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Electrical Design Training Class: Conduit Sizing

This document provides an overview of conduit sizing and fill requirements. It discusses National Electric Code requirements for maximum allowable conduit fill of 26% for new conduits and 40% for existing conduits. Examples are provided to demonstrate how to calculate conduit fill for various conductor combinations and ensure it does not exceed the allowable limits. Key points covered include definitions of conduit fill, the importance of not exceeding fill limits, and recommendations for installing spare conduits when crossing roadways.

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Cong Viet
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81 views

Electrical Design Training Class: Conduit Sizing

This document provides an overview of conduit sizing and fill requirements. It discusses National Electric Code requirements for maximum allowable conduit fill of 26% for new conduits and 40% for existing conduits. Examples are provided to demonstrate how to calculate conduit fill for various conductor combinations and ensure it does not exceed the allowable limits. Key points covered include definitions of conduit fill, the importance of not exceeding fill limits, and recommendations for installing spare conduits when crossing roadways.

Uploaded by

Cong Viet
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 22

Electrical Design Training Class

Conduit Sizing
WSDOT
Fall / Winter 2004

Presented by: Keith Calais

1
What is conduit fill?
• Conduit fill is the amount, in square inches, of conductors
inside a section of conduit.

• NEC 2002 - Article 344 - Rigid Metal Conduit: Type RMC

• NEC 2002 – Article 352 - Rigid Nonmetallic Conduit: Type


RNC (Note this Article includes PVC schedule 40 and PVC schedule 80 as well
as HDPE schedule 40).

2
Why do we need to worry
about Conduit fill?
• Dissipate heat.

• Pulling of wires.

• Potential high cost change orders when the conductors that


you specified do not fit inside the conduit.

3
When do we need to worry about
conduit fill?
• When you are installing new conduit and
conductors.

• When you are adding new conductors to an existing


conduit run.

4
Allowable conduit fill
• The maximum allowable fill for new conduit is 26% full.
(Design Manual Chapter 850, page 840-15 (c) Conduit)

• The maximum allowable fill for existing conduits is 40%


full. (NEC 2002 – Chapter 9, Table 1) and (Design Manual Chapter
850, page 840-15 (c) Conduit)

5
26% Conduit Fill Æ 1 ½” Conduit
Conductors Æ 4 - #2
= 0.532 in^2

6
40% Conduit Fill Æ 1 ½” Conduit
Conductors Æ 4 - #2, 2 - #4, and 2 - #8
= 0.838 in^2

7
60% Conduit Fill Æ 1 ½” Conduit
Conductors Æ 5 - #2, 2 - #4, 2 -#6,
3 - #8, 1 - #10, and 1 - #12
= 1.232 in^2

8
9 9
Conductor Sizes
Conductor Conductor Conductor Conductor Conductor Conductor
Type Size (in2) Type USE Size (in2) Type USE Size (in2)
2C(sh)-#14 0.090 #12 0.026 1/0 0.222
3C(sh)-#20 0.070 #10 0.033 2/0 0.262
4C(sh)-#18 0.060 #8 0.056 3/0 0.312
5C-#14 0.140 #6 0.073 4/0 0.372
7C-#14 0.170 #4 0.097 250 0.460
10C-#14 0.290 #3 0.113 300 0.528
6pcc-#19 0.320 #2 0.133 350 0.596
RG59Ucc 0.046 #1 0.190 400 0.662
24 (SM) fiber 0.196
48 (SM) fiber 0.196
72 (SM) fiber 0.196
96 (SM) fiber 0.478
144 (SM) fiber 0.478

10
Conduit Sizes-GRS (2002 NEC chapter 9, table 4 - Article 344 RMC)
Conduit Size Max Fill 26% Max fill 40%
(inches) (square inches) (square inches)
½” 0.082 0.125
¾” 0.143 0.220
1” 0.231 0.355
1 ¼” 0.397 0.610
1 ½” 0.539 0.829
2” 0.886 1.363
2 ½” 1.265 1.946
3” 1.950 3.000
3 ½” 2.603 4.004

11
Conduit Sizes – PVC schedule 40, and HDPE
Conduit Size Max Fill 26% Max fill 40%
(inches) (square inches) (square inches)
½” 0.074 0.114
¾” 0.132 0.203
1” 0.216 0.333 (2002 NEC
1 ¼” 0.378 0.581 chapter 9, table
1 ½” 0.516 0.794 4 - Article 352
RNC)
2” 0.856 1.316
2 ½” 1.221 1.878
3” 1.890 2.907
3 ½” 2.532 3.895
Conduit Sizes – PVC schedule 80
Conduit Size Max Fill 26% Max fill 40%
(inches) (square inches) (square inches)
½” 0.056 0.087
¾” 0.106 0.164 (2002 NEC
1” 0.179 0.275 chapter 9, table
4 - Article 352
1 ¼” 0.322 0.495 RNC)
1 ½” 0.445 0.684
2” 0.747 1.150
2 ½” 1.071 1.647
3” 1.675 2.577
3 ½” 2.259 3.475 12
Examples
New 1” GRS conduit with 3-#8
1” conduit 26% fill is 0.231 sq.in.
#8-0.056 sq.in. - 3*0.056=0.168 sq.in.
0.168 sq.in. < 0.231 sq.in.
Conduit fill OK.

Existing 1” GRS conduit with 5-#8


1” conduit 40% fill is 0.355 sq.in.
#8-0.056 sq.in. - 5*0.056=0.280 sq.in.
0.280 sq.in. < 0.355 sq.in.
Conduit fill OK.
13
Examples
New 2” GRS conduit with 6-#8, 3-#6, 4-#4, 3-#2

2” GRS conduit 26% fill is 0.89 sq.in.


#8-0.056 sq.in. - 6*0.056=0.336 sq.in.
#6-0.073 sq.in. - 3*0.073=0.219 sq.in.
#4-0.097 sq.in. - 4*0.097=0.388 sq.in.
#2-0.133 sq.in. - 3*0.133=0.399 sq.in.
1.342 sq.in.
1.342 sq.in. > 0.89 sq.in. Conduit fill is NOT OK.

Try 3” GRS conduit 6-#8, 3-#6, 4-#4, 3-#2

3” GRS conduit 26% fill is 1.95 sq.in.


#8-0.056 sq.in. - 6*0.056=0.336 sq.in.
#6-0.073 sq.in. - 3*0.073=0.219 sq.in.
#4-0.097 sq.in. - 4*0.097=0.388 sq.in.
#2-0.133 sq.in. - 3*0.133=0.399 sq.in.
1.342 sq.in.
1.342 sq.in. < 1.95 sq.in. Conduit fill is OK. 14
Examples
New 2” PVC Schedule 40 conduit with 6-#8, 3-#6, 4-#4, 3-#2

2” PVC Schedule 40 conduit 26% fill is 0.856 sq.in.


#8-0.056 sq.in. - 6*0.056=0.336 sq.in.
#6-0.073 sq.in. - 3*0.073=0.219 sq.in.
#4-0.097 sq.in. - 4*0.097=0.388 sq.in.
#2-0.133 sq.in. - 3*0.133=0.399 sq.in.
1.342 sq.in.
1.342 sq.in. > 0.856 sq.in. Conduit fill is NOT OK.

Try 3” PVC Schedule 40 conduit 6-#8, 3-#6, 4-#4, 3-#2

3” PVC Schedule 40 conduit 26% fill is 1.890 sq.in.


#8-0.056 sq.in. - 6*0.056=0.336 sq.in.
#6-0.073 sq.in. - 3*0.073=0.219 sq.in.
#4-0.097 sq.in. - 4*0.097=0.388 sq.in.
#2-0.133 sq.in. - 3*0.133=0.399 sq.in.
1.342 sq.in.
1.342 sq.in. < 1.890 sq.in. Conduit fill is OK. 15
Examples
New 2” PVC Schedule 80 conduit with 6-#8, 3-#6, 4-#4, 3-#2

2” PVC Schedule 80 conduit 26% fill is 0.747 sq.in.


#8-0.056 sq.in. - 6*0.056=0.336 sq.in.
#6-0.073 sq.in. - 3*0.073=0.219 sq.in.
#4-0.097 sq.in. - 4*0.097=0.388 sq.in.
#2-0.133 sq.in. - 3*0.133=0.399 sq.in.
1.342 sq.in.
1.342 sq.in. > 0.747 sq.in. Conduit fill is NOT OK.

Try 3” PVC Schedule 80 conduit 6-#8, 3-#6, 4-#4, 3-#2

3” PVC Schedule 80 conduit 26% fill is 1.675 sq.in.


#8-0.056 sq.in. - 6*0.056=0.336 sq.in.
#6-0.073 sq.in. - 3*0.073=0.219 sq.in.
#4-0.097 sq.in. - 4*0.097=0.388 sq.in.
#2-0.133 sq.in. - 3*0.133=0.399 sq.in.
1.342 sq.in.
1.342 sq.in. < 1.675 sq.in. Conduit fill is OK. 16
Examples
New 1 1/2” GRS conduit with 3-#8, 3-#4

1 1/2” GRS conduit 26% fill is 0.539 sq.in.


#8-0.056 sq.in. - 3*0.056=0.168 sq.in.
#4-0.097 sq.in. - 3*0.097=0.291 sq.in.
0.459 sq.in.
0.459 sq.in. < 0.539 sq.in. Conduit fill is OK.

New PVC Schedule 40 conduit with 3-#8, 3-#4

1 1/2” PVC Schedule 40 conduit 26% fill is 0.516 sq.in.


#8-0.056 sq.in. - 3*0.056=0.168 sq.in.
#4-0.097 sq.in. - 3*0.097=0.291 sq.in.
0.459 sq.in.
0.459 sq.in. < 0.516 sq.in. Conduit fill is OK.

1 1/2” PVC Schedule 80 conduit 26% fill is 0.445 sq.in.


#8-0.056 sq.in. - 3*0.056=0.168 sq.in.
#4-0.097 sq.in. - 3*0.097=0.291 sq.in.
0.459 sq.in.
0.459 sq.in. > 0.445 sq.in. Conduit fill is NOT OK.

17
Examples

Existing 2” GRS conduit with 6-#8, 3-#6, 4-#4, 3-#2

2” GRS conduit 40% fill is 1.36 sq.in.

#8-0.056 sq.in. - 6*0.056=0.336 sq.in.


#6-0.073 sq.in. - 3*0.073=0.219 sq.in.
#4-0.097 sq.in. - 4*0.097=0.388 sq.in.
#2-0.133 sq.in. - 3*0.133=0.399 sq.in.
1.342 sq.in.
1.342 sq.in. < 1.36 sq.in.
Conduit fill is OK.

18
Things to remember when sizing conduit

• Every time you cross a roadway put a spare conduit in.


• If the conduit crossing is for illumination or power supply,
put in a spare 2” conduit.
• If the conduit crossing is for signal conduits at an
intersection put in a spare 3” conduit. If the crossing is not
at the intersection put in a spare 2” conduit.
• A 2” conduit should be the minimum size used for all
crossings.
• Install a spare 2” conduit into a service cabinet.
• Install a spare 2” conduit between all transformers and the
improvement the transformer is serving. (ITS cabinet, VMS
cabinet, etc.)
19
Things to remember when sizing conduit.
• Try not to use too many different sizes of conduit. It makes
it easier to design your job and makes it easier for the
contractor to build when you use less conduit sizes. Stick
with even sized conduits (1”, 2” 3”, or 4”).

• Leave room for future conductors. Running 2” conduit near


the service or where there is potential for future expansion
usually provides plenty of future room.

• The conduit from the luminaire pole to the adjacent junction


box 5’-10’ away shall be 1”. This is usually the only place
you would ever run a 1” conduit in grade (except the
grounded electrode conductor).
20
21
Any
Questions?
22

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