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COMPETENCY BASED LEARNING MATERIAL

Sector : CONSTRUCTION

Qualification Title : ELECTRICAL INSTALLATION AND MAINTENANCE NC


11

Unit of Competency : PERFORM ROUGHING-IN ACTIVITIES FOR


COMMUNICATION AND DISTRIBUTION

Module Title : PERFORMING ROUGHING-IN ACTIVITIES FOR


COMMUNICATION AND DISTRIBUTION

Technical Education and Skills Development Authority


LANAO NORTE NATIONAL AGRO-INDUSTRIAL SCHOOL
BUALAN, TUBOD, LANAO DEL NORTE
HOW TO USE THIS COMPETENCY – BASED LEARNING
MATERIALS
Welcome!
The unit of competency “Perform Roughing-in Activities for Communication
and Distribution.” A course which comprises the knowledge, skills and attitudes
required for a Certificate level 11 in Electrical Installation and Maintenance trainer
to possess.
The module, Performing Roughing-in Activities for Communication and
Distribution, contains training materials and activities related to identifying
learner’s requirements, preparing session plan, preparing basic instructional
materials and organizing learning and teaching activities for you to complete.
In this module, you are required to go through a series of learning activities
in order to complete each learning outcome. In each learning outcome are
Information Sheets, Self-Checks, Operation Sheets and Task/Job Sheets. Follow
and perform the assistance from your trainer.
Remember to:
 Work through all the information and complete the activities in each
section.
 Read information sheets and complete the self-check. Suggested
references are included to supplement the materials provided in this
module.
 Most probably, your trainer will also be your supervisor or manager.
He is there to support you and show you the correct way to do things.
 You will be given plenty of opportunities to ask questions and practice
on the job. Make sure you practice your skills during regular work
shifts. This way, you will improve your speed, memory and your
confidence.
 Use the Self-Checks, Operation Sheets or Task or Job Performance at
the end of each section to test your own progress. Use the
Performance Criteria Checklist or Procedural Checklist located after
the sheet to check your own performance.
 When you feel confident that you have had sufficient practice, ask
your Trainer to evaluate you. The results of your assessment will be
recorded in your Progress Chart and Accomplishment Chart.

You need to complete this module before you can perform the next module,
Install wiring devices for floor and ground fault current interrupting outlets.

CBLM on Electrical Installation Date Developed: Document No.


and Maintenance NC II May 1, 2015 Issued by:
Date Revised:
Performing Roughing-In May 1, 2016 Page |
LNNAIS
Activities For Communication Revised By:
And Distribution Jonard A. Mamalias, RME Revision # 01
COMPETENCY-BASED LEARNING MATERIALS

List of Competencies

No. Unit of Competency Module Title Code

Prepare Electrical Preparing and


Power and Hydraulic Maintaining Electrical
1. CON724308
Tools Hydraulic and Power
Tools

Perform Roughing-in Performing Roughing-


Activities for in Activities for
2. CON7243009
Communication and Communication and
Distribution Distribution

Install Wiring Devices Installing Wiring Devices


for Floor and Ground for Floor and Ground CON724310
3.
Fault Current Fault Current
Interrupting Outlets Interrupting Outlets

Install Electrical
Installing Electrical
Protection System for CON724311
4. Protection System for
Lighting and
Lighting and Grounding
Grounding

Install Electrical Installing Electrical


Lighting Systems on Lighting Systems on CON724312
5.
Auxiliary Outlets and Auxiliary Outlets and
Lighting Fixtures Lighting Fixtures

CBLM on Electrical Installation Date Developed: Document No.


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MODULE CONTENT

Qualification Title : ELECTRICAL INSTALLATION AND MAINTENANCE NC


11
Unit of Competency : PERFORM ROUGHING-IN ACTIVITIES FOR
COMMUNICATION AND DISTRIBUTION
Module Title : PERFORMING ROUGHING-IN ACTIVITIES FOR
COMMUNICATION AND DISTRIBUTION

Introduction:
This module covers the knowledge, skills and proper attitude in laying-out,
electrical metallic conduits for communication and distribution. It deals with
laying-out of metallic conduits, wireways and cable trays, telephone terminal
cabinets and cable bridge.

Learning Outcomes:

LO1. Install electrical metallic conduits

LO2. Install wireways and cable trays

LO3. Install telephone terminal cabinet

LO4. Install cable bridge

Assessment Criteria:

1. Electrical metallic conduits are installed according to the latest edition


of Philippine Electrical Code and National Electrical Code.
2. Electrical metallic conduits are installed according to the job
requirements
3. Tools/equipment and materials needed for the installation are prepared
in line with job requirements.
Safety procedures in installing electrical metallic conduits are strictly observed
according OHS guidelines and procedures.

CBLM on Electrical Installation Date Developed: Document No.


and Maintenance NC II May 1, 2015 Issued by:
Date Revised:
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LEARNING OUTCOME # 1 Install Electrical Metallic Conduits
CONTENTS:
 PEC provisions on electrical metallic conduits
 Bending electrical metallic conduit
 Procedures in installing electrical metallic conduit
 Safety procedures in installing electrical metallic conduits

ASSESSMENT CRITERIA:
1. Electrical metallic conduits are installed according to the latest edition of
Philippine Electrical Code and National Electrical Code.
2. Electrical metallic conduits are installed according to the job
requirements
3. Tools/equipment and materials needed for the installation are prepared
in line with job requirements.
4. Safety procedures in installing electrical metallic conduits are strictly
observed according OHS guidelines and procedures.

CONDITION:
Students/trainees must be provided with the following:

 Tools and Equipment  Materials


o Lineman’s pliers o Electrical metallic conduits
o Long nose pliers o lock nuts, bushing, adapters
o Diagonal cutting pliers o fastening devices
o Set of screw driver o Conduit supports
o Claw hammer
o Hacksaw
 Learning Materials
o Measuring tools
o Learning elements
o Pipe vise
o Manuals
o Pipe cutter
o Books and
o reamer
o Philippine Electrical
o Simulated
Code/National Electrical Code,
workplace/wiring booth
Latest Edition
o Ladder
o Hickey Bending

ASSESSMENT METHOD:
 Demonstration
 Direct observation and questioning

CBLM on Electrical Installation Date Developed: Document No.


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Learning Experiences

Learning Outcome # 1

Learning Activities Special Instructions

Read Information Sheet 2.1-1 You can ask the assistance of your
trainer to show you and explain further
 Theories/Principles the topic you can’t understand.
 Tools, Equipment and Materials
 Tasks (Steps) & Key points

Self-Check 2.1-1 Answer the following questions

Answer Key 2.1-1 Compare your answers to answer key

Task Sheet 2.1-1 Perform the following task to develop


skills in bending metallic conduit

Performance Sheet 2.1-1 Perform how to operate Hickey bender.

Job Sheet 2.1-1 Prepare in installing electrical metallic


conduits

After doing all activities of this LO, you


are ready to proceed to the next LO on
Install wiring devices for floor and
ground fault current interrupting
outlets.

CBLM on Electrical Installation Date Developed: Document No.


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Information Sheet 2.1-1
INSTALL ELECTRICAL METALLIC CONDUIT

Learning Objectives:
After reading this Information Sheet, you must be able to:
1. Classify rigid conduit.
2. Enumerate and apply the PEC requirements concerning rigid conduit
preparation (bending) for installation.
3. Preparing and cutting pipes.
4. Bend rigid conduit to the following forms.

4.1 rigid angle


4.2 off-set
4.3 cross-over or saddle
4.4 gooseneck

I. THEORIES/PRINCIPLES

Rigid conduits are classified as:

1. Rigid metal conduit


2. Electrical metal tubing (EMT) or thin wall metal conduit
3. Non-metallic conduit/PVC pipe (Polyvinyl chloride)

Rigid Metal Conduit

 They are commonly used in;

- Wiring building to minimize if not totally prevent fires due


to electricity.
- Wiring that must be buried in concrete, masonry or similar
materials.
- Exposed or open wiring where maximum protection from
mechanical damage is necessary.

 They are normally galvanized or zinc coated to prevent


corrosion, when exposed to weather, imbedded in concrete,
installed in wet locations.

CBLM on Electrical Installation Date Developed: Document No.


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 The standard length is 3.048 meters (10 ft.) including a
coupling. Its usual diameter is 12.7 – 152.4 mm (“1/2 to 6”).

The radius of the curve of the inner edge or the field bend shall not be less
than what is specified in table I. A run of conduit between an outlet and a fitting
shall not contain more than the equivalent of 4 quarter bends (360°, total
including those bends located immediately at the outlet or fitting).

Size of conduit Radius of bends with Radius of bends with


conductors without lead lead sheathed
sheathed conductors
(Inches) (Inches)
½ 4 6
¾ 5 8
1 6 11
1-1/4 8 14
1-1/2 10 16
2 12 21
2-1/2 15 25
3 18 31
3-1/2 21 36
4 24 40
4-1/2 27 45
5 30 50
6 36 61

Table I. Radius of conduit bends (inches)

Field bend is any field bend made by the electrician during the installation
of the conduit.

CBLM on Electrical Installation Date Developed: Document No.


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Types of corrosion-resistant Rigid conduit

1. Aluminum
2. Silicon bronze alloy
3. Plastic coated

The rigid metal conduit wiring, the electrician cuts, bends, threads and
reamed conduits before installing them. Cutting rigid conduit is done with a
hacksaw or a pipe cutter.
Sharp edges or burrs at the ends could seriously damage the insulation of
the wire as it is pulled into the conduit. These burrs have to be removed by a
reamer or by a file as per PEC requirements.
Bending conduit is done to produce a desired bend angle on conduit for
installation.
This is done with a hickey or conduit bender. Bends on rigid conduit pipes
should be made so that the pipes are not injured nor the effective internal
diameter reduced.

The illustration in figure 1. show a run of conduit which contains more than
two quarter bends which is against the PEC requirements.

Figure I. Violation of PEC Requirements on


Run of conduit with 4 quarter bends

Figure 1.

CBLM on Electrical Installation Date Developed: Document No.


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The fewer the bends, the easier it is to fish-in or pull wires into metal
conduits.
One of the practical ways of determining the radius of a field bend is to
multiply by 5. Diameter which is less than 1” should consider as 1” in determining
the radius of bend. See the illustration below.

Example:

Size of conduit = ½ diameter

Radius = Diameter x 5
= 1x5
= 5”

The illustrations in figure 2. Show how to figure 90 ˚or right angle in


electrical metal tubing.

Figure 2. Figuring a right angle

CBLM on Electrical Installation Date Developed: Document No.


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Bend on Electrical Metallic Tubing

Suppose the right angle bend is to be made and that the conduit is to have
a rise of 18” above the floor. Assuming that the conduit is ½ in diameter, subtract
5” from the rise of 18” that leaves 13”. Hook the bender over the rigid metal
conduit so that the arrow on the bender points to a point 13 inches from the end
of the metal conduit as shown in figure 2. If the size of the conduit is ¾, subtract
6”. If the size is 1”, subtract 8” from the desired measurements.

The different bends that are common in a conduit installation are that the
following:

1. Right- angle bend


2. Off-set bend
3. Cross-over or saddle bend
4. Gooseneck bend

Figure 3. shown the application on the above-mentioned bend

Figure 3. Application of the different


Bends in Conduit Installation

CBLM on Electrical Installation Date Developed: Document No.


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In bending a metal conduit, a pipe bender or hickey is commonly used by
electricians.
There are several methods however, that are used in bending in the absence
of hickey, like the one illustrated below.

Figure 4. Methods of Bending

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Metal Conduits

I. Tools, Equipment and Materials

1. Tools:

1.1 Pipe vise


1.2 Hacksaw
1.3 Pipe reamer & brace
1.4 Pipe wrench
1.5 ½ stock & die
1.6 Pipe bender or hickey, ½” and ¾”
1.7 Pencil or chalk
1.8 Pull push or steel tape
1.9 Oiler

2. Materials:

2.1 1 length rigid metal conduit, ½ dia. 10 ft. long


2.2 Lubricating oil

Important

1. Use the rigid-sized pipe bender or hickey for each size


conduit.
2. Regularly clean the pull-push tape.
3. For adjustable stock and die, thread little by little in
about 3 adjustments.

II. Tasks (steps) & Key points

Cutting conduits using hacksaw

When cutting any conduit with a hacksaw, use a blade with 18 to 32 teeth
per inch. A blade with fewer teeth hangs up, binds, or even breaks (Figure 5.
below). Put the blade in the hacksaw frame (with the teeth pointing forward) so
that the teeth cut when you push the saw forward. Place the pipe in the vise so
that there is ample room between the vise and the cut.

CBLM on Electrical Installation Date Developed: Document No.


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Figure 5.

1. Preparing and cutting pipes for installation:

1.1 A hacksaw is the most


important cutting tool for
sawing metal to size.

1.2 There are many different types of


hacksaws, but in general they
consist of a fixed or adjustable
frame with a renewable hacksaw
blade.

CBLM on Electrical Installation Date Developed: Document No.


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1.3 The hacksaws illustrated show
one with a straight handle and
one with a pistol grip handle.

1.4 Hacksaw blades are classified


by length and the number of
teeth per 25 mm cutting edge.

1.5 For cutting conduit pipe,


blades with a pitch of 24 teeth
or 32 teeth per 25 mm of the
cutting edge are
recommended.

1.6 Pipes to be cut must be held steady and


prevented from rotating by holding them in
a suitable vise. This is a self-locking,
hinged pipe vise and is available in a
number of sizes.

1.7 The portable folding pipe vise is very practical


as a mobile workplace and is used especially
on building sites.

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1.8 Chain pipe vises are made to hold pipes
with an outside diameter of up to 8" or
200 mm. They are mounted on solid
benches.

1.9 Open the vise and insert the pipe so it is


horizontal and parallel to the jaw
serrations.

1.10 Keep the part which is to be cut as


close to the jaws as possible in order
to stop vibrations.

1.11 Before you cut any conduit pipes,


make sure you have measured and
marked the correct length exactly.

CBLM on Electrical Installation Date Developed: Document No.


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1.12 Check that the blade is lightly
tightened in the frame and that the
teeth point forward.

1.13 Take up the hacksaw and position


yourself as shown here, with yourself
shoulder pointing in the direction you
intend to cut. Note the position of the
feet, which allows free and controlled
movement of the body when cutting.

1.14 Before finishing the cutting operation, the pipe


must be supported with the left hand.

1.15 This will prevent the blade of the


hacksaw being damaged.

CBLM on Electrical Installation Date Developed: Document No.


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2. Bending 90-degrees angle on metal rigid conduit

2.1 Lay the conduit on the ground and slip the hickey on the conduit
where the first bend is to be made. See figure 5.

- If it is necessary, thread the ends of the conduit before bending.

Figure 5. Making the first bend

2.2 Step on rigid conduit and bend it at 20 to 30 degrees at a time.


Refer to figure 6.

Figure 6. Bending a conduit with a hickey


- The bend must be gradual and equal to a radius 6 times the diameter of
the conduit.

- The hickey should be move downward after applying pressure to it.


CBLM on Electrical Installation Date Developed: Document No.
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- The rigid conduit may be held on a pipe vise instead of stepping on it.

3. Bending a 90˚ angle on ½ thin- wall metal conduit or electrical


metal tubing (EMT).

Layout the right angle bend 1/2” Electrical Metal Tubing (EMT) or
thin wall conduit. See figure 7.

Figure 7. Laying Out a Right Angle Bend on an EMT

- From the rise, subtract 5” for ½” conduit, 6” for ¾” and 8” for 1” conduit.

Supposed the desired rise of a bend is 16” you will have 11” left

3.1 Hook the bender over the conduit. Let the arrow on the bender point
to the 11” marks from the end of the conduit. See figure 8 below

Figure 8. Hooking the Bender over the Conduit

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Illustration on figure 9 shows the movements and position of the hickey in
making the 90 – degree bend on a conduit.

First Bend Second Bend

Third Bend Fourth Bend

Figure 9. Movements and Positions of Hickey in Making a 90 – Bend

3.2 Apply pressure on the handle of the Bender, while one foot is
stopping on the conduit and the other on the bender. See figure 10

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Figure 10. Holding and applying pressure on the conduit with foot

 BESURE THAT THE RADIUS OF THE BEND IS AT LEAST 5 TIMES THE


DIAMETER OF THE CONDUIT

4. Bending a Rigid Conduit for an Off-set

4.1 Determine the distance of the first bend (from one end of the conduit)
and the throw of the off – set. See figure 11

Figure 11. Off-Set Bend

4.2 Insert the hickey just a few centimeters from the end of the conduit
and make the first bend. See figure 12.
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Figure 12. Making the First Bend on the Conduit

4.3 With the hickey in upside down position, slip the conduit in the jaw of
the hickey and make the second bend to complete the off-set. See
figure 13.

 BE SURE TO BEND
GRADUALLY TO AVOID
CRIMPING THE CONDUIT

Figure 13. Completing the Off-set Bend


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5. Bending a Rigid Conduit for a saddle bend

5.1 Mark a straight line on the floor and on the center draw a
perpendicular line 6 inches high as shown in figure 14 on the next
page.

Figure 14. Drawing a Perpendicular Line from the Straight Line on the
Floor

5.2 Bend the conduit and mark the point to be bent. Refer to figure 15
below.

- The distance between “A” and “B” should depend on the diameter of the
structure where it will cross over.
- Check the bend using the sketch on the floor.

Figure 15. Making the point to be bent on a


Conduit for a Saddle Bend

5.3 Slip the hickey over the conduit 4 inches from mark “Y” to the center
of the saddle bends.

5.4 Rest the handle of the hickey on the floor then place your foot against
it.

- You may ask somebody to hold the other end of the conduit in the proper
position while bending. See figure 16.

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Figure 16. Slipping the Hickey over the Conduit for a Saddle Bend
5.5 Insert 1 inch pipe at one end of the conduit being bend as shown in
Figure 16. Pull down the pipe sleeve.

- Pipe vise may be used to hold the conduit while bending with the hickey.

- Slip the hickey towards you little by little while bending conduit
gradually.

5.6 Thread both ends of the saddle bead if necessary as shown below.

Figure 17. Saddle Bends with Threaded Ends

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6. Bending a Gooseneck-Shape on Rigid Conduit

6.1 Draw a guide on the flat surface for bending a gooseneck-shape on


conduit.
6.2 Mark the part on the conduit where bending for the arc will begin and
end. See figure 17.

- If necessary, thread the conduit before bending.

Figure 17. Marking a Conduit for a Gooseneck Bend

6.3 Slip the hickey on the mark point and form the arc as shown in the
illustration in figure 18.

Step on the conduit to control its motion.

Figure 18. Forming an Arc on a Conduit for a Gooseneck Bend.

6.4 Slip the hickey over the point where the second bend would be made
to finish the gooseneck bend as shown in figure 19.

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- For the second bend, use a pipe vise to hold the conduit when bending.

Figure 19. The Gooseneck-Shape Bend

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Self-Check 2.1.1

INSTRUCTIONS

Read the direction carefully:

DO NOT WRITE ANYTHING ON THE TEST BOOKLET. Write your answers on the ½
sheet of paper.

1. What is meant by PEC?


2. What is meant by NEC?
3. What is meant by EMT?
4. What is meant by PVC?
5. What is meant by IMC?
6. What is the radius bend of a ½ size conduit pipe?
7. What is the allowable number of bend on a conduit run?
8. What are the different of corrosion-resistant rigid conduit?
9. What are the different bends that are common in a conduit installation?
10. What tool is used for bending conduit pipe?

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Answer Key 2.1.1

1. Philippine Electrical Code


2. National Electrical Code
3. Electrical metallic Tubing
4. Poly Vinyl Chloride
5. Intermediate Metallic Conduit
6. 5 inches
7. Not more than two bends
8.
1. Aluminum
2. Silicon Bronze alloy
3. Plastic coated
9.
1. Right angle bend
2. Off-set bend
3. Cross-over bend
4. Gooseneck bend
10. Hickey

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Task Sheet 2.1-1
Title: Develop skills in bending metallic conduit

Performance Objective: Given in bending metal conduit, you should be able to


use hickey bender in the following standard size of conduit
in order to bend properly.

Supplies/Materials : Hacksaw, Hickey Bender

Equipment : Hickey bender

Steps/Procedure:
1. Use the rigid-sized pipe bender or hickey for each size of conduit.
2. Make a level in the floor.
3. The bend must be gradual and equal to a radius 6 times the diameter of
the conduit.
4. Apply pressure on the handle of the hickey bender depends of the
specific direction.
5. Good housekeeping and safety practices are applied in line with job
requirements.

Assessment Method:
Actual demonstration, Observation

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Performance Criteria Checklist 2.1-1

CRITERIA
YES NO
Did you….

1. Properly use the rigid-sized pipe hickey bender for each


size of conduit?

2. Accurately make a measurement or level in the floor


before begin to do a task?

3. Carefully bend gradually and equal to a 6 times the


diameter of electrical metallic conduit?

4. Exactly bend a rigid metallic conduit free from any


defects according to established standards depends of
the specific direction?

5. Use a tools and materials properly?

6. Properly apply safety in installing metallic conduit


strictly according OSH standards?

CBLM on Electrical Installation Date Developed: Document No.


and Maintenance NC II May 1, 2015 Issued by:
Date Revised:
Performing Roughing-In May 1, 2016 P a g e | 25 of
LNNAIS 29
Activities For Communication Revised By:
And Distribution Jonard A. Mamalias, RME Revision # 01
Operation Sheet 2.1-1
Title: 0perating hickey bender

Performance Objective: Given operating hickey bender, you should be able to


know how used the bender in different types in conduit.

Supplies/Materials : Hickey Bender and hickey handle

Equipment : Hickey Bender

Steps/Procedure:
1. Select proper tools in bending a conduit.
2. Do not direct adopt too much pressure in hickey bending.
3. Secure properly tools in selecting to bend different sizes of conduit.
4. Apply good housekeeping or standardized.

Assessment Method:
Demonstration, Observation

CBLM on Electrical Installation Date Developed: Document No.


and Maintenance NC II May 1, 2015 Issued by:
Date Revised:
Performing Roughing-In May 1, 2016 P a g e | 26 of
LNNAIS 29
Activities For Communication Revised By:
And Distribution Jonard A. Mamalias, RME Revision # 01
Performance Criteria Checklist 2.1-1

CRITERIA
YES NO
Did you….

1. Properly select accurate tools in bending a


conduit?

2. Gently adopt pressure in bending a conduit using


hickey bender?

3. Properly use the correct size hickey bender for the


conduit size being bent?

4. Properly apply good housekeeping and safety


practices?

CBLM on Electrical Installation Date Developed: Document No.


and Maintenance NC II May 1, 2015 Issued by:
Date Revised:
Performing Roughing-In May 1, 2016 P a g e | 27 of
LNNAIS 29
Activities For Communication Revised By:
And Distribution Jonard A. Mamalias, RME Revision # 01
Job Sheet 2.1-1
Title: Prepare an installing electrical metallic conduits

Performance Objective: Given in preparing installing electrical metallic


conduits, you should be able to practice in different
steps/procedure in order to master that task.

Supplies/Materials : Hacksaw and Hickey bender

Equipment : Hickey bender

Steps/Procedure:
1. Classify rigid conduit.
2. Apply the PEC requirements concerning rigid conduit in preparation
(bending) for installation.
3. Use hacksaw for cutting tool in metal conduit.
4. Measure properly a conduit before subject in cutting.
5. Remove cutting burrs from the cut conduit ends.
6. Mark the distance at which the conduit must change direction.
7. Gently pressure in bending.
8. Bend gradually to avoid crimping the conduit?
9. Apply good housekeeping and Personal Protective Equipment (PPE)

Assessment Method:
Demonstration, Observation and Questioning

CBLM on Electrical Installation Date Developed: Document No.


and Maintenance NC II May 1, 2015 Issued by:
Date Revised:
Performing Roughing-In May 1, 2016 P a g e | 28 of
LNNAIS 29
Activities For Communication Revised By:
And Distribution Jonard A. Mamalias, RME Revision # 01
Performance Criteria Checklist 2.1-1

CRITERIA
YES NO
Did you….

1. Properly classify rigid conduit?

2. Properly apply PEC requirements?

3. Directly use hacksaw for cutting tool in metal


conduit?

4. Properly know in measurement technique?

5. Properly remove cutting burrs from the cut


conduit ends?

6. Gently adopt pressure in bending a conduit using


hickey bender?

7. Properly bend gradually to avoid crimping the


conduit?

8. Apply good housekeeping and safety practices?

CBLM on Electrical Installation Date Developed: Document No.


and Maintenance NC II May 1, 2015 Issued by:
Date Revised:
Performing Roughing-In May 1, 2016 P a g e | 29 of
LNNAIS 29
Activities For Communication Revised By:
And Distribution Jonard A. Mamalias, RME Revision # 01

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