Wireman · Pulling wire · 2023 NEC ·
Field guide
Pulling wire
Planning the pull, making a good head, and getting it through without skinning the insulation.
Plan the pull
- Check the fill first. If the run is over 40% (three or more conductors), it won't pull well, and it isn't allowed. Use the conduit fill calculator.
- Feed from the end nearest the bends. Pulling tension multiplies through every bend, so you want the bends early in the pull, while the tension is still low.
- Count the bends. No more than 360° between pull points. On long or bendy runs, add a pull box or plan to pull in two stages.
- Stage the spools on a cart or dolly so they pay off freely, in the order they go on the head. Have a feeder at the spools on every pull bigger than a few wires.
- Radio or phone between the feeder and the puller. Stop the moment anyone calls it.
Getting a line in
- Fish tape for short runs with few bends. Push from the end with the bends nearest you.
- Vacuum or blower and a foam piston (mouse) pulls a string line through long runs and underground in seconds. Use mule tape or rated rope for the actual pull.
- Pull a spare string in with the wire on runs where more conductors might be added later.
- Clean out underground conduit with a mandrel or swab first if it might have water, mud or a crushed spot.
Making the pulling head
- Strip the conductors back and stagger them, so the head tapers instead of making one big lump.
- Loop each conductor through the eye of the fish tape or rope (or a pulling grip on large cable), folding the ends back.
- Wrap the whole head tightly with electrical tape, starting on the wire and working forward, so no edge can catch on a coupling.
- Tug-test the head before you start pulling.
Lubricant and jamming
- Lube the head and keep lubing the conductors as they go in, not just the first few feet. Use a lubricant compatible with the insulation.
- Jam ratio: with three conductors of the same size, the wires can wedge side by side in a bend when the conduit's inside diameter is about 2.8 to 3.2 times one conductor's outside diameter. Go up a conduit size or change the conductor arrangement if you land there.
- Pull steady. Stopping and starting takes more force to break loose again than keeping it moving.
Pulling tension
- A rule of thumb used in industry: copper conductors pulled by the conductor should see no more than about 0.008 lb of tension per circular mil. The cable maker's data governs: check it for big pulls.
- With a power puller, use rope rated well above the expected force and stay out of the rope's line. A snapping rope whips back hard.
- Feed wire off the spool in a gentle curve into the conduit. Sharp bends at the mouth of the pipe skin insulation; use a feeding sheave or have the feeder guide it.
At the boxes
- Leave at least 6 in of free conductor at each box, and at least 3 in sticking out past the face of boxes with an opening under 8 in.
- Don't skin conductors on the edge of a box or a cut end of conduit: ream every cut, and use bushings where the code calls for them on 4 AWG and larger.
- Identify conductors as you go: tag or tape each circuit at both ends.
- Check insulation damage with a megohmmeter on feeders before you terminate.
NEC: Chapter 9 Table 1, 300.14, 300.4(G), 358.26