Before starting any wire pulling project, proper planning and preparation are crucial to avoiding wasted time and materials. Here are some tips to streamline the wire pulling process:
Gather All Required Materials and Tools
Having all your materials and tools organized and easily accessible will prevent delays during the pulling process. Be sure to have:
- Fish tape or pull string
- Wire lubricant
- Electrical tape
- Wire strippers
- Voltage tester
- Flashlight
- Ladder
- Wire cart or equipment dolly
Pre-plan your conduit runs and measure your wire needs accurately to have the right amounts on hand. Running short on wire during a pull wastes time and materials.
Organize and Stage Your Wire
When wire is disorganized and tangled, it leads to snags and wasted time untangling wire during pulls. Proper wire staging helps streamline the process:
- Use a wire cart or reel holders to neatly pay out wire and prevent tangles
- Stage different wire rolls separately based on run
- Keep extra slack out of wire by staging close to pull entrance
- Have an assistant feed wire to prevent snags
Lubricate Wire Generously
Wire lubricant is essential for reducing friction and drag during pulls. Use lubricant liberally on wire when pulling through conduit:
- Apply lubricant by spraying wire as it enters conduit
- Reapply frequently, especially on long pulls
- Use lubricant compatible with wire jacket to avoid damage
The more lubricant used, the easier and faster the pull will be. Don't skimp on lubricant.
Pull in the Optimal Sequence
For conduit containing multiple wire runs, pull sequence matters:
- Pull largest wires first, then smaller wires after
- Pull wires for same circuit together
- Don't mix power and low voltage wiring in same conduit
Proper pull sequence minimizes wasted effort and time from wires jamming in conduits.
Use Pulley Systems for Larger Wire
For conduit runs longer than 100 feet or wires larger than #6 AWG, use pulleys or a power pull system:
- Mount pulleys aligned with the conduit run
- Use a pulling eye on the wire end to connect to rope/cable
- Pulley systems reduce manual pulling effort and prevent wire jacket damage
Avoid manually pulling large wires over long distances - use mechanical advantage.
Watch for Overfilled Conduits
Trying to pull too much wire into a conduit leads to jams and wasted time:
- Check conduit fill calculations before pulling
- Use a conduit fill chart to avoid overfilling
- Pull wires for other circuits in separate conduits if needed
Overflowing conduit capacity ruins wire and leads to painful rework.
By gathering all materials ahead of time, properly staging and lubricating wire, sequencing your pulls, and watching for overfilled conduits, you can eliminate common snags in the process. Staying organized and planning thoroughly allows efficient, streamlined wire pulling without headaches or wasted materials.