Ouch, that sounds like a frustrating day! You definitely put that fish tape through its paces. Here's a breakdown of suggestions for a more rugged non-conductive fish tape, along with some considerations based on your 3/4" EMT and 6#12 THHN scenario

Understanding the Limitations of Fiberglass Tapes

First, a quick note: Fiberglass tapes, while great for non-conductivity and moderate flexibility, do have inherent weaknesses: Tendency to Split

They are essentially bundles of fiberglass strands held together. Repeated bending and abrasion inside conduit can cause the strands to separate and eventually break. This is more pronounced in smaller diameter tapes.

UV Degradation (less of a concern indoors)

Sunlight exposure weakens fiberglass over time.

Repair Vulnerability

Each repair point introduces a new weak spot.

Options for More Rugged Non-Conductive Fish Tapes

Here are a few alternatives to consider, along with their pros and cons:1. Klein Tools Non-Conductive Fish Tape (Various Materials)



Klein's Polyethylene Coated Steel or Steel Core options

These are not fully non-conductive. They have a non-conductive coating, but a steel core. If the coating is damaged you would loose the non-conductive aspect. However, they are generally far more rugged than fiberglass, especially for longer runs with more bends.

Klein 56332: 50' Non-Conductive Flexible Fish Tape, with LED Tip. I have not used this, but Klein makes decent products. Klein offers a few of the glow in the dark fiberglass tapes, and that is not what you are looking for. Pros

Very durable, good for long, difficult runs. Offers a good balance of stiffness for pushing and flexibility for maneuvering.

Cons

Can still kink if abused.2.

Greenlee Fish Tapes (Fiberglass Options - Consider Upgrading Size)



Consider a thicker diameter fiberglass tape

Greenlee makes fiberglass tapes in various diameters. A larger diameter (e.g., 3/16" or 1/4") will be significantly more robust than a smaller one. Check for ones marketed as "heavy-duty" or "high-strength."

Pros

Still non-conductive, familiar feel.

Cons

Will still eventually break under stress, though a larger diameter will last longer.

Note

Greenlee also makes steel tapes (similar to Klein).3.

Jameson Duct Rodders (Consider for Underground or Very Difficult Runs)



Description

These are essentially very stiff fiberglass rods, often used for running conduit underground or in extremely long, difficult runs. They come in sections that screw together.

Pros

Extremely strong and resistant to breaking. Excellent for pushing through obstructions.

Cons

Less flexible than fish tapes, can be difficult to maneuver in tight spaces, expensive. Probably overkill for your described situation.

Tips for Extending the Life of Your Fish Tape (Regardless of Type) Proper Lubrication

Use a good wire pulling lubricant! This is probably the most important thing you can do to extend the life of your fish tape and make pulling easier. It reduces friction and stress on the tape. Ideal Yellow 77 is a classic.

Avoid Sharp Bends

Try to minimize the number of sharp bends in your conduit run. If possible, use sweeps (long-radius bends) instead of elbows.

Smooth Edges

Make sure the ends of your conduit are reamed smooth after cutting. Burrs and sharp edges will damage the fish tape.

Proper Storage

When not in use, fully retract the fish tape into its case to protect it from damage and UV exposure.

Inspect Regularly

Check your fish tape for signs of wear and tear (splintering, cracks, kinks) before each use.

Avoid Over-Pulling

Don't try to force the fish tape through extremely tight or obstructed runs. It's better to use a different method or re-route the conduit.

Consider a Pull String First

For long or complex runs, consider using the fish tape to pull a strong pull string into the conduit. Then use the pull string to pull the wires. This reduces the wear and tear on the fish tape.

Recommendation for Your Situation (3/4" EMT, 60ft, 6#12 THHN)

Given your description, I'd recommend these:

First Choice

Klein Tools Polyethylene Coated Steel Fish Tape: It offers a great balance of durability and flexibility. Be aware that it is only non conductive if the insulation is undamaged.

Alternative

A heavier-duty fiberglass tape (3/16" or 1/4" diameter) from Greenlee. But, understand that you will likely have problems with it down the road.*

Don't forget the lubricant! Seriously, it makes a huge difference.Good luck with your next pull! Flag for review