CABLE INSTALLATION PRACTICES FOR AIW’S THHN-THWN-2 BUILDING WIRE

A. LIMITATIONS OF USE:

1) UL Listing
UL File Numbers: E18964/ E51461

2) Maximum Operating Temperature:

900 C in dry locations or wet locations per table 310-13 (A) of the 2008 NEC.

3) Locations:
Dry, damp, wet per article 310-8 of the 2008 NEC.

4) Wiring Methods:
In conduit or approved raceway and, in sizes 1/0 AWG and larger, in cable tray
per article 392.3 (B) (1).

B. APPLICATION CONDITIONS:

1) GENERAL INSTALLATION RECOMMENDATIONS:

Preparation

A. Immediately prior to pulling cable into conduit or duct, any dirt, scale, water, or other
foreign substances should be removed. This can be accomplished by the use of
mandrels and duct cleaners which are available from several sources.

B. Whenever the cable to be pulled will enter a manhole or be installed in cable trays,
auxiliary pulleys may be required to ensure that the bending radius is sufficiently
large.

The following recommendations should be followed whenever cables must be pulled, whether
into conduit, duct, cable tray, or an open trench. This will increase the likelihood of a successful
pull; however, these recommendations are not expected to cover every situation which might be
encountered.
Methods of Gripping Cables

A. Basketweave pulling grip – This is a device consisting of a woven metal mesh with
loops at one end for attachment to the pulling line. It acts similarly to a “Chinese
finger grip” in that as the tension is increased, it will grip more tightly. They are
generally used with light to medium weight cables on relatively short pulls.

B. Pulling eye – Pulling eyes are connected directly to the conductor (s). Commercially
available eyes are generally applied by crimping them tightly around the conductor.
This necessitates having the correct size eye and crimping dies available for each
range of wire size to be pulled. Medium to heavy cables and/or long pulling lengths
will require the use of pulling eyes.

C. Forming the conductor into a loop – This method has been used for all types of pulls.
Care must be taken to ensure that the method of forming the loop will withstand the
tension required to pull the cable.

D. Swivels – A swivel should be used with all methods of attachment to ensure free
rotation.

2) MAXIMUM PULLING TENSION:

See tables I and II (Below)

3) COLD WEATHER INSTALLATIONS

The PVC and Nylon are thermoplastic materials and may stiffen at temperatures lower
than -10ºC (14ºF) per 2008 NEC article 310.13.

For cold weather installations, we recommend the following procedure:

• During winter months, it is better to store the cable indoors with controlled
temperature of 65ºF or higher. If you did store it outside, please bring the reel
inside in a heated room (65ºF) for 24 hours prior to the installation.

• Install the cable as soon as possible after removing it from the storage area.

• Do not install the cable at temperatures lower than -10ºC (14ºF).

• Do not impact the cable when it is very cold by dropping the cable end on the
floor or by dropping an object on the cable

• In a stationary position after the cable is installed, it can withstand temperatures

lower than -10ºC.

4) MINIMUM BENDING RADII:

 Not less than 4 times the cable O.D. in inches for sizes 14 AWG thru 500 KCMIL
for permanent training (A one-time bend after installation to connect the wire to
the source or load). During installation when the cable is pulled under tension
around a curved surface, use 2 times the value calculated above.

5) PULLING LUBRICANTS:
AIW recommends the use of pulling lubricants to reduce the coefficient of friction. The
lubricant must be removed from the cable where the terminations or splices are to be
made. It is incumbent upon the user of any lubricant to verify its suitability for their
particular application.

Generous amounts of lubricant should be applied to both the cable and conduit to
reduce friction in conduit or duct pulls.*

* NOTE: No lubricant is required for AMERI-GLIDETM Lubeless THHN/THWN-2

 Product Specification

TABLE I

MAXIMUM PULLING TENSIONS FOR TFFN & THHN 1 / C WIRES & CABLES

MAXIMUM PULLING TENSIONS (LBS) FOR GROUPS OF CABLES WITH

NUMBER OF 18 AWG 16 AWG 14 AWG 12 AWG

CABLES CABLES CABLES CABLES CABLES
1 13 21 33 52
2 22 34 55 87
3 32 52 82 131
4 39 62 99 157
5 45 72 115 183
7 64 101 161 256
8 73 116 184 293
9 82 130 207 329
10 91 144 230 366
11 100 159 253 402
12 109 173 276 439
13 110 174 277 441
14 118 188 298 475
15 126 201 321 509
16 135 215 342 543
17 143 228 363 577
18 152 241 385 611
19 160 255 406 645
20 168 268 427 679
24 202 322 513 815
30 253 402 641 1019
32 270 429 684 1087
37 312 496 791 1256
61 514 818 1304 2071

NOTES:
1. All values rounded to nearest pound.
2. The above pulling tensions are based on pulling by the conductors. Do not exceed either
1,000 pounds or the value listed above when pulling by the jacket.
3. The values 2 thru 61 cables include a reduction factor to account for unequal tensions
during installation.
 Product Specification

TABLE II

MAXIMUM PULLING TENSIONS FOR 1 / C TYPE THHN WIRES & CABLES

MAXIMUN PULLING TENSIONS (LBS) FOR GROUPS OF CABLES WITH

CONDUCTOR
SIZE 1 CABLE 2 CABLES 3 CABLES 4 CABLES
10 AWG 83 138 208 249
9 AWG 105 174 262 314
8 AWG 132 220 330 396
6 AWG 210 350 525 630
4 AWG 335 555 835 1,000
2 AWG 530 885 1,325 1,590

1 AWG 670 1,115 1,675 2,010

1/0 AWG 845 1,410 2,110 2,535
2/0 AWG 1,065 1,775 2,660 3,195
3/0 AWG 1,340 2,235 3,355 4,025
4/0 AWG 1,695 2,820 4,230 5,080

250 MCM 2,000 _ 5,000 6,000

300 MCM 2,400 _ 6,000 7,200
350 MCM 2,800 _ 7,000 8,400*
400 MCM 3,200 _ 8,000 9,600*
500 MCM 4,000 _ 10,000* 12,000*

600 MCM 4,800 _ 12,000* -

750 MCM 6,000 _ 15,000* -
1000 MCM 8,000 _ 20,000* -

NOTES:
1. All values rounded to nearest pound.
2. The above pulling tensions are based on pulling by the conductors. Do not exceed either 1,000
pounds or the value listed above when pulling by the jacket.
3. The values 2 thru 4 cables include a reduction factor to account for unequal tensions during
installation.

* Although the conductor (s) will withstand the tension given, it is recommended that the tension not
exceed 6,000 pounds on single conductor cable or 7,000 pounds on multi-conductor cables when pulling
by the conductors.