[TowerTalk] Pulling long length of 7/8 hardline in conduit

[Grant Saviers]

I think this is all great advice - I'd add a bit more

Use pull tape or braided rope so you don't put twist into the cables 
when being pulled.  Pull tape comes in various sizes and strengths, 
something around 3/4" sounds right.  7/16" braid would be ok. Polyester 
lines are fairly cheap on ebay.

Most important: install the biggest radius sweeps you can buy for the 
hardline.  At least 48", 60" might be available.  If the larger ones are 
only available sch 80 then the couplings might leave an edge to catch 
the pull so check the ID match.  I second the idea of a separate conduit 
for other lines.  With three x 3" conduit x 120' I have 2x LDF5 + 1x  
LDF4 in one,  2 x LDF4 and 1x LDF5, and control wires in a third.

There are end bushings that chafe guard the open ends, use them as the 
bare conduit edge easily  strips insulation from wires.  If you can 
suspend the hardline reel above the feed-in point this is much better.

If the 7/8 is AVA5 you need to be *extremely* careful because the very 
thin shield is easy to dent.  LDF5 is much more forgiving.  In either 
case the number of large radius bends you have isn't a problem, check 
the specs for minimum radius repeat bending life. I'm not a fan of 
adding  conduit to the full length, too many chances for a dent or glue 
in the wrong place or dirt, especially with the length you are 
installing.   Feeding thru the sweeps is tricky.

One post from a cell installer said they refuse delivery of any AVA 
reels shipped on their side since it is so easy to damage.  Direct 
burial of 7/8 and larger AVA sounds very risky to me unless in a full 
sand bedding. You didn't mention the hardline you will install.

If you can borrow a capstan winch with a foot switch that is the most 
controllable means to adjust the pull rate and tension.  How the pros do 
it.  With a car or lawn tractor you have little feel for the tension.  
Another choice is to rig some blocks or chain fall above the pull out 
and pull in segments.  If the tower is at the exit then this is easier.

I'd use a Kellems pull grip for the bundle.  The pull Kellems have a 
swivel that further reduces the chance for twisting, check ebay for used 
ones.

A team of 4 or so is needed, talk it through and go slow with plenty of 
lube.

Something I haven't tried but might help is to prelube the conduit with 
a several mouse pulls both ways.  Maybe a grouting sponge would be a 
good mouse.

Good luck,

Grant KZ1W

On 9/2/2016 12:23 PM, Mike Smith VE9AA wrote:
> Having been an apprentice electrician in a former life for a few yrs, and
> having only a 160' run of 4" conduit with wires and hardline I can only
> offer
>
> some partial advice.  Take it as offered.
>
>   
>
> -Use more lube than you think you'll need. (lube it ever 30-40', not just
> the nose of the pull)
>
> -Tape everything really really really good.
>
> -Leave a flap of tape so when you unwrap the hardline from the rope it'll be
> easy (unless you plan on just cutting the hardline and rope)
>
> -If you can, pull all the wires at the same time.
>
> -Pull a pull string in with your hardline (instead of trying to put a mouse
> or fish tape through next)
>
> -Keep your hardline and 2nd pull string on spools if at all possible. (don't
> ask)
>
> -Put a 2nd conduit down for your other wires?
>
> -If you can see both ends, you can yell to the guy driving the lawn tractor
> (or otherwise controlling the pull) otherwise, handi-talki's are manadatory.
> I've seen pulls go bad
>
> and wires having to be replaced as something got tangled and wrecked (even
> on a manual pull) so communication is key.
>
> -When doing the pull it will be imperative to have someone feeding (pushing
> almost) the hardline in so it doesn't get gouged, scraped or bent, while
> someone else is pulling.
>
> Likely you're looking at a lawn tractor or car or something doing the pull.
>
>   
>
> This sounds like a real doozy of a pull.  Reminds me of an electrical job we
> did pulling 300+' of 3 x 0 cable, but we had a special electric motor with a
> huge reel in the electrical room to do the pull.
>
> GL !
>
>   
>
> YMMV,
>
>   
>
> I stand to be corrected.
>
>   
>
> Mike VE9AA
>
>   
>
> Mike, Coreen & Corey
>
> Keswick Ridge, NB
>
>   
>
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