single core cables.Calculate a suitable trunking size.
Solution
Using cable factors from table 12E we obtain total cable factor being:
(40x10.2) +(10x15.2) +(5x22.9) ¿408+152+114.5¿674.5
From table 12F the smallest trunking with a factor exceeding or equal to 674.5 is75mm by
25mm and its factor being 738.
Example 2
A trunking is required to carry the following cables:
80 conductors of 2.5 sq.mm solid core cables
20 conductors of 4.0 sq.mm single core cables
20 conductors of 6.0 sq.mm single core cables
Calculate the smallest trunking size allowed.
Solution
Using cable factors from table 12E we obtain total cable factor being:
(80x10.2) +(20x15.2) +(20x22.9) ¿816+304+458¿1578
From table 12F the trunking with a factor equal to or exceeding 1578 is 100mm by 50mm
which has a factor of 2091.

With regard to trunking system,the IEEE Regulation states the following:


i. lighting and power cables must not be installed in the same section with cables of
other voltages eg telephone cables
ii. trunking must not be installed where flammable vapours are present
iii. fire barriers i.e. asbestos must be installed in the trunking where it passes through
floors
iv. all bus bar trunking must be marked DANGER with voltage stated
v. all lids must be fitted securely
vi. allowances must be made to allow for expansion in long sections of trunking at
places of high temperature
vii. the number of cables drawn into an enclosure shall be such that no damage caused
to the cables during their installation
viii. space factor of 45% must be observed when calculating trunking size

There are many advantages of using a trunking instead of using multiple conduits. Some of
the advantages being:
i. trunking is lighter
ii. It is cheaper
iii. It is quicker and easier to install
iv. It is easier to add more cables or to add more trunking to the system
v. Installing the wires is easier as the wires are laid instead of being drawn in
vi. Multi-compartment trunking is available to operate services e.g. to install
telephone cables and fire alarm cables in the same trunking.

Trunking can be for both indoors and outdoors, ranging from domestic, commercial and
industrial purpose. Many applications includes decorative skirting in homes, lighting
fixtures in restaurants and departments store.

Cable trays
Cable tray is a sheet-steel channel with multiple holes.The most common finish is hot-dipped
galvanized but PVC-coated tray is also available.In the industrial or commercial installations,
a cable tray system is used to support insulated electric cables used for power distribution 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. See figure 2.9.
Figure 2.9 typical cable tray.
They are especially useful in situations where changes to a wiring system are anticipated,
since new cables can be installed by laying them in the tray, instead of pulling them through a
pipe. Cables laid on tray must be secured with cable ties through the tray holes.
Cable tray fittings available are straight piece, flat bend,flat tee, flat four way, reducer piece,
straight coupler,angle coupler tray, etc

Preparation and installation procedures of cable trays


The preparationprocess involves the following stages:
j. Identify the required size of the cable tray piece(s).
k. Anticipate the number and nature of corners each tray should pass
l. Gether useful tools,equipments and materials required in the whole process
m. Indicate markings on the tray for bending or cutting purposes.Be very precise to avoid
undesirable material destruction
n. Cut or bend the tray in the required shapes and corners e.g. 90° angle of bend etc
o. Collect the processed tray pieces for fitting or installing on wall or board.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,tray bending machine,set of screw
drivers,bolts and nuts,tray supporting brackets and screws.Cable laying and
termination should automatically be the last stape in the task.

Safety measures to observe


During the practical performance you must be wearing overall and safety boots.Make
sure you maintain best practice and good workmanship.
Chapter 2 Questions
1. Why should you prefer PVC trunking to metallic trunking?
2. What are the advantages of using metallic trunking?
3. Why is there a space factor in trunking?
4. By the use of table 12E and 12F of the IEEE Regulations calculate the smallest
trunking size allowed to carry the following cables:
i. 50 solid core conductors of 2.5 mm2 each
ii. 20 single core conductors of 6.0 mm2 each and
iii. single core conductors of 10.0 mm2 each
5. Draw cable trays used in electrical installations.

CHAPTER 3
3.0 DUCTING WIRING SYSTEM
3.1 INTRODUCTION
Cables need to be protected especially when they are run in non-protective area where cables
need to be secured. Cable enclosures are necessarily to be learnt because it develops and
underpins the security awareness when dealing with cables. Ducts are among the cable
enclosures which protects cables from being damaged. Cables are damaged mostly from
different pressures. When weather changes to an extreme then is easy to damage cables.
During the winter when earth’s surface area is fully of fell down ice may cause cables to
absorb wet which ultimately causes the cable cores insulation to puncture ( short
circuit).Likewise when extreme heat is generated within the cable itself or by another
source ,causes the insulation as well to puncture(short circuit between cores).Therefore
protection by means of electrical enclosures against mechanical pressure must be avoided for
use and shelf life

3.1.1 Ducting systems.


A duct system is an assembly whose primary function is to convey air between specified
points. Duct systems can be categorized aseither single path or dual path.
Majority of large buildings are provided with solid concrete floors,the under floor duct
systems are brought into use to solve the problems of providing a distribution network of
cables for power and light circuit. In most of large buildings, for easy distribution of
electrical power and lighting circuits are done through electrical ducting system. One of the
advantages of the ducting system is that where a change of tenant is attended by new power
layout requirement, the alterations required are easily carried out. Therefore, various ducts
are arranged to feed ceiling points for the floor below and socket outlets for the floor above.
The cover plates which are fixed flush with the floor finish are provided to cover Junction
box. Since the ducting is laid out in straight lines between junction boxes, it is easier to locate
the runs. Under floor ducting is made of sheet metal or an insulated fibre material. Ducting is
used to provide a network of cable ducts in concrete floors

3.1.2 REINFORCEMENT ARRANGEMENTS OF A DUCT


The basic elements of duct construction consist of duct wall(s), transverse joints, and
reinforcements at, or between, joints and supports. All of these form an integrated
combination for each pressure class and duct size. Each size in a pressure class has a
minimum duct wall thickness and a minimum specification for joints, reinforcements, etc. An
element from a higher pressure class or larger duct size may be substituted in a construction
of a lower pressure class or smaller duct size. This is generally acceptable because the
substituted element will exceed the minimum requirements. However, using some
overdesigned elements does not justify under designing other elements in the composite
assembly unless the overall resulting construction can be shown to meet the minimum
standards.

3.1.3 PERFORMANCE REQUIREMENTS FOR ALL DUCTS


In fulfilling the function of moving air and running electrical cables, the duct assembly must
satisfy certain fundamental performance criteria. Elements of the assembly are sheets,
reinforcements, seams, and joints. Theoretical and/or practical limits for the following criteria
must be considered for the duct assembly and its elements.
1. Dimensional stability (shape deformation and strength).
2. Containment of the air being conveyed (leakage control).
3. Vibration (fatigue and appearance).
4. Noise (generation, transmission, or attenuation).
5. Exposure (to damage, weather, temperature extremes, flexure cycles, wind, corrosive
atmospheres, biological contamination, flow interruption or reversal, underground or
other encasement conditions, combustion, or other in-service conditions).
6. Support (alignment and position retention).
7. Seismic restraint.
8. Thermal conductivity (heat gain or loss and condensation control).
In establishing limitations for these factors, consideration must be given to effects of the
pressure differential across the duct wall, airflow friction losses, air velocities, infiltration or
exfiltration, as well as the inherent strength characteristics of the duct components.
Construction methods that economically achieve the predicted and desired performance must
be determined and specified. To the extent that functional requirements for ducts are not
identified by test or rating criteria, the construction details here represent acceptable practice
in the industry except in special service conditions. Where other construction details are
needed to meet the special needs of a particular system design, the designer should comply
with appropriate construction standards.

3.2 TYPES OF DUCTS


There are three types of ducting; concrete, steel under floor and fibre under floor. Concrete
ducts are formed in the ground by erecting shuttering in a channel and pouring a concrete mix
around the shuttering. Concrete ducts are fabricated by concrete and suitable only for laying
armoured cables. The ducts are covered with heavy steel plates. The steel under floor ducting
is fabricated in steel material and is like of that of heavy steel trunking with removable
outlets. Fibre ducting is fabricated by using fibres and is laid in position before the floor is
made.

3.3 Ducts Standard sizes for Electrical, Telephone and communication system

Table 3.1Metric Units


Nominal Outside Standard Wall thickness,mm Socket Tolerance of
size in diameter,mm length(m) insertion Outside
inches Maximum Minimum depth,mm Diameter,
mm
1.25 42.15 4.0 4.06 3.56 23.8 - 50.8 0.13
1.5 48.26 4.0 4.19 3.68 27.0 - 50.8 0.15
2 60.32 4.0 4.42 3.91 28.6 - 50.8 0.15
2.5 73.02 4.0 5.77 5.16 38.1 - 76.2 0.18
3 88.90 4.0 6.15 5.49 41.3 - 79.4 0.20
3.5 101.6 5.8 6.43 5.74 42.9 - 82.6 0.20
4 114.30 5.8 6.73 6.02 44.5 - 85.7 0.23
5 141.30 5.8 7.34 6.55 49.2 - 92.1 0.25
6 168.28 5.8 7.98 7.11 54.0 - 95.3 0.28

Table 3.2U.S customary units


Nominal Outside Standard Wall thickness,mm Socket insertion Tolerance
size in diameter,mm Length (m) depth,mm of Outside
inches Maximu Minimum Diameter,
m mm
1.25 1.660 4.0 0.160 0.140 15/16 - 2 0.005
1.5 1.900 4.0 0.165 0.145 1 1/6 - 2 0.006
2 2.375 4.0 0.174 0.154 1 1/8 - 2 0.006
2.5 2.875 4.0 0.227 0.203 1 1/2 - 3 0.007
3 3.500 4.0 0.242 0.216 1 5/8 - 3 1/8 0.008
3.5 4.000 5.8 0.253 0.226 1 11/16 - 3 1/4 0.008
4 4.500 5.8 0.265 0.237 1 3/4 - 3 3/8 0.009
5 5.563 5.8 0.289 0.258 1 15/16 - 3 5/8 0.010
6 6.625 5.8 0.314 0.280 2 1/8 - 3 3/4 0.011

3.3.1Space factor
This is a ratio (%) of the sum of the overall cross sectional area of cables (including
insulation) to the internal cross-sectional area of ducts and must not exceed 35%.1.2
GENERAL

3.4 Typical Cable Diameters for application in Ducts

The following outside diameters are for reference only and will vary depending on cable
manufacturer.

Table 3.3For 600/1000V Armoured cable


Cross 1 core 2cores 3 cores 4 cores
sectional
area,mm2
1.5 12.3 12.8 13.5
2.5 13.6 14.1 15.0
4 14.7 15.3 16.4
6 16.9 16.6 18.7
10 18.0 19.5 21.1
16 20.0 21.2 22.9
25 24.1 26.7 28.9
35 27.9 29.6 32.1
50 17.5 25.8 28.5 32.0
70 20.2 29.0 32.2 37.7
95 22.3 33.1 37.0 41.7
120 24.2 36.1 40.0 47.7
150 27.4 39.3 45.5 51.4
185 30.0 44.7 49.8 56.6
240 32.8 49.0 55.1 63.0
300 35.6 53.5 60.2 68.8
400 40.4 59.0 66.6 78.1
500 44.2
630 48.8
800 55.4
1000 60.6

3.4.1 Calculation of duct sizes to accommodate cables

1. Required fill factor k=40% (in percentage)=0.40 (in decimal)


2. Cable diameter d, giving a cable area, a:

a = π d2/4 …………………………………………………………………. (3.1)


3. Cable total area Ca = sum of area for all cables
4. Minimum duct diameter D:

D=√4Ca/ π k ………………………………………………………………...
(3.2)
Examples
1. Calculate the minimum size of duct, if two cores of 35mm 2
cable are required to be installed and the fill factor 40%
Solution:
D=√4Ca/ π k
=√4 x 2 x 35/ π x 0.4
=√280/ π x 0.4
=222.9299mm
2. When the required size for duct is 350mm, and the fill factor
is 35%, what is the total area of cables? Give the standard
number of cores equivalent to the area.
Solution:
Ca= π k D2/4
=3.14 x 0.35 x 3502/4
=33,656.875mm

3.5 CABLE DUCT SEALS

3.5.1 To prevent ingress of water & hazardous gas in water applications

An uninterrupted electricity supply is essential for the continued operation of substations


powering water treatment plants, Hospitals and other necessary units. Electrical power supply
can be threatened by several factors – some can be eliminated, some mitigated against but
others are out of our control.

One natural threat is the weather and some culminates. In some continents including Europe,
have the wettest winter up 6mm of winter rainfall fall and in Asia and Africa face extreme
hot temperatures. Water, high temperature and electricity do not mix – flood and other
weather conditions damages substations, due to ineffective cable sealing, can result in power
outages and cause serious disruption to consumers, businesses and industry. Although we
cannot control the weather, we can contain the flood.

3.5.2Cable Duct Seals for Water and Electrical Utilities

Cable duct seals are simple, fast and safe to install providing an effective cable seal against
water ingress (2.5 bar pressure), gas migration and fire spread (4 hour rating) into electrical
substations in the water utility industry.

Cable duct seals provide assured long term protection of water utility assets with a 50 year
accelerated age test – effectively sealing substation cables against flood water dangers.
Furthermore, the cable seal resists gases including methane, hydrogen sulphide (H2S) and
chlorine. The Cable duct seals can effectively seal single or multiple cables entering vertical
or horizontal cable ducts. Thereare duct seals which replace polyurethane expanding foam for
compliance with regulations and the requirement for gas tight seals – expanding foam should
not be used for critical applications where duct sealing is required to prevent the ingress of
harmful or flammable gases, liquids or smoke.See figure (3.1)
Figure 3.1 Cable duct sealing

Figure 3.2 Cable Duct Seals application


Figure 3.3 Dangerous Substances and Explosive Atmospheres

3.6 DUCT CONSTRUCTION AND INSTALLATION STANDARDS

General Requirements
S1.0
Because of the use of adhesives, gaskets, tape systems, or combination of these to close
openings are important in the surface of the ductwork and field-erected plenums and casings
through which air leakage would occur or the use of continuous welds.
S1.1
The prudent selection and application of sealing methods by fabricators and installers,
giving due consideration to the designated pressure class, pressure mode (positive or
negative), chemical compatibility of the closure system, potential movement of mating parts,
workmanship, amount and type of handling, cleanliness of surfaces, product shelf life, curing
time, and manufacturer-identified exposure limitations.
S1.2
That where distinctions are made between seams and joints, a seam is defined as joining of
two longitudinally (in the direction of airflow) oriented edges of 1.8 duct surface materials
occurring between two joints. Helical (spiral) lock seams are exempt from sealant
requirements. All other duct wall connections are deemed to be joints. Joints include but are
not limited to girth joints, branch and sub-branch intersections, so-called duct collar tap-ins,
fitting subsections, louver and air terminal connections to ducts, access door and access panel
frames and jambs, and duct, plenum, and casing abutments to building structures
S1.3
The sealing requirements do not contain provisions to:
a. resist chemical attack;
b. be dielectrically isolated;
c. be waterproof, weatherproof, or ultraviolet ray resistant;
d. withstand temperatures higher than 120°F (48°C) or lower than 40°F (4.4°C);
e. contain atomic radiation or serve in other safety-related construction;
f. be electrically grounded;
g. maintain leakage integrity at pressures in excess of their duct classification;
h. be underground below the water table;
i. be submerged in liquid;
j. withstand continuous vibration visible to the naked eye;
k. be totally leak-free within an encapsulating vapour barrier; and
l. create closure in portions of the building structure used as ducts, such as ceiling
plenums, shafts, or pressurized compartments;
m. the requirements to seal apply to both positive and negative pressure modes of
operation
n. Externally insulated ducts located outside of buildings shall be sealed before being
insulated, as though they were inside. If air leak sites in ducts located outside of
buildings are exposed to weather, they shall receive exterior duct sealant.

An exterior duct sealant is defined as a sealant that is marketed specifically as forming a


positive air-and watertight seal, bonding well to the metal involved, remaining flexible with
metal movement, and having a service temperature range of -30°F (-34°C) to 175°F (79°C).
If exposed to direct sunlight, it shall also be ultraviolet ray-and ozone-resistant or shall, after
curing, be painted with a compatible coating that provides such resistance. The term sealant is
not limited to adhesives or mastics but includes tapes and combinations of open-weave fabric
or absorbent strips and mastics.

3.7 DUCT SEALING COMMENTARY

Ducts must be sufficiently airtight to ensure economical and quiet performance of the system.
It must be recognized that airtightness in ducts cannot, and need not, be absolute (as it must
be in a electrical piping system). Codes normally require that ducts be reasonably airtight.
Concerns for energy conservation, humidity control, space temperature control, room air
movement, ventilation, maintenance, etc., necessitate regulating leakage by prescriptive
measures in construction standards. Leakage is largely a function of static pressure and the
amount of leakage in a system is significantly related to system size. Adequate airtightness
can normally be ensured by a) selecting a static pressure, construction class suitable for the
operating condition, and b) sealing the ductwork properly.

Some sealants can adversely affect the release function of breakaway connections to fire
dampers; consult the damper manufacturer for installation restrictions.

3.7.1 Leakage
Apparent differences of about ten percent between fan delivery and sum of airflow
measurements at terminals do not necessarily mean poor sealing and excess leakage.
Potential accuracy of flow measurements should be evaluated.
Otherwise, open access doors, unmade connections, missing end caps, or other oversights
contribute to such discrepancies. When air terminals are at great distances from fans (over
500 feet (152m)), more effective sealing is probably required to avoid diminished system
performance.
Schools, shopping centers, airports, and other buildings may use exposed ductwork. Selecting
sealing systems for such ducts may involve more attention to the final appearance of the duct
system than with ducts in concealed spaces.
Certain types of paint may form reliable seals, particularly for small cracks and holes. Further
research and confirmation is needed in this area.

Figure 3.4 Sealed duct Cables

Systems must control connector length and notch depth on rectangular duct ends to facilitate
sealing. Failure to do so will compromise seal effectiveness. Round duct joints are normally
easier to seal than other types. However, with proper attention to joint selection,
workmanship, and sealant application, almost any joint can achieve low leakage. The mere
presence of sealant at a connection, however, does not ensure low leakage. Applying sealant
in a spiral lock-seam can result in poor seam closure and less satisfactory control. No single
sealant is the best for all applications. Selecting the most appropriate sealant depends
primarily on the basic joint design and on application conditions such as joint position,
clearances, direction of air pressure in service, etc.

3.7.2 Liquids
Many manufacturers produce liquid sealants specifically for ducts. They have the consistency
of heavy syrup and can be applied either by brush or with a cartridge gun or powered pump.
Liquid sealants normally contain 30 to 60 percent volatile solvents; therefore, they shrink
considerably when drying. They are recommended for slip-type joints where the sealant fills
a small space between the overlapping pieces of metal. Where metal clearances exceed 1/16
inch (1.6 mm), several applications may be necessary to fill the voids caused by shrinkage or
runout of the sealant. These sealants are normally brushed on to round slip joints and pumped
into rectangular slip joints. See figure 3.5

Figure 3.5 Liquid sealant

3.7.3 Mastics
Heavy mastic sealants are more suitable as fillets, in grooves, or between flanges. Mastics
must have excellent adhesion and elasticity. Although not marketed specifically for
ductwork, high quality curtain wall sealants have been used for this application. Oil-base
caulking and glazing compounds should not be used.

3.7.4 Gaskets
Durable materials such as soft elastomer butyl or extruded forms of sealants should be used
in flanged joints. For ease of application, gaskets should have adhesive backing or otherwise
be tacky enough to adhere to the metal during joint assembly. The choice of open cell or
closed cell rubber gaskets depends on the amount and frequency of compression and on the
elastic memory.

3.7.5 Tapes
Nothing in this standard is intended to unconditionally prohibit the use of pressure sensitive
tapes. The shelf life of tapes may be difficult to identify. It may be only six months or one
year. Although initial adhesion may appear satisfactory, the aging characteristics of these
tapes in service are questionable. They tend to lose adhesion progressively at edges or from
exposures to air pressure, flexure, the drying effects at the holes or cracks being sealed, etc.
The tape’s adhesive may be chemically incompatible with the substrate, as is apparently the
case with certain non-metal flexible ducts. Application over uncured sealant may have
failures related to the release of volatile solvents. Sea air may have different effects on
rubber, acrylic and silicone-based adhesives.

Tapes of a gum-like consistency with one or two removable waxed liners have become
popular for some applications. They are generally known as the peel and seal variety and
have been used between flanges and on the exterior of ducts. Such tapes are typically of
thicknesses several times that of tapes traditionally known as the pressure sensitive type.
Some may have mesh reinforcement. Others may have metal or non-metal backing on one
surface.
3.7.6 Heat Applied Materials
Hot melt and thermally activated sealants are less widely known but are used for ductwork.
The hot melt type is normally a shop application. Thermally activated types use heat to either
shrink-fit closures or to expand compounds within joint systems.

3.7.7 Mastic and Embedded Fabric


There are several combinations of woven fabrics (fibrous glass mesh, gauze, canvas, etc.) and
sealing compounds (including lagging adhesive) that appear better suited for creating and
maintaining effective seals than sealant alone. Glass fabric and Mastic (GFM) used for
fibrous glass duct appears to adhere well to galvanized steel.

3.7.8 Surface Preparation


Surfaces to receive sealant should be clean, meaning free from oil, dust, dirt, rust, moisture,
ice crystals, and other substances that inhibit or prevent bonding. Solvent cleaning is an
additional expense. Surface primers are now available, but their additional cost may not result
in measurable long-term benefits.

3.7.9 Sealant Strength


No sealant system is recognized as a substitute for mechanical attachments. Structural grade
adhesive systems are being developed to replace spot welded and soldered connections of
metals. They have lap shear strengths of 1000 (6895) to 5000 psi (34475 KPa) or more.
SMACNA is not able to comprehensively define their characteristics at this time; however,
authorities are encouraged to monitor their development progress and consider their use.

3.7.10 Shelf Life


The shelf life of all sealant products may be one year or less; often it is only six months. The
installer is cautioned to verify that the shelf life has not been exceeded.Sealant systems may
be flammable in the wet, partially cured, or cured state.

3.8 InstallationProcedures

1. Pull the product pipe off of the reel, cut it to theproper length, square it off and then de-
burr theend of the pipe. If you are using SecondaryContained(SC) piping, cut back the scuff
guard layerto the sump wall (approximately 22.86cm in dispensersumps - tank sump
dimensions may vary) andcut back the SC layer 11.43cm.
2. Install the ducted-style pipe entry boots in thesump wall per the ducted entry boot or the
ductedbulkhead boot installation instructions depending.
Figure 3.6: Ducted Entry Boot Connection

3. Pull the ducting and cut it to the proper length, butdon’t attach it to any entry boots at this
time.
Note: If you’re working with two pieces of ducting that need to beconnected, use the
deducted entry boot (Figure 2). Use the F connector by placing it between the two pieces of
ducting and
then tightening the band clamps down into the ducting.
Caution: Do not over-tighten the band clamps.

Figure 3.7: F Connector

4. Make sure your ducting has been squared off andall burrs have been removed. Insert duct
bushing(Figure 3) inside the ducting (Figure 4).
Figure 3.8: Duct Bushing

Figure 3.9: Bushing in Duct End

The ducting system allows primary or secondarily contained pipe to be easily retracted and
then reinstalled. This ducting acts as a conduit for the pipe to run through and should not be
used as an additional containment layer. The ducting can be air tested to check system
integrity and fire protection association codes should be adhered to prevent from severe
injury, death, and serious property damage or any environmental contamination.
. All components of this systemshould be installed according to the manufacturer’s
specifications so that the system’s integrity isnot compromised. Test the complete system
after installation accordingly. Failure to properly verify operation could lead toenvironmental
contamination.
5. Insert the duct seal (Figure 3.8) into the first valleybehind the bushing (Figure 3.9).
Figure 3.10: F Connector

Figure 3.11: F Connector


6. After the ducting seal has been installed, check tomake sure seal is seated correctly in the
ductingvalley (Figure 7).

Figure 3.12: F Connector


7. Feed the pipe through the ducting.
Note: Attach a rounded object to the end of the pipe to keep itfrom catching on the ducting
ribs as it is fed through.
8. Push the pipe through the entry boots.
9. If the necessary fitting connections or test bootshave not already been installed, then do so
now.
10. After the primary pipe has been prepared andall of the fittings have been installed, the
ductingcan be attached to the entry boots. Applying athin layer of lithium grease to the
ducting seal canmake installation go easier. Slide the ducting intothe ducted entry boot. Using
the stainless steelband clamps provided, tighten the clamps to 20in / lbs of torque.
11. If you’re using air-testable entry boots,check the system integrity by attaching a Test
Regulator Kit(TRK) to the ducted entry boot (DEB)or ducted bulkhead boot (DBB) air fitting
andcharge the lines to 2 to 4 PSI. Expect some initialline expansion which will result in some
pressureloss. After the line pressure has stabilized, test theline for 30 minutes with no
pressure drop.
12. Soap all of the boot/ducting interfaces to check forleaks.If any leaks are found, tighten the
clampsand retest.
Do NOT over-tighten the band clamps.
13. After installation is complete, the backfillingprocess can begin. Only backfill with pea
gravel,clean compacted sand or crushed stone whenusing ducting.
14. If you’re using air-testable boots, recheck the air test after backfilling to confirm system
integrity.

CHAPTER QUESTIONS
1. What is ducting system?
2. What do you understand by the following terms in relation to cable ducts :
a. Tapes
b. Shelf life of sealant
c. Gasket
d. Liquid
e. Leakage

3. List down at least ten (10) sealing requirements in relation to construction and installation
standards.
4. Find the minimum size of duct, if four (4) core of armoured cable each having diameter of
32.0mm and a fill factor of 35% are provided?
5. What are the performance requirements for all ducts?
6. List down the standard size of armoured cable as from 1mm2 up to 185mm2.
7……… is the space factor for duct.

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