The cleats wiring method is a neat and orderly way to run electrical wires that has been largely forgotten over the years. As an electrician, I have found that learning this old school technique can really come in handy for certain situations. In this comprehensive guide, I will walk through everything you need to know to utilize the cleats wiring method for your electrical projects.
What Are Cleats and How Do They Work?
Cleats are long, thin strips of insulated material with holes or notches along them that allow electrical wires to be laid in place and secured. The most common material for cleats is wood or fiber, but plastics and composites are also sometimes used.
The key advantage of the cleats method is that it allows wires to be run horizontally and vertically in a fully exposed and organized way. The wires are mounted securely into the notches on the cleats, keeping them neatly spaced and aligned. This differs from other methods like conduit where wires are fully enclosed.
Some of the key properties and benefits of the cleats wiring system:
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Non-conductive - Usually made of fiber or plastic, cleats do not conduct electricity themselves. This keeps everything insulated and protected.
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Open access - With wires fully exposed, it's easy to reach them for alterations and repairs. Conduit and raceways can make access difficult.
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Neat appearance - The parallel wires aligned on cleats has a clean, orderly aesthetic when done properly.
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Versatile - Cleats wiring can be used in a wide range of indoor commercial, residential, and industrial applications.
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Air circulation - Open air around wires allows for better heat dissipation and air circulation.
Where is Cleats Wiring Still Used?
While largely overtaken by more modern techniques like conduit, the cleats method is still a practical choice in certain situations:
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Historical buildings - Maintaining historical accuracy in restorations may require using older techniques like cleats that originally were in the structure.
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Temporary wiring - For short term electrical work, cleats can provide a quick, easy, and removable wiring method.
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Renovations - Cleats may already be present in older homes, allowing for simpler rewiring upgrades to existing electrical systems.
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Commercial buildings - Places like factories, warehouses, and garages with open structural elements can make good use of exposed cleats wiring in some cases.
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Raceways - Cleats are sometimes integrated on top of metal raceway sections for wire management.
So while rare today in new construction, there are definitely still situations where cleats wiring is a good fit, and it's a useful technique to know.
How to Install Electrical Wiring on Cleats
Now that we've covered the basics, let's get into the step-by-step process for completing a cleats wiring installation:
Gather Materials
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Cleats - Match cleat size to wire gauge being used. Have additional lengths for vertical runs.
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Wires - THWN or THHN wires are commonly used. Match wire gauge to circuit amperage needs.
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Fasteners - Wood screws, bolts, or adhesives to mount cleats depending on surface.
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Conduit fittings - If transitioning from conduit, use proper fittings like split clamps.
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Disconnects - Have switches or breakers turned off for safety.
Prepare Installation Location
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Mark layout lines for horizontal and vertical wire mounting locations.
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Clean surfaces thoroughly where cleats will be mounted. Remove obstructions.
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Drill any necessary holes for fasteners. Depth depends on cleat and fastener size.
Mount Cleats
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Begin mounting horizontal cleats first using level lines. Space 12" apart or closer.
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Use wood screws, bolts, or adhesive to secure depending on surface material.
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Install vertical cleats leading to outlets, devices, and junction boxes. Space by wire bend radius.
Run Wires
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Start by gently laying in the hot, neutral, and ground wires along the horizontal runs.
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Neatly run individual wires through notches on the straight sections of cleats. Do not strain or staple tightly.
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Use smooth bends at corners and vertical runs to not break insulation or deform wires.
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Follow proper color coding with black for hot, white for neutral, and green for ground.
Secure and Finish Wires
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With all wires laid into place, gently tighten any loose wire sections to remove slack.
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At cleat ends, anchor the wires with properly sized staples or clamps. Leave a little slack.
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Install conduit fittings as needed for any transitions to conduit or armored cable runs.
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Review connections, replace covers, turn back on power when complete.
Following these steps properly will result in a safe, neat cleats wiring installation that will perform reliably for many years. While labor intensive, the orderly appearance and easy access can make cleats wiring worth considering. Just be sure to get any electrical work permitted and inspected as required by local regulations. And always turn power off prior to working on existing circuits.
Common Cleats Wiring Mistakes to Avoid
As when learning any new wiring technique, there are some potential pitfalls to be aware of with the cleats method:
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Spacing cleats too far apart - Can result in loose, sagging wires if spacing exceeds 12 inches.
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Bending wires too tightly - Sharp bends can damage insulation and break conductors. Avoid 90 degree turns.
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Over-tightening - Excessive force on screws or staples can deform and degrade wires over time.
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Mixing wire types - Keep similar wire types together. Don't mix different gauges or insulation types randomly.
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Crossing neutral and ground - Never allow neutral and ground wires to cross on the same cleat. Space them apart.
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No slack at ends - Always leave a little extra wire length at termination points so wires stay loose in cleats.
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Not checking for damage - Inspect for any nicks, scrapes, crimps, or cuts in insulation after installing and secure as needed with electrical tape.
Avoiding these mistakes will ensure your cleats wiring job meets national electrical code and performs safely for the long term.
When to Use Alternatives Instead of Cleats
While suitable for some applications, there are many situations where other wiring techniques are better suited than using cleats:
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Wet or damp locations - Conduit is required for most wet areas. Cleats leave wires exposed.
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High temperature areas - Armored cable or conduit may be better for extremely hot locations.
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Corrosive environments - Plastic coated conduit works better for areas with saltwater, chemicals.
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High vibration - Conduit provides more support and protection from movement.
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Greater wire capacity - Raceways and conduit allow higher wire fill for large circuits.
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Frequently altered wiring - Conduit makes changing out individual wires easier.
Considering these factors will help you decide if alternatives like EMT, flexible metal conduit, or armored cable are preferable for a particular electrical project.
Conclusion
The cleats wiring technique provides a professional, neat way to securely mount electrical wires when aesthetics and open access are priorities. Although not as common as conduit and raceways for new construction, cleats still offer benefits for renovations, historical restorations, and certain commercial/industrial applications provided installation practices follow national electrical code. By learning proper cleats wiring methods, electricians gain a valuable skill that can provide great utility in the right circumstances. Just be sure to exercise good judgment when deciding where and when cleats are the optimal wiring solution.