How to pull wires through a long conduit with multiple bends
Long conduit runs involving 220 feet of 3-inch pipe, four 90-degree bends, and added innerduct complexity require specialized real-world techniques. Without prior experience managing a large bundle of wires through restricted access points, executing the pull properly becomes a major challenge.
What people tried
Every workaround mentioned in the threads below. We haven’t tested any of them — and nobody here is claiming they worked.
Found another way around this?
Share your steps and trade-offs so fellow engineers don't have to reinvent the wheel. No account required.
- 1Using lots of pulling lubricantDid this help you?
- 2Having help at both endsDid this help you?
- 3Trying to center the innerduct between the cables to prevent catching or crushing around cornersDid this help you?
- 4Routing the sensor wire through the entire length of the intake pipe and splicing connections inside the pipe using solder and electrical tape.Did this help you?
- 5Pouring mineral spirits down the conduit and letting it sit over the weekendDid this help you?
- 6Flashing the conduit length with a torch while tugging on a few outer wires at a timeDid this help you?
- 7Using a cutting auger or carbide auger to eat the inside of the pipeDid this help you?
- 8Using hot water with dish soap left to sit overnight, followed by removing conductors one by oneDid this help you?
In their words
Unedited, grouped by where they were said, most upvoted first within each place, each linked to the thread it came from.
“Before we can run the new 50-conductor cables to replace all these 16ga individual wires, but how to get the old wires out is the struggle.”source ↗
“2,000lb tugger won’t even budge the wires.”source ↗
“It’s just that old wire that is almost impossible to break free.”source ↗
“The bid is very much factoring in many man hours to reclaim this conduit. They wouldn’t approve new conduit but was fine paying dearly to reclaim this existing conduit. It’s whatever but I wish I had an easier way.”source ↗
“Hey folks. Looking for any advice as I prepare for this big conduit pull through 220 feet or 3" conduit with 4 90 degree bends.”source ↗
“I've done a few long pulls with big wires before but nothing with this many wires and the added innerduct complexity, so I'm hoping someone can lend some real-world experience here.”source ↗
“Whoever installed it originally didn’t run the outdoor sensor anywhere near the outside of the house, so it is useless. I’d like to correct this.”source ↗
“The PVC intake pipe runs inside a wall perpendicular to the outside wall, so I cannot access the pipe within 3 feet of the outside wall.”source ↗
Where this came up
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