Working with Conduits (Conduit Types and raceways, conductors, and corresponding fittings necessary to

connect the system together.

Characteristics, Installing Conduits, Bending
Rigid Metal Conduit
Conduits, Mating Conductors and Conduits)

Conduit Types and Characteristics

 Conduit is a safe and rugged wiring system. It provides an

excellent, permanent electrical path to ground as well as a high
level of protection against electrical shock and fire. For
example, if someone accidentally contacted the thick wall of
the tubing with a nail or drill, the tubing would resist the
attack. Conduit is also highly resistant to hammer blows,  Rigid conduit looks like galvanized threaded water pipe, but it’s
animal chewing, or the jolts of minor earth tremors. softer, which makes bending easier. The interior of the rigid
 A rigid-metal conduit is just one of several types of raceways conduit is also smoother, which makes pulling wires easier and
that are available for wiring systems. A raceway is defined as reduces the possibility of damaging insulation.
any channel that’s designed to hold wires, cables, or bus bars.  Rigid conduit is made in 10-foot lengths and in standard
 Raceways are made from both metal and non-conducting diameters, or trade sizes. The trade size is the approximate
materials and can be either rigid or flexible. Other types of inside diameter of the conduit, which may vary between 1/2
conduit such as rigid nonmetallic conduit (PVC), flexible metal inch and 6 inches.
conduit, intermediate metal conduit (IMC), electrical nonmetallic  The inside diameter of a conduit is larger than its trade size.
tubing (ENT), and electrical metallic tubing (EMT) are also For example, a 1-inch rigid conduit has an actual inside
available. diameter of 1.049 inches. Both ends are threaded and reamed,
 Besides these various types of conduit, several other types of and a sleeve (threaded coupling) is included with each 10-foot
raceway are also available. Under floor raceway, cellular length.
concrete floor raceway, cellular metal floor raceway, surface  Rigid conduit is commonly made of mild steel and protected
raceway, wire way, and bus way are all used in electrical with a galvanized finish so it can be used in practically all
work, chiefly in commercial and industrial wiring. applications.
 Wiring systems are usually named after the type of raceway  Rigid aluminum conduit is used around chemical plants and
that’s used in the installation. When raceway isn’t used, the wherever severely corrosive gases are present.
wiring method or system is described by the type of conductor  Aluminum conduit is also used in standard commercial work
or cable used, and whether the conductor is installed in the because it’s light and easy to handle, bend, and thread. Rigid-
open or concealed behind walls. A wiring system includes the metal conduit is also available with a polyvinyl chloride (PVC)
coating for use in corrosive environments.
  Rigid-metal conduit is considered the best system for these
applications because it provides maximum protection to the
conductors or wires. At the same time, it provides an effective
grounding conductor for equipment. Because of its strength
and resistance to damage, it’s often used for service equipment,
even in areas where simpler wiring methods are used for the
general wiring.

Electrical Metallic Tube

 Rigid conduit is also made from nonmetallic materials such as

PVC and plastic. These materials are approved for wet
locations (such as dairies where the walls are frequently
washed).
 However, nonmetallic materials don’t provide as much
protection for the wires as metallic conduit, and some aren’t
approved for use in sunlight or in areas of extreme heat.
 Both metallic and nonmetallic rigid conduit should be used
only as permitted by the Philippine Electrical Code (PEC).  Electrical metallic tubing (EMT) has most of the advantages of
rigid conduit. EMT is sometimes called thin wall conduit, not
because it goes behind thin walls, but because its wall
thickness is less than that of rigid-metal conduit.
 Rigid-metal conduit has a wider range of application than any  The inside diameter of EMT up to the 2-inch size is the same
other type of wiring system. It’s approved for both exposed and as that of rigid-metal conduit, but the outside diameter is
concealed work in all types of buildings. It’s the principal much smaller than that of rigid-metal conduit.
wiring system used in fireproof buildings, and can also
 EMT is manufactured in sizes of 1/2 inch through 4 inches.
withstand the harsh effects of cement found in masonry
Because EMT has thinner walls than rigid metal conduits, the
buildings.
outside diameter of a piece of EMT is smaller than the outside
 Installing a wire system with rigid conduit costs more than diameter of a same-size piece of rigid-metal conduit.
other systems, but the advantages of rigid conduit make it the
 When you’re using EMT that’s larger than 2 inches in
preferred wiring system for many applications. Certain
diameter, you’ll find that the outside diameters are identical to
hazardous locations also require the use of rigid-metal conduit.
those of same-size rigid conduit.
 In larger-diameter conduit, the internal diameters of EMT are
slightly larger than those of rigid and IMC conduit.
  Since the walls of EMT are thin, the NEC states that it’s not
permissible to thread the tubing. Practically speaking, it’s not even
possible to thread EMT. In contrast, rigid-metal conduit can be
threaded, and usually is. Since you can’t thread thin wall conduit,
you’ll need to use threadless fittings, couplings, and connectors
instead.
 EMT is popular for residential installations because it’s more
economical to use than rigid-metal conduit and, in most cases,
performs similarly. The PEC allows you to use EMT in both concealed
and exposed applications, on the face of masonry walls, and on wood
or metal studs in walls. It can also be buried in concrete or plaster.
 EMT is often the preferred choice, but there are a few restrictions on
its use. EMT is somewhat rugged, but it’s not as strong as rigid metal.
When you encounter an installation situation such as the direct-
buried conduit, you may have to use rigid-metal conduit. The weight
of poured concrete can collapse the EMT, or change its shape,
particularly in installations where larger sizes of EMT are used.

 Threadless connectors and couplings are made in setscrew,

compression, and indenter types. These fittings are classified as
 concrete-tight or as rain-tight. The rain-tight fittings are also  A standard blade screwdriver is used to install setscrew fittings and
concrete-tight. Only rain tight types can be used outdoors or in wet the indenter fitting uses a special tool designed just for that purpose.
locations. Don’t attempt to improvise on an indenter connection if you don’t
 In general, only compression fittings are used in wet locations. In have an indenter tool; instead, get the proper tool you need to do the
concrete, it’s permissible to use setscrew and indenter fittings, but job. The connection represents a permanent installation that will give
they sometimes must be wrapped with electrical tape to be made you many years of service without maintenance if installed properly.
concrete-tight.

Intermediate Metallic Conduit

 In general, only compression fittings are used in wet locations. In  Intermediate metallic conduit (IMC) is a metal raceway with a circular
concrete, it’s permissible to use setscrew and indenter fittings, but cross section. IMC has associated fittings that are approved for the
they sometimes must be wrapped with electrical tape to be made installation of electrical conductors. IMC is larger in wall thickness
concrete-tight. than EMT and smaller than rigid conduit.
 Since IMC has the same outside diameter as rigid conduit, it has a
greater interior cross-sectional area. In general, the increased area
 Threadless connections are required to be sturdy and tight to doesn’t permit any more conductors to be used than with the same
maintain electrical ground continuity and mechanical rigidity and trade size of rigid conduit, but it does make wire pulling much easier.
strength. A ground wire is sometimes used with a metal conduit  IMC is also slightly lighter and easier to bend, which makes
system. Therefore, if a connection comes loose, the ground could be installation less laborious. IMC is available in sizes from 1/2 inch to 4
lost, and a shock hazard will be present. This means that the inches and comes in 10-foot lengths which also include a coupling for
connections must be tightened using the proper tools, and not just each length.
your hand or fingers.  Either threaded or non-threaded rigid conduit fittings can be used
with IMC. The same general usage rules apply to both IMC and rigid
 conduit, except that IMC can’t be used in hazardous areas. When IMC
is buried, follow the usage rules that apply to EMT and rigid-metal
conduit.

Flexible Metallic Conduit

 Flexible metal conduit is often used with motors. Its flexibility permits
the motor to be moved slightly to tighten drive belts or align
equipment. Also, less noise is transmitted when flexible conduit is
used to connect motors and transformers to rigid conduit.

 Flexible metal conduit (sometimes called by the trade names

Greenfield or flex) is similar to AC armored cable. Standard flexible
metal conduit diameters range between 3/8 inch and 4 inches, and
lengths range between 25 feet and 250 feet.
 The 1/2-inch size is the minimum size used for general wiring
purposes. The 3/8-inch Greenfield is limited to motor applications
and certain kinds of lighting equipment, but isn’t used for general
wiring.
 Another use for flexible conduit is the connection between outlet
 Flexible metal conduit is simple to install because it’s flexible and the
boxes, where it might be difficult to bend rigid conduit properly.
installation requires no special tools. Where the conduit is exposed, it
should be fastened at least every 4 1/2 feet and within 1 foot of every
outlet box or fitting.
 However, at terminals where flexibility is necessary, the conduit can
be fastened 3 feet from the terminal. Every bend should be well
secured to prevent the conduit from deforming when the wires are
being pulled. A deformed conduit can cause wires to bind.
 Installing Conduits

Conduit Fittings

 Conduit fittings can serve one or more functions when installed. First,
they may be used to join two or more sections of conduit that are the
same type or different types. Fittings that are used for this purpose
are called couplings.

 The squeeze connector clamp is tightened around the conduit with a

screw.

 When flexible metal conduit is used in wet locations, it must be liquid

tight. This type of flexible metal conduit has an outer plastic jacket
that keeps liquids out. When you’re using liquid-tight flexible metal
conduit, the requirements for the number of conductors, the number
of bends permitted, and the number of supports are the same as for
standard flexible metal conduit. It’s important to remember that
special liquid tight fittings must also be used where liquid-tight
conduit is required.
 Second, they’re used to terminate conduit at an outlet box, pull box,
or other type of junction box or panelboard. Fittings that are used for
this purpose are called connectors.
 Third, when metal conduit is used, the fittings must preserve the
continuity of the electrical ground circuit, since a ground wire is
sometimes not used in this situation.
  Fourth, fittings called conduit bodies are used to allow access to the  Even better than a hacksaw is a cordless metal-cutting saw, because
system conductors. This makes it easier to make splices and pull it does the job easier and faster.
wires through long conduit runs.

Cutting, Reaming and Threading Conduits

 After a length of conduit is cut, a reamer is used to quickly remove all

burrs and smooth the inside edge of the conduit end.

 When a short piece of conduit is needed, it’s often cut from a longer
piece with a hacksaw or pipe cutter. A hacksaw is preferred over other
methods because it leaves less burr to remove with a half-round file
or a reamer.
 Threads are then cut on the conduit using a hand-threader or a
 Note that when a lot of conduit is installed, electrically powered
power threader. A given threader stock will hold several different sizes
cutting and threading equipment is a necessity.
of dies for cutting threads on different sizes of conduit.

 While conduit is being cut, reamed, and threaded by hand, it’s held in
a pipe vise mounted on a workbench or a pipe stand.
Grounding Conduits

 Conduit enters an enclosure (such as a panelboard or pull box)

through holes called knockouts. Often electricians will make their own
knockouts, rather than use the concentric-ring or multiple-ring
knockout provided by the manufacturer. An electrician chooses to cut
a new knockout if he or she believes it will provide a better ground.

 Good ground connections are assured by using two locknuts on rigid

conduit. Threadless fittings (such as those for EMT) are designed to
allow the use of one locknut on the inside of the enclosure; the body
itself acts as a stop on the outside.
 When using rigid conduit with two locknuts, one locknut is placed on
each side of the metal box so that the metal is solidly clamped
between two locknuts.

 In addition, an electrician might need to connect a fitting to a box

where a knockout from the manufacturer isn’t provided. Holes for
conduit are usually made by using a knockout punch
 When a knockout has to be made, a pilot hole is drilled in the metal
where the conduit is to go. Then the bolt of the knockout punch is
passed through the pilot hole and the die is screwed on it.
 When the bolt is tightened with a wrench, the die cuts the metal. The
bolt is tightened until the die has cut a complete ring of metal from
the panel and the proper-size hole for the conduit is made.
 Knockout punches are made for conduit diameters between 1/2 inch
and 5 inches.
 Table 3.46.2.8b2 Supports for Rigid Metal Conduit

Maximum Distance Between

Conduit Size (mm) Rigid Metal conduit Supports
(mm)

15 - 20 3,000

25 3,600

32 - 40 4,200
 You can’t depend on a bushing to provide a good ground, because the
conduit may extend into a box a greater distance than the thickness
of the bushing. Thus, the bushing may not touch the inside surface of 50 – 65 4,800
the box.
80 and larger 6,000

 When the voltage between a wire and ground is more than 250 volts,
two locknuts are required by the PEC. The double-locknut
 The minimum support distances are a guideline for you to use. There
requirement, however, doesn’t apply to service entrance conductors.
are instances where the weight of the conduit, plus the weight of the
Standard, single-locknut EMT fittings are sufficient for EMT use.
conductors, will cause the conduit to sag if it’s only supported at
Supporting Conduits 3,000 mm intervals. In these cases, it would be appropriate to
support the conduit every 1,800 mm or 2,100 mm.
 The PEC requires that EMT, IMC, and rigid-metal conduit be fastened  In most buildings, conduit has to be supported on wood or masonry
securely in place at least every 3,000 and within 900 mm of each surfaces. It’s fairly easy to install conduit on a wood surface, because
junction box, outlet box, cabinet, or fitting. These support requirements there are several types of pipe straps and hangers you can use to
are different when rigid-metal conduit is used with threaded secure the conduit into position. To install a pipe strap or hanger on a
couplings. In this case, the support distance can be increased to wood surface, you’ll usually need to notch or bore studs or rafters
6,000 mm for vertical risers, if the conduit is supported at the top
and bottom of the riser.
  However, it’s generally more difficult to install pipe hangers in
masonry surfaces. In a typical masonry installation, you’ll need to
drill holes in the stone or concrete, and plastic or lead expansion
anchors will have to be installed. Screws can then be turned into the
anchors to hold the EMT firmly in place. In the past, wooden plugs
were used in place of the screws, but are now prohibited because
they eventually dry out and loosen in the hole.
 If you have to use several parallel runs of conduit, U-channel hangers
and supports are ideal. Conduit clamps, rod hangers, and spring
clips are used to secure the EMT to U-channel supports. The U-
channel installation is also very handy in rooms that use lift-out
ceiling panels. The combination of U-channel runs and lift-out panels
provides easy access to the electrical and mechanical equipment.

Typical Conduit Fittings

 Threadless fittings, are used primarily with EMT. One type of

threadless fitting is the compression fitting. A compression fitting
consists of a body and a split ring that provide tremendous pressure
and electrical continuity when the nut is securely tightened.
 A setscrew fitting contains a screw that’s tightened against the
outside surface of the conduit. You’ve already seen several examples  The grounding bushing is a metal bushing with a large screw that’s
of typical fittings that would be used with rigid and flexible conduits. used to connect a grounding wire, and a small screw with a sharp
point that’s tightened securely after the grounding bushing is
tightened.

 Conduit fittings that are used in service entrances were different from
those used in boxes. The locknut used isn’t flat; it’s bent or dished.  An entrance elbow is used where the wires enter the building. An
An insulating bushing is made of metal, plastic, or nylon. It’s used in entrance elbow has a cover that’s removable to make installation of
outlet boxes, panelboards, and meter sockets. wires easier.
 An entrance elbow is also called a type LB conduit or conduit body. A
conduit body, is a separate portion of a conduit system that has a
Conduit Nipples and Elbows
removable plate.
 Conduit can be properly installed in an outlet box by first step  Nipples are short pieces of threaded rigid conduit. Three styles of
screwing the locknut onto the conduit. To do this, hold the outwardly conduit nipples are available in standard lengths from 1 1/8 inches to
curved side of the locknut toward the conduit. The conduit with the 12 inches and in trade diameters ranging from 1/2 inch to 6 inches.
locknut is slipped through a hole in an outlet box or panelboard. For example, if 3 1/2 inches diameter-conduit is being used, long
 If the surface of the panelboard or other device is painted, scrape the nipples are available only in lengths of 4, 5, 6, 8, 10, and 12 inches.
paint off so that the locknut will make good contact with the metal.
Tighten the locknut with a screwdriver or tongue-and-groove pliers.
Then, screw on the bushing and tighten it with a screwdriver or
tongue-and-groove pliers. The rounded bushing surface protects the
wire insulation as the wires are being pulled through the end of the
conduit.
  When conduit nipples are installed, they can’t exceed 600 mm in  For economic reasons, choose the smallest-size conduit that will
length between boxes and panels. Within the panel, the total cross- satisfy the requirements of the present installation (plus any planned
sectional area of conductors may not exceed 60 percent of the total future wiring changes).
cross-sectional area of conduit.  Choose the conduit size that’s appropriate for the available physical
 Pre-bent elbows are also available, and using them will help to speed space. For example, you may need to install two or more smaller
up an installation. However, in many cases pre-bent elbows won’t conduit runs in place of one larger run.
look as good as conduit that has been shaped to fit the job. Pre-bent  Consider the conductor fill when you’re choosing the conduit size. The
elbows come in standard angles, so there may not always be one conductor fill is the total cross-sectional area required by the wiring in
available if you need to make a nonstandard angle. a particular run. The PEC allows only a certain maximum percent of
the cross-sectional area of conduit to be “filled” with conductors,
depending on the number of conductors in the run.
 Since the cross sectional area of a conductor depends on the type and
size of the conductor, the conduit size is determined by the number,
type, and size of the conductors.

Bending Conduits

One of the important skills electricians rely on is that of bending conduit. It

sounds simple and when you watch an expert using conduit bender, it looks
easy. When you try it yourself though, you’ll find it’s not as easy as it looks.
Conduit bends easily, but it doesn’t always bend correctly.

 Making good bends demands care and precision. Bad bends don’t
Selecting Conduit Size look professional, and quite often won’t pass inspection. The length
and angles of a bend have to be exact. There can’t be creases or kinks
The conduit size that’s used in a particular installation depends on three on the inside of the bend, and the internal diameter must be
factors: maintained around all corners.
 You must make an effort to develop the good bending techniques.
1. economic reasons
Once you have a basic understanding of how to make quality bends,
2. size of physical space for installation the only way to perfect them is practice.

3. conductor fill
Manually Operated Benders

 There are many types of bends, such as offsets, front bends, back
bends and saddles. In order to make these bends, you need to learn
about the tools used to bend conduit and also how to use these tools
correctly.

 There are four features of a bender: the foot pad, the starting mark,
the handle, and the hook. To begin a bend, the length of conduit is
usually placed on the ground and marked with a bend-starting point.
The bender’s hook is placed around the conduit, and the bender’s
starting mark is aligned with the starting point marked on the
conduit.
 Next is placing your hand on the handle and your foot on the foot
pedal. It’s important that pressure is applied equally to the handle
 The hand bender is most commonly used on metallic conduits of sizes
and foot pedal. Without proper foot pressure applied, the conduit is
1/2, 3/4, and 1 inch. There are hand benders that can be used with
likely to kink and the bend won’t be a smooth one.
conduits up to 1 ¼ inches. You must have the bender that
accommodates the size of conduit you’re bending.
  There are mechanical benders available in the market that can bend
rigid conduit with diameters between 1/2 and 1 1/2 inches or thin
wall conduit with diameters between 3/4 and 2 inches.
 The conduit is placed on the pin and roller and underneath the shoe
unit. The clamp holds the conduit against the shoe unit so that the
 The bender has an angular scale and as conduit bends, the bent leg conduit is bent into the shape of the shoe unit as the lever is pushed
will line up with each of the bend marks. Obviously, a 60° bend down.
represents more of a bend than a 10° bend. The amount of bend is  The ratchet makes it possible to apply short, powerful strokes for
controlled by the distance the handle is pushed. You must practice to faster bending. Conduit benders may also include a bending gage to
consistently produce the proper bend angle. Today, most benders indicate the angle of the bend in the conduit.
come equipped with bend-angle gages as well as tables and guides  A double-shoe unit allows bending of two sizes of conduit. Shoe units
affixed to the handle. are easily changed to bend other sizes of conduit.

Hydraulic Benders
  When hydraulic benders are set up, the correct shoe support and
 Elbows and other bends can be made with electric or hydraulic bending shoe must be selected. Using the wrong-size shoes will likely
benders. The conduit is placed in the frame, where it rests against the result in kinks in the bend. Kinked bends won’t pass inspection. The
two pipe supports. pipe supports are then rotated to match the conduit size.
 The pipe supports, which are shaped to match several sizes of  The frame has two rows of seven holes for holding the pipe supports
conduit, are fastened to the frame by the pipe support pins. The ram at the proper position in the frame. Decals on the frame give the
unit, which consists of a cylinder and a ram, or piston, pushes the information necessary to set up the hydraulic bender quickly for
shoe support against the bending shoe. different sizes of conduit.
 The bending shoe presses against the conduit. Because the conduit is
held by the pipe supports, it bends to match the shape of the bending
shoe as the ram is forced out of the cylinder by the hydraulic oil being
Radius of Bends
pumped into the cylinder.
 Hydraulic oil is pumped into the cylinder by either an electric or hand  In addition to the angle of the bend, another important consideration
hydraulic pump. When a hand hydraulic pump is used, many strokes is the bend radius. That can be confusing, since at first glance two
of a handle, or lever, are needed to bend the conduit. 90° angles would seem to have the same dimensions. The angles
 After the conduit is bent, a valve is opened to allow the hydraulic oil themselves are the same. However, it’s the radius of the angle formed
in the cylinder to return to the pump. Then the ram can be pushed by the shoe unit that has to be considered.
back easily into the cylinder and the conduit removed.  Different shoe units for different-size conduit benders are purposely
constructed with different diameters or radii. If the radius gets too
small, you could have a lot more trouble pulling wire through a sharp
90-degree angle than through an angle with a larger radius.
  To make a proper bend, you must consider the bend’s radius. The
PEC dictates minimum radii depending on the size of the conduit.
Measuring from the center of the conduit to the center of the shoe
unit, the radii can’t be less than the conduit bending tables indicate.
 For instance, 1 inch conduit can’t have a radius less than 5 3/4
inches for the one-shot bend.

Table 3.46.2.6 Radius of Conduit Bends

Size of Conduit (mm) Conductors Without Lead Sheath

(mm)

 A bender with a shoe unit can make what’s called a one-shot bend. A 15 100
one-shot bend is made in one continuous curve or motion of the
bender.
20 125

25 150

32 200

40 250
50 300  The conduit angle is made up of a number of multiple bends, that
when added together give the desired angle. In these cases, you need
65 375 to use a slightly larger radius.
 The measurement is made, not from the center of the conduit, as in
the one-shot bend, but from the inner edge of the conduit to the
80 450
center of the shoe.
 When making a multiple bend, you need to consider an imaginary
90 525
circle following the inside curve of the bend and measure to the center
of the curve.
100 600
 The bend can’t have a radius smaller than what Table 3.46.2.6
dictates. For example, the 25 mm conduit with a multiple bend
125 750 requires a 150 mm minimum radius.

150 900

Bending for a Given Rise

 When bending a section of a conduit, the first thing you need is the
right bender. To bend 3/4-inch conduit, you’ll need a 3/4-inch hand
bender. A 3/4-inch EMT bender will also fit on a 1/2-inch rigid metal
conduit or 1/2-inch IMC. The 1/2-inch rigid metal conduit and 1/2-
inch IMC have about the same outside diameter as the 3/4-inch thin
wall.
 In general, a given size of EMT bender will bend the next smaller size
of rigid conduit and IMC. The bender is usually labeled with both
numbers in case it’s used on rigid metal conduit.
 A very common bend in electrical installation is a 90 degree bend also
known as a stub up. The height the stub reaches above its starting
point at floor level is known as the rise. The rise is made up of two
components: the height of the curved portion, known as the take-up,
and the straight portion above the bend known as the stub.

 Sometimes, instead of one continuous curve, a bend consists of a

number of short bends with a short length of straight conduit
between the bends. This is known as a multiple bend or segment
bend.
BENDING CONDUITS
Bending for a Given Rise
 Making the first bend on a piece of conduit is relatively easy and fast.
Making the second or third bend as related to the original bend gets
more complicated. With practice, though, you’ll develop techniques
that work. Bending conduit is custom work, and no two conduit
installations are exactly alike. You must practice the technique and
master the skill of making bends of the correct angle at the correct
location.
 A common two-bend configuration is the back-to-back bend which is
typically a mirror image bend of the 90-degree bend. This type of bend
occurs when you’re required to attach a piece of conduit between two  The back bend isn’t quite as easy to make. This is because the back
outlet boxes on facing walls. In this case, the first bend, the bend on bend can’t be measured from the other end of the tubing. The
the left-hand side, is easy to make since it’s made on a piece of measurement must be made from the first bend.
straight tubing. The first bend’s starting position is measured from
the end of the tubing.
  To avoid having to make the two offset bends, some electricians just
run the conduit at a slant into the outlet box. This is poor technique
and doesn’t meet PEC regulations. The NEC requires that the conduit
enter the fitting as it was designed, and connectors are designed only
to accept conduit ends that are straight. Conduit work should be
straight and square.
 Since offsets require two bends, they’re a bit more difficult to execute
than one regular bend of 90 degrees. Many offsets are small bends to
match up fractions of an inch and must be made by eye. Practice and
experience are the only way to learn to make them expertly.
 The larger offsets can’t be made by eye; they have to be calculated
and measured. That’s a bit more difficult and definitely requires some
practice. The trick to making offsets is measuring and marking the
conduit for the two bends.

 An offset is a bend that takes the tubing out of line with the run and
then returns it in a direction parallel to the original run. Offsets are
used to account for a change in elevation. In an offset, you’ll see
actually two separate bends. The first bend takes the tubing out of
line, and the second bend returns it to the same direction, on a
different line of run.
 Quite often you’ll encounter a row of beams, conduits, ductwork, or
some other obstruction over the top of which you have to continue a
conduit run. In some cases, only one offset is required for the conduit
run. In others, you may only need to rise over one beam and then
return the conduit to its original line of run by adding a second offset
bend.
 For instance, the conduit will take a 45-degree drop on one side of the
beam, then another 45-degree rise back into line. Such a rise over or
under the beam is called a saddle. A good saddle has legs that
straddle the beam identically in both length and angle. To complete a
full saddle, you’ll note that four 45-degree bends were made.
 Other angles, such as 22 1/2 degree or 30 degree, could have also
been used. Even 90-degree bends could be used, but note that the
total would be 360 degrees, the maximum total allowed in run. You
wouldn’t be able to have any other bends in the run. Also, it would be
much more difficult to pull wires through 90-degree bends.
Conduit Run Requirements

 The main concern after installing the conduit is whether the

conductors that are going to be run through the conduit can be
pulled into the conduit and withdrawn easily. When conductors are
pulled through conduit, insulation is subject to injury and small
wires can get stretched and broken. As more and more wire is pulled
through the conduit, more and more insulation surface area makes
contact and the friction between wires increases.
 The tension on the wire being pulled becomes greater and greater as
the friction increases. A rule of thumb is that no more than 1,000
pounds of pull should be exerted on a conductor being pulled through
a straight run of conduit. Even though you might use some sort of
pulling lubricant for difficult pulls, the tension increases directly with
the length of the pull and the number of bends in the run.
 The PEC states that a run of conduit between outlets, between a
fitting and an outlet, or between an outlet and a fitting shall contain
not more than the equivalent of four 90-degree bends, including the
bends located immediately at the outlet or fitting. Therefore, the total
allowed is 360 degrees.
  The total can be made up of four 90-degree bends, two 90-degree
bends and four 45-degree bends, or any other combination. You can
see that it will be difficult to pull the conductor through each bend,
and the more bends you have, the more difficult the conductor-
pulling will be.

Mating Conductors and Conduits

Sizing Conductors for Conduits

 There are strict rules specifying how much of a conduit can be packed
with wires. The NEC has prepared a number of tables that dictate
how much wire you’re allowed to pull through the tubing. The
reasons for the restrictions are twofold.
 First of all, it’s important that a conduit wiring job can be easily
 Even though you’re allowed to have 360 degrees of bends in a run,
repaired. That means that all the wires can be pulled and removed if
you would seldom bend the conduit as shown here.
the need arises. There are times when wiring must be removed or
 Instead, use box offset bends of 10 degrees to 15 degrees instead of
replaced. This is usually due to insulation deterioration or the
45 degrees. Another option would be to use a back-to-back bend,
installation of new appliances. If the wires are jammed too tight in the
tubing, the wiring removal task becomes much more difficult.
 The second consideration is heat. If too many wires are installed in a
Bending Rigid Non-Metallic Conduits conduit, the conductors can overheat and the insulation may break
down and cause a hazardous situation.
 Rigid non-metallic conduits such as those made of PVC has the same
 The amount of conductor that’s installed in a run of conduit is known
bending requirements like those of rigid metal conduits only that the
as the fill. Several tables that govern the conductor fill in conduit are
manner of bending is different. To bend non-metallic conduits, heat is
available. These tables are based on careful analysis of conductor
needed to soften the conduit so that bends can be easily made.
ampacity, insulation quality, and conduit size.
 Ampacity derating shouldn’t be confused with filling conduit with
conductors. Derating is separate and has to do with how much
current capacity is allowed for the particular conductors of a circuit.
 Conductor fill is based on the size of the wires installed in a conduit Conductor Fill
and on the internal area of the conduit.
 Conductor fill is the total of all of the CSA’s of the conductors in a run.
The following steps are required when you’re using conduit in a wiring That is, it’s the total cross-sectional area required by all of the wires.
system: It’s an extremely important area to consider when conduit is used.
 The PEC allows only a portion of the conduit CSA to be utilized or
1. Determine the conductor size.
occupied by conductors. The usable portion depends on the number
a. Know the basic ampacity of the conductor. of conductors in the run and whether the conductors are lead-
covered. It’s expressed as a percent of conduit CSA. 53 percent of the
b. Derate the basic ampacity according to the number of conductors conduits CSA is allowed to be filled with one wire, 40 percent for two
in the wiring run. wires, and 31 percent if over two wires passes through a conduit.
 The Appendix C – Conduit & Tubing Fill Table Section of the PEC
c. Derate the basic ampacity according to the ambient temperature
summarizes the number of different kind and sizes of conductors
conditions.
allowed for different sizes of conduits.
d. Determine the conductor size necessary to meet the circuit or load
requirements.

2. Find the total number of and sizes of conductor that will be run in the
same section of conduit.

3. Determine the conduit size based on allowed usable area of conduit

(maximum conductor fill).

Conduit Cross-Sectional Area

 Conduit dimensions are quite standardized, with each trade size

representing an exact internal diameter. We’re interested in the
internal diameter because the usable area of a conduit is based on
the conduit’s internal CSA. The formula for finding the CSA of a
conduit is the one we’ve used for conductor CSA, except that the
internal diameter of the conduit, rather than the conductor diameter,
is used in the calculation.
SELF CHECK NO. 1

At the end of every module, you’ll be asked to check your

understanding of what you’ve just learned by completing a “Self
Check.” Writing the answers to these questions will help you review
what you’ve learned so far. Please complete Self Check 1 now.

1. A ____________ is defined as any channel that’s designed to hold

wires, cables, or bus bars.

2. What is the standard length of a conduit?

3. What is another name for an electrical metallic tubing?

4. What is the largest trade size of an EMT?

5. (For items 5 – 7) What are the three types of threadless connectors?

8. What is another name for an FMC?

9. FMC should be fastened at least every 4 1/2 feet and within ________
of every outlet box or fitting.

10.(For items 10 – 12) Give 3 functions of conduit fittings.

13. When the voltage between a wire and ground is more than
________ volts, two locknuts are required by the PEC.

14. The PEC requires that EMT, IMC, and rigid-metal conduit be
fastened securely in place at least every _______ mm and within 900
mm of each junction box, outlet box, cabinet, or fitting.

15. When conduit nipples are installed, they can’t exceed _______ mm in
length between boxes and panels.

16. What is the PEC requirement of the radius of conduit bend for a 25
mm diameter conduit?

17. (For items 17 – 20) Identify at least 4 types of conduit bends.