User: Simpuller, Location: MO
Asked on: Sunday, May 11, 2025 at 4:23 pm EDT
Answered on: Tuesday, May 13, 2025 at 8:23 pm EDT
Question: I have a 38 FT run of 2-1/2 IMC from my disconnect outside to my first enclosure inside the building.It has (3) standard radius 90s and (1) 30 for a total of 300 degrees of bend.This is a 200A 3P High leg Delta installation.The pull consists of:(4) 3/0 conductors, 3P + Neutral(1) #4 EGCFor referencce from the fill chart I am allowed (7) 3/0 conductors in 2-1/2 IMC.From your guys experience how hard will this pull be to be done by hand?Big thanks
Okay, let's break down this conduit run and assess the pull difficulty. Given the details you've provided, here's my assessment based on my experience
Factors making this pull CHALLENGING (but doable with the right approach):
Conduit Size and Fill
You're well within the fill limit (7 conductors allowed, you have 5). That's good. The fill calculation is not the issue here.
Long Run
38 feet is a substantial length. Friction accumulates over distance.
Significant Bends
300 degrees of bend is a LOT. Every bend significantly increases pulling friction. Standard radius bends are slightly better than short radius, but still contribute.
Conductor Size
3/0 copper is a decent size, making it a little harder to move and adding to the cumulative friction.
Factors that MIGHT make it easier
IMC (Intermediate Metal Conduit)
IMC generally has a smoother interior surface compared to rigid (GRC) which helps reduce friction. This is a plus.
Assessment and Recommendations
Based on my experience,
this pull will be difficult, but manageable with proper preparation and technique. It's going to require a good amount of force. Here's what I'd strongly advise:1. Proper Lubrication is ESSENTIAL
Use a high-quality wire pulling lubricant designed for electrical conductors.
Generously apply it to the conductors before you even start the pull. Don't skimp! Lubricate again mid-pull if you encounter significant resistance. Consider a larger container to dunk a larger section of the conductors into.2. Conduit Alignment
Make absolutely sure all conduit joints are tight and properly aligned. Even a small lip or misalignment can snag the conductors and drastically increase friction.3.
Pulling Technique
Staggered Pulling
If possible, slightly stagger the starting points of the conductors at the pulling end. Don't try to pull them all perfectly even at first. This can help distribute the friction.
Steady, Consistent Force
Avoid jerking or sudden movements. Use a slow, steady, and consistent pulling force.
Communication is Key
If you have a helper (strongly recommended!), establish clear communication signals. Coordinate the pull so one person is pulling while the other is feeding the conductors.4.
Consider a Pulling Elbow
If physically possible to install one at an accessible point, a pulling elbow after the first 90 degree bend would be ideal. This allows you to break the pull into 2 segments and re-lubricate as needed.5.
Use a Pulling Eye/Basket
A pulling eye or basket grip provides a secure and even grip on the conductors, minimizing the risk of damage. Avoid using just the bare conductors themselves to pull on, as this can cause insulation damage.6.
Inspect the Conduit
Run a fish tape through the entire conduit run before pulling the conductors. This verifies there are no obstructions, sharp edges, or other potential problems.7.
Don't Force It
If you encounter extreme resistance, STOP. Trying to force the pull can damage the conductors, the conduit, or both. Re-lubricate, re-evaluate the situation, and possibly consider a pulling elbow or other alternatives.8.
Helper is Strongly Recommended
This is a two-person job. One person to pull steadily, the other to feed and keep the conductors straight and lubricated.
Will you need a puller? Hand Pull with a Helper
I believe it's
possible to do this by hand with a helper, IF you follow the recommendations above meticulously. Rental Option
If you are not confident or you encounter significant resistance during the pull, renting a small hand-operated cable puller is a good idea. This gives you mechanical advantage.*
Safety
Be mindful of your body mechanics when pulling. Use your legs, not your back. Proper gloves are a must.
Bottom line: Proper preparation, liberal lubrication, careful technique, and a helper are essential. Be ready to re-evaluate if you encounter excessive resistance. Don't be afraid to rent a puller if needed.Good luck! Flag for review