Republic of the Philippines

City of Iloilo
TECHNICAL INSTITUTE OF ILOILO CITY
MOLO CAMPUS
M.H del Pilar St., Molo, Iloilo City
Email: [email protected] Tel. No. (033) 337-6711

LESSON 2: Wires and Cable Layout

Performing Roughing-In Activities, Wiring and Cabling Works for Single-Phase Distribution,
Course:
Power, Lighting and Auxiliary Systems
Book: LESSON 2: Wires and Cable Layout
Printed
Rekhnor Magbanua
by:

Table of contents
 Introduction
 TOPIC 1: Preparing Wires and Cables
 TOPIC 2: Laying Out Cables
 TOPIC 3: Wire Pulling
 TOPIC 4: Basic Electrical Connection Using Splices, Joints, and Solderless Connectors
 TOPIC 5: Tagging of Wires
Introduction

Wires and cables are a crucial part of circuits since it allows the flow of electricity from the source to the
load. Any defect on wires and cables can interrupt the movement of electricity, which stops the device's
operation and can even lead to more damage to the device and property, and people. This is why preparing
and laying out cables and wires must be conducted properly.

This lesson focuses on the necessary preparations when performing cable pullings, such as the number of
conductors, raceway allowances, cable protection, cable pulling process, and cable tagging to ensure the
cabling process is performed in accordance with the latest edition of the Philippine Electrical Code.

TOPIC 1: Preparing Wires and Cables

Cabling or wire pulling, also known as fishing, is the process in which wires and cables are inserted inside
the conduit. According to PEC, only 40% of the area of the conduit must be occupied by the conductors to
provide space for ambient temperature. 

The table below from the NEC shows the maximum number of allowed conductors to be placed inside an
Electrical Metallic Tubing:
SPLICING OF WIRES AND CABLES

Splicing or joining by interweaving conductors inside the raceway is prohibited because wire pulling
becomes difficult to conduct. Instead, splicing must be performed in a splice box except for direct-buried
conductors or cables, which can be spliced or tapped without using splice boxes.

WIRES AND CABLES SHARING A RACEWAY

Conductors that have non-shielded insulation and operate at different voltage levels must not be in the same
enclosure, cable, or raceway. Conductive optical fiber cables and conductors for electric light, power, non–
power-limited fire alarm, or medium power network-powered broadband communications circuits must not
occupy the same cable tray or raceway.
When combination surface nonmetallic raceways are utilized for signaling and for lighting and power
circuits, then they must be run in separate compartments which will be labeled by stamping, imprinting, or
color-coding of the interior finish as an identifier.

There must be at least 100 mm distance between all conductors inside the building and the conductors of any
electric light, power, or signaling circuit.

LENGTH OF FREE CONDUCTORS

The free conductor must have at least 150 mm, measured from the point in the box where it comes out from
its raceway or cable sheath, left at each outlet, junction, and switch point for the splicing or connecting of
luminaires (fixtures) or devices. 

If the opening to an outlet, junction, or switch point is smaller than 200 mm in any dimension, each
conductor must be long enough to extend at least 75 mm outside the opening.

INSULATED FITTINGS

Raceways containing  22 mm2 or larger ungrounded conductors that enter a cabinet, box enclosure, or
raceway must have the conductors protected by a substantial fitting with a smoothly rounded insulating
surface unless the conductors and the fitting or raceway are separated from each other through a securely
fastened substantial insulating material.

TOPIC 2: Laying Out Cables

Basic Rules of Laying Out Cables

 Layout and bind power cables, signal cables, ground cables, and other different types of cables
separately.
 Layout cables of the same type in the same direction.
 Layout cables at a small distance in crossover mode.
 Power cables must have a distance longer than or equal to 30 mm from signal cables when they are
laid out in parallel.
 Attach engineering labels to the cables to distinguish different types of cables if they cannot be
identified by labels.
 Protect cables from burrs, heat sinks, and active accessories that can damage the insulation layers of
the cables.
 Use cable ties to bind cables. Never tie two or more cable ties together for binding cables. After
cables are bound using cable ties, cut off the excess part and make sure that the cuts are neat and
smooth.
 Layout, support, or fix cables properly in cable troughs/gutters inside a rack to prevent excessive
stress on the cables or wiring terminals, loose connections, and damage to the cable insulation layer.
 Coil and bind surplus parts of cables in the proper position of the rack.
 Route cables straightly and bound neatly in a rack. The bending radius of a cable depends on the
bending position.
 If bending a cable in the middle is required, the bending radius must be at least twice the cable
diameter.
 If bending a cable at the output terminal of a connector is required, the bending radius must be at
least five times the cable diameter and bind the cable before bending.
 Using cable ties at positions where the cables are bent is prohibited since the core wires of the cables
may break.

Common Methods of Laying Out Cables Inside a Rack

 Layout power cables behind the rack along the left side. Select overhead or under floor cabling
according to equipment room conditions, such as the locations of the AC power distribution cabinet,
surge protection device (SPD), and terminal block.
 Route service data cables at the back of the rack and bind them to the right cable trough. They can
also be routed at the front of the rack and bound to the cable troughs on both sides. Determine the
overhead or underfloor cabling for service data cables based on equipment room conditions, for
example, the cabling mode (overhead or underfloor cabling) used by signal cables.
 Position the connectors of all service data cables at the bottom of the rack in order so that the
connectors are not easily reached.

Underground Laying of Power Cables

(Basic Vocational Knowledge - Electrical Installation)

 Firmly place the cable drum on cable jacks or a cable car. Carefully situate the cable drum
horizontally a few centimeters above the ground to prevent the cable drum from slipping off laterally
when the cable is run out. Provide a braking device at the cable drum.
 During reeling off, continuously run out the cable under tension from above
 Pull the cable off the drum opposite to the rolling direction indicated on the cable drum. There must
be no kinks, formed loops, or curls on the cable.
  Use appropriate devices for mechanical cable laying such as winches and cable handling machinery
when laying cables. 
 In case of long and winding routes, make use of cable handling machinery.
 When cables are laid using a winch, join the cables to a pulling rope through a cable stocking of
metal. 

 Gradually adapt the pulling speed to the tensile force of the cable. Do not go over the permissible
tensile forces.
 Position idlers in distances of 5 m idlers on the cable runs.
 Arrange the angular idlers in curves. If the cable cannot be laid using a machine, it will have to be
laid manually by carrying them with arms spread downwards. 
 Observe the allowed minimum bending radius during cable laying. Relate the minimum bending
radius to the external diameter of the cable.

 Do not lay the cables if the temperature is below 4°C. Low temperature causes cables to become
brittle and easily broken. In urgent cases, warm up the cables using a heater fan before being laid
out. 
 Cover cables in cable ditches using bricks or concrete ducts as cable covering hoods. While cables
are allowed to be laid into cable ditches embedded in the sand without cover, the route of the cable
must be marked by an approximate 10 cm wide yellow plastic tape, set 30 cm above the cable. This
applies only to cables with a concentric conductor.
 If cables are laid into the ground without cover, it must be buried at least 1 m deep. 
 Surround the cable in the sand if cable covering hoods are being used. Existing cavities between the
cable and covering hood will block heat dissipation from the cable to the soil.
 Cables are passed and laid in cement ducts beneath street roads. There are cement ducts for 1 to 4
drafts. They are made of concrete and put together without a gap between them.
 Cables must be laid in tubes 1.5 m deep beneath railway tracks. Cables must be laid at a distance of
approximately 25 cm alongside gas pipelines. 
 In case cables such as telecommunication cables cross other cables, they must be protected
mechanically. There will be markings using plastic cable marking tape at every 3 to 5 m of the laid
cables.
 Color and printing on the cable marking tape indicate:

1. voltage
2. cable type and number of cables
3. cross-sections

TOPIC 3: Wire Pulling

TOPIC 4: Basic Electrical Connection Using Splices, Joints, and
Solderless Connectors
Conductor splices and joints are essential components of an electrical circuit. When conductors are joined
together or connected to the load, splices and solderless connectors may be necessary. Therefore, it is
important that they are properly performed to avoid being the weakest link in the system which can cause
electrical system failure, damage to property, and even death.
The basic requirement of any splice or connection is that it must be both mechanically and electrically as
good as the conductor or device with which it is used. Make sure to employ quality workmanship and
materials to guarantee lasting electrical contact, physical strength, and insulation.

The following are the most common electrical splices and joints being used in electrical installations. Click
the boxes below to know how to perform splices & joints and soldering techniques.

Spliced and jointed wires need to be insulated. Watch the video below for the steps in insulating spliced and
jointed wires using electrical tape:
  
 

On the other hand, wires can also be connected without soldering or splicing. Here are the steps in joining
electrical conductors using solderless connectors:
NOTE:
When performing splices, joints, and soldering techniques, always remember to:

 Wear proper PPE

 Treat all wires as live wires
 Observe and practice OHS procedures
 Use the correct tools properly
TOPIC 5: Tagging of Wires