Sofia Martinez
Running wire through a plastic conduit is a common task in electrical installations, whether you're wiring a new building, running electrical cables for renovations, or installing communication lines. It is a fundamental skill for electricians and anyone installing wiring systems. Conduits provide protection for electrical wires, shielding them from damage and corrosion, and aiding with maintenance. The process can be complex and needs to be done in an efficient and safe manner. There are several methods to pull wire through a conduit, and the best one for you will depend on the length of the run, the type of wire, and the available equipment.
| Characteristics | Values |
|---|---|
| Purpose of conduit | Provides a secure barrier between electrical wiring and exterior conditions that could damage or corrode it over time |
| Types of conduit | PVC, EMT, flexible, HDPE, corrugated, smooth |
| Types of wire | THHN, THWN, NM, Romex |
| Wire-pulling methods | Rod and string, fishing weight, fish tape, mule tape, vacuum, rodder, manual pulling |
| Wire-pulling tools | Wire pullers, lubricants, safety gear, wire strippers, linesman pliers, shop vacuum, pulling rope, electrical tape, wire pulling grip |
| Wire-pulling considerations | Length of conduit, number of bends, temperature, humidity, presence of dust or moisture, existing wires in conduit |
| Conduit preparation | Inspect for debris or sharp edges, apply lubricant, trim excess wire length, strip wire ends |
| Wire connection | Connect to electrical boxes, outlets, or termination points, verify secure connections, conduct tests |
| Underground wiring | Dig trench, bore hole in wall, cut plastic conduit, use propane-powered heat gun to bend conduit |
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What You'll Learn
Using a pulling rope or string
Pulling wires through a conduit is a challenging task. A conduit provides a secure barrier between electrical wiring and exterior conditions that could damage or corrode it over time. One of the methods to pull wire through a conduit is by using a pulling rope or string.
The string method is the simplest technique for pulling wire through a conduit and relies on a strong string called a pull string. This method works best on short and straight conduits. Longer pieces of conduit or lengths with more curvature will require an alternative method. To use this method, tie a strong string to a long, thin, rigid rod. Push the rod through the conduit, with the tied end going in first. The loose end of the string should remain at the conduit's start. Once the tied end emerges from the conduit end, tie the electrical wire to the loose end of the string. Pull the rod from the conduit's end, pulling the tied wire through to the end.
The fishing weight method is a variation of the string method that uses a heavy fishing weight to guide wiring directly through a conduit. Tie a heavy fishing weight to the end of the wires using string or fishing wire to give the weight a 2- to 3-inch lead in front of the wiring. Be sure to choose a fishing weight that is thin enough to run through the conduit but heavy enough to pull lubricated wire. Place the fishing weight inside the conduit and adjust the placement of the wiring so that it can easily move behind the weight. Drop the fishing weight into the conduit. If you are working with a free-moving length of conduit, lift the end of the conduit higher than the weight so that gravity can pull the weight along. When necessary, adjust the conduit orientation to get the weight around curves in the conduit.
The mouse method is another variation of the string method that uses a tool called a conduit mouse or conduit piston instead of a rod. This tool is a small foam cylinder that is slightly smaller in diameter than the interior of the conduit. It is used in tandem with a shop vacuum. Tie a strong, light string to the conduit mouse. There should be a wire loop running through the mouse for this purpose. Place the mouse into the conduit opposite from the side you plan to pull from. Fit the mouse so that it fills the conduit space and so that the string follows behind it. At the opposite end, fit the hose of a shop vacuum over the mouth of the conduit. Turn on the vacuum and remove the mouse once it is sucked out at the end. Secure the pull string to the wires at the start of the conduit. Lubricate the wires, as needed. One person should feed the wires straight into the conduit while the other person uses the pull string to guide the wire into the conduit.
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The fishing weight method
Firstly, tie a heavy fishing weight to the end of the wires using string or fishing wire. Leave a lead of 2 to 3 inches between the weight and the wiring. The weight must be thin enough to run through the conduit and heavy enough to pull the lubricated wire.
Next, place the fishing weight inside the conduit and adjust the wiring so that it can easily move behind the weight. Drop the weight into the conduit. If the conduit is free-moving, lift the end of the conduit higher than the weight so that gravity can pull the weight along. Adjust the conduit orientation to guide the weight around curves.
Once the weight reaches the bottom, retrieve it along with the pull string from the other end of the conduit. Securely tie the wire to the pull string, using electrical tape to ensure a smooth connection. Pull the string from the opposite end, feeding the wire into the conduit as you pull. Apply wire lubricant if necessary to ease the pull.
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The fish tape method
Fish tape is a tool used by electricians for pulling electrical or other wires through conduits. It is a long, stiff, flat steel wire that is rolled up and stored in a round, plastic casing. The fish tape is manually pulled out of the casing and then reeled up by rolling it back into the casing.
To use the fish tape method to run wire through a plastic conduit, follow these steps:
Firstly, examine your conduit and measure the length, taking note of any curves that may pose problems. This step is important as it helps you determine if the fish tape method is suitable for your specific conduit.
Then, prepare your fish tape. Pull out 5 to 6 inches of the fish tape from the plastic housing. If your fish tape has a button release, you may need to push it to release the tape. With other types, simply pull the tape out.
Next, feed the fish tape into the conduit. Push the fish tape forward and feed it into the end of the conduit from which you wish to pull. Continue feeding the tape until a foot or two of the tape is exposed at the other end.
Now, attach the wire to the fish tape. Using wire strippers, strip the insulation from the end of each wire, stripping each wire a different amount. For instance, if you have three wires, strip one about six inches, another about four inches, and the last one about two inches. Then, grab all the wires with linesman's pliers and twist their bare ends together to align their insulation. Finally, bend the longest wire into a hook and loop it through the hook of the fish tape.
Finally, pull the wire through the conduit. Slowly pull the fish tape out of the conduit, bringing the wire along with it.
Some additional tips for using the fish tape method include:
- Using a lubricant, such as a wire-pulling compound or soapy water, to make it easier to slide the wire through the conduit.
- Using a leader, such as a fiberglass leader, between the fish tape and the wire, especially for longer runs.
- For cables with four or more wires, cut the wires to staggered lengths to slim down the bundle.
- After use, run the fish tape through a towel to remove any rust or dirt.
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Using a lubricant
There are two primary types of wire-pulling lubricants: water-based and wax-based. Water-based lubricants are the most commonly used type as they are easy to clean, environmentally friendly, and effective across a wide range of temperatures. Wax-based lubricants, on the other hand, are thicker and better suited for extreme conditions, such as hot or cold environments.
Wire-pulling lubricants come in various forms, including gel, liquid, foam, and wax. They often contain additives like silicone to enhance the wire's sliding ability. It is important to note that while dish soap can be used as a last resort, it is not recommended due to its fast-drying nature, which can cause stickiness and hinder progress. Other alternatives like petroleum jelly can corrode wiring, and talc powder is not as effective and creates a mess.
When using a lubricant, it is essential to apply it generously and evenly to the wire before starting the pull. Extra lubricant should be applied at the conduit's entry point to minimise resistance. If the pull is particularly long or challenging, you can pause midway and add more lubricant. It is also important to follow the manufacturer's instructions for proper application.
In addition to using a lubricant, employing tools like fish tape, conduit mice, or pulling ropes can aid in pulling the wire through the conduit. These tools, along with the lubricant, can help ensure a smooth and safe wire installation process.
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Removing old wires
Before attempting to remove old wires, it is important to have the necessary tools and safety equipment. Safety goggles and gloves are essential to protect your eyes and hands. You will also need a wrench, a pipe cutter or conduit saw, and possibly a threading tool. It is recommended to have a helper to assist with the process, especially if you are dealing with a large or complex conduit system.
Begin by turning off the power supply to the conduit to ensure safety. Then, use the wrench to unscrew the electrical conduit fittings on both ends. If the conduit is damaged, you may need to cut out the affected section using a pipe cutter or conduit saw. Cut a couple of centimetres into the undamaged parts of the conduit to ensure a clean removal. Measure the size of the section that needs to be replaced, and cut the new piece of conduit accordingly.
Now, you can start removing the old wires. If the wires are not stuck and can be easily pulled out, grip the wires firmly and pull them out of the conduit. If the wires are stuck, do not force them, as this may cause breakage. Try using a twisting motion instead of a straight pull. This can be achieved by using a carpenter's brace without a bit and channel locks. Have one person turn the brace clockwise while another person lifts and twists the cable. A third person can assist by holding the cable with another set of channel locks and helping to reposition it as needed.
If the wires are still difficult to remove, you can try using a specialised product like American Polywater, which is designed to free stuck wires. Alternatively, you can attempt to soften any wax buildup by blowing hot air down the pipe using a heat gun or a hair dryer set to low heat. You can also try using compressed air or hot water to loosen the wires. Another option is to use a lubricant, such as wire-pulling compound or dish soap, to help the wires slide out more easily. However, be cautious when using lubricants, as they can make a mess or cause corrosion over time.
Remember to work carefully and patiently when removing old wires from a conduit. If you encounter any complications or safety concerns, don't hesitate to consult a professional electrician for assistance.
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Frequently asked questions
The best method depends on the length and curvature of the conduit. For short and straight conduits, the simplest method is to manually pull the wire through the conduit by hand. For longer or more curved conduits, the fish tape method is the most common solution. This involves feeding a long, flat metal wire with a hook at the end through the conduit, then using wire strippers and linesman pliers to pull the wire through.
The fishing weight method uses a heavy fishing weight to guide wiring directly through a conduit. First, tie a heavy fishing weight to the end of the wires using string or fishing wire. Place the fishing weight inside the conduit and adjust the placement of the wiring so that it can easily move behind the weight. Drop the weight into the conduit and adjust the conduit orientation to get the weight around curves.
Before pulling wire through a plastic conduit, it is important to carefully prepare the conduit to prevent unnecessary strain and avoid complications. Inspect the conduit for any debris or sharp edges that could damage the wire. If there are existing wires in the conduit that are no longer needed, remove them. If they need to stay in place, consider how much room is left in the raceway for the new wire.
The type of wire you use depends on the intended application. Most wires installed in conduits are insulated (e.g. THHN or THWN) rather than sheathed cables, as these are difficult to pull through the conduit and are usually not recommended. Larger gauge wires may be more challenging to pull, especially in longer runs.
