260533_Conduit_ _Raceways_TechSpecs_JULY_2012.pdf

26 05 33: TECHNICAL SPECIFICATIONS: CONDUIT, RACEWAYS, AND BOXES

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Conduit, Raceways, and Boxes Technical Specs

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1. GENERAL

1.1. SUMMARY

1.1.1. This specification includes boxes and raceways including conduits, wire-ways, and related installations and accessories necessary to support and protect cables, feeders, sub-feeders, and branch circuit wiring.

1.2. SUBMITTALS

1.2.1. Product Data: Submit data for approval including, but not limited to, manufacturers' catalogues with specifications of raceways including conduits, trunking, boxes, etc. and related accessories.

1.2.2. Shop and Construction Drawings: Submit drawings for approval including, but not limited to, the following:

1.2.2.1. Exact routing of conduits, trunking etc. with indication of boxes, accessories and expansion joints, size and type of conduits and boxes.

1.2.2.2. Typical assembly details of installation of trunking, conduits etc.

1.2.2.3. Construction details of pull boxes.

1.2.2.4. Typical installation details including connection of conduits to enclosure, connection of flexible conduits, vapor-tight installations in cold rooms, weatherproof installations outdoors etc. and earthing connections.

1.2.3. Samples of each type of raceway, box, and accessory.

1.3. QUALITY ASSURANCE

1.3.1. Regulations and Standards: Conduits, wire-ways, cable trays and fittings are to be designed, constructed and installed to give safe installation and reliable mechanical protection for wires and cables in accordance with the Regulations. Standards of products are to be as specified.

1.4. COORDINATION

1.4.1. Coordinate layout and installation of raceways and boxes with other construction elements to ensure adequate headroom, working clearance, and access.

2. PRODUCTS

2.1. MANUFACTURERS

2.1.1. Approved Manufacturers: Subject to compliance with requirements, provide products by one of the following or approved equal:

2.1.1.1. Conduit, Wire-ways, Junction & Pull Boxes and Related Accessories:

2.1.1.1.1. Allied (U.S.A.)

2.1.1.1.2. Barton (England)

2.1.1.1.3. EGA Tubes (England)

2.1.1.1.4. Steel city (U.S.A.)

2.1.1.1.5. Matsushita (Japan)

2.1.1.1.6. Marshall-tuffles (England)

2.1.1.1.7. Decoduct (England/U.A.E.)

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2.1.1.1.8. Eslon Egypt (Egypt)

2.1.1.1.9. PPP (Egypt)

2.1.1.1.10. El Sewedy (Egypt)

2.1.1.2. Metal Conduits (for exposed circuits):

2.1.1.2.1. Allied (U.S.A.)

2.1.1.2.2. Weatland (U.S.A.)

2.1.1.2.3. EGA Tubes (England)

2.1.1.2.4. Steel city (U.S.A.)

2.1.1.3. Metallic Outlet Boxes

2.1.1.3.1. Same manufacturers as conduit or approved equal.

2.1.1.4. Moulded Plastic Outlet Boxes

2.1.1.4.1. Egatube (England)

2.1.1.4.2. M.K. (England)

2.1.1.4.3. El Sewedy (Egypt)

2.2. RIGID HEAVY GAUGE STEEL CONDUIT

2.2.1. Material: Heavy gauge drawn and welded steel, threaded at both ends, to CEE 23, BS 4568 Part 1 and BS 31 Class B (threaded), with class 4 protection for rigid steel conduit, zinc coated inside and outside by hot-dip process or sherardizing.

2.2.2. Fittings Generally: Threaded type, galvanized or cadmium plated malleable cast iron. Fittings used in corrosive atmospheres are to be specially treated. Fittings and components are to comply with CEE 23, BS 4568 Part 2 and BS 31.

2.2.3. Locknuts for securing conduit to metal enclosure are to be heavy hexagonal or castellated pattern, for fastening.

2.2.4. Bushings for terminating conduits are to be smooth rounded brass rings.

2.2.5. Miscellaneous fittings including reducers, chase nipples, three piece unions, split couplings and plugs are to be standard fittings designed and manufactured for the particular application.

2.3. LIGHT GAUGE STEEL CONDUIT (ELECTRICAL METALLIC TUBING- EMT)

2.3.1. Material: Welded steel, non-threaded type galvanized externally and protected internally with corrosion resistant enamel, and to U.S. Federal Specifications.

2.3.2. Corrosion Resistance: Conduits used in corrosive atmospheres are to be copper silicon alloy, highly resistant to corrosion.

2.3.3. Fittings Generally: Threadless pressure type, galvanized or cadmium plated malleable cast iron.

Fittings used in corrosive atmospheres are to be specially treated.

2.4. FLEXIBLE STEEL CONDUIT

2.4.1. Material: Steel, cold rolled and annealed, non-threaded type, formed from continuous length of

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helically wound and interlocked strip steel, with fused zinc coating on inside and outside, and to BS 731.

2.4.2. Liquid-tight flexible conduit is to have PVC jacket extruded over core.

2.4.3. Fittings Generally: Threadless, hinged clamp type, galvanized or cadmium plated malleable cast iron. Fittings used in corrosive atmospheres are to be specially treated.

2.4.4. Straight Connectors: One piece body, female end, having hinged clamp and deep slotted machine screws for securing to conduit, male end having thread and locknut.

2.4.5. Angle connectors of 45 or 90 degree and terminal connectors are to be as specified for straight connectors, except that body is to be two-piece with removable upper section.

2.5. RIGID HEAVY GAUGE PVC CONDUIT

2.5.1. Material: Rigid unplasticized polyvinyl chloride with high impact and high temperature resistance, flame retardant, non-hygroscopic and non-porous, to CEE 26, BS 4607 and BS 6099, DIN 49016 or other equal and approved standards conforming to IEC 423,6 14-1 and 614-2-2.

2.5.2. Fittings Generally: Unbreakable, non-inflammable, self extinguishing, heavy moulded plastic.

Expansion couplings are to be telescoping double tube type, with at least two inner water-tight neoprene rings.

2.5.3. Assembly: Conduits, boxes and accessories are to be assembled by cementing, using manufacturer's recommended products and appropriate connectors or spouts. Where no spouts are available use smooth bore male PVC bushes and sockets.

2.6. FLEXIBLE PVC CONDUIT

2.6.1. Material: Flame retardant, heat resistant, non-hygroscopic PVC, high resistance to impact, ribbed on circumference for flexibility.

2.7. STEEL CONDUIT ACCESSORIES

2.7.1. Sleeves Through Outside Walls: Cast iron, with end and intermediate integral flanges, and internal diameter larger than diameter of through-conduit. Length is to correspond to wall thickness. Space between sleeve and conduit is to be packed with oakum to within 50 mm of both faces of wall, remainder of sleeve packed with plastic compound or lead, held in place by heavy escutcheon plates bolted at both ends to flanged ends of sleeve. Alternatively, sleeves are to be O.Z/Gedney, Type WSK or other equal and approved, with cable or conduit bolted pressure sealing.

2.7.2. Supports and Hangers: Galvanized malleable cast iron straps or structural steel sections with hot dip galvanized bolts and nuts.

2.7.3. Expansion Joint for Embedded Steel Conduits - Type A: Watertight, flexible conduit with end fittings to receive fixed conduits. Length is to allow movement within range of joint and is not to be less than 20 times diameter of conduit. Conduit is to be covered with thick rubber tubing with 5 mm minimum gap all around tube. Bonding jumper with earth clamp is to electrically connect both sides of joint. Fitting is to be O.Z/Gedney, Type DX or other equal and approved.

2.7.4. Expansion Joint for Exposed Steel Conduits - Type B: Sleeve with fittings to permit telescoping of

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one conduit into sleeve. Movable conduit is to be fitted with watertight bushing. Joint is to be weatherproof, of galvanized malleable iron or steel. Bonding jumper with earth clamp is to electrically connect both sides of joint. Expansion fitting is to be O.Z/Gedney, Type DXX or other equal and approved.

2.7.5. Expansion Joint for Exposed Steel Conduits - Type C: PVC sheathed flexible steel conduit terminating in pull boxes and securely fixed on each side of structural expansion joint. Bonding jumper is to electrically connect both sides of joint.

2.7.6. Tags: 50 mm diameter steel with indented lettering, rust inhibiting treatment and baked enamel finish.

2.8. WIRING AND CABLE TRUNKING

2.8.1. Components are to include wire-way base, clip-on covers, couplings, end plates, wall flanges, panel to trunking rubber grommets, elbows, tees, adaptor plates and necessary hangers, supports and accessories.

2.8.2. Steel Trunking: To BS 4678 Part 1, galvanized sheet steel, minimum 1.5 mm thick, protected internally and externally with corrosion resistant finish such as zinc or cadmium with top coat of enamel.

2.8.3. PVC Trunking: High impact, heavy duty, self-extinguishing, rigid PVC with grooved double locking action of the clip-on cover. Design is to be approved by Engineer before ordering materials.

Trunking is to be capable of receiving functional slot-in hangers and demountable separators to segregate wiring systems as needed.

2.8.4. Sizes: To accommodate number of conductors permitted by the Regulations.

2.9. OUTLET BOXES, GENERAL

2.9.1. Surface or recessed boxes are to be suitable for type of related conduit or cable system. Shapes and sizes of boxes are to be of compatible standards as switches and socket outlets specified and lighting fixtures selected and of various types and mounting methods required.

2.9.2. Unused openings in outlet boxes are to be closed with knock-out closers manufactured for the purpose.

2.9.3. Floor outlets and plates are to be water-tight and impact resistant.

2.10. METALLIC OUTLET BOXES

2.10.1. Recessed and Concealed Boxes: Galvanized pressed steel, with knock-outs for easy field installation. Special boxes are to be punched as required on Site.

2.10.2. Exposed Surface Mounted Boxes: Galvanized cast iron with threaded hubs.

2.10.3. Outdoor Surface or Recessed Boxes: Galvanized cast iron with threaded hubs and PVC gaskets to ensure water tightness and with stainless steel or non-ferrous, corrosion resistant screws.

2.10.4. Floor Boxes: Watertight, cast iron or cast metal alloy with corrosion resistant finish, adjustable mounting, standard duty, round or square, factory drilled and tapped for required conduit sizes, and with brass cover and flange with brushed finish free from markings other than required for

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mounting screws.

2.10.5. Floor Boxes: Non-standard size, flush floor mounted, cast metal alloy, with watertight neoprene gasketed and hinged cover, and with drilled and tapped conduit entries and adjustable mounting.

Metal barriers are to separate services for power and low current.

2.11. MOULDED PLASTIC OUTLET BOXES

2.11.1. Type: Boxes and covers used with PVC conduit systems are to be heavy gauge pressure moulded plastic, minimum 2 mm thick, self extinguishing, with softening point not less than 85 deg. C. Boxes are to have provision for securely terminating conduits and are to be manufacturer's standard for required application.

2.11.2. Fittings: Boxes are to have brass inset threads to receive cover screws and for mounting devices or accessories, push-fit brass earth terminals, and steel insert clips to provide additional support for pendants or for heat conduction. Neoprene gaskets are to be provided for weatherproof installations.

3. EXECUTION

3.1. EXAMINATION

3.1.1. Examine surfaces to receive raceways and boxes for compliance with installation tolerances and other conditions affecting performance of raceway installation. Do not proceed with installation until unsatisfactory conditions have been corrected.

3.2. CONDUIT, WIREWAYS, AND BOXES, GENERAL

3.2.1. Use: Unless otherwise specifically indicated all light and power circuits, communications, signal and low current systems wiring are to be drawn inside conduits or wire-ways up to the various electric power consuming equipment.

3.2.2. Separate conduits and wire-way installations are to be used for medium voltage cables, low voltage feeders and sub-feeders, normal light and power circuits, emergency light and power circuits and communication, signal and other low current systems wiring. Cables of different voltages are not to be mixed within the same conduit or wire-way as per the regulations.

3.2.3. Boxes: Junction, pull, and splice boxes of ample capacity are to be provided as indicated or required. Boxes are to remain permanently accessible.

3.2.4. Exposed Outlet Boxes: Securely fasten to wall with machine screws to permanent inserts or lead anchors.

3.2.5. Recessed Outlet Boxes: Make neat openings, to the satisfaction of Engineer, allowing for thickness of finishing, and use extension rings if required. Repair damaged finishing to original condition before installation of fittings or plates.

3.2.6. Boxes Mounting Heights and Location: Mounting heights for outlet boxes and similar equipment are to be uniform within the same or similar areas. Mounting is to be as shown on the Drawings or as approved by the Engineer. Unless otherwise shown or instructed, mount lighting switches and socket outlets generally at 1200 mm and 300 mm from finished floor level respectively. Mount

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switches with long dimension vertical and operating handle, if of the toggle type, up when in the on position. Mounting heights indicated are to bottom of unit for suspended devices and to center of unit for wall-mounting devices.

3.2.7. Tools and accessories for forming and installing conduit and wire-way systems are to be purpose made for the particular application and used in accordance with manufacturers' instructions.

3.2.8. Fixing: Conduits and wire-way installations are to be concealed as much as possible.

3.2.9. Sizes of conduits and wire-ways, not shown on the Drawings, are to be selected in accordance with the Regulations and in relation to the number and size of conductors and the space factor as recommended by the regulations. Minimum size of conduit for all applications is to be 20 mm diameter, unless otherwise shown on the Drawings.

3.2.10. Mechanical Continuity: Conduits and wire-ways are to be effectively joined together and connected to electrical boxes, fittings and cabinets to provide firm mechanical assembly. Earthing jumpers are to be installed on steel conduits where required to ensure effective electrical continuity irrespective of whether a separate protective earth conductor is required or not.

3.2.11. Metal conduits and enclosures are to be mechanically fastened, and to be connected to electrical boxes, fittings and cabinets to form low electrical resistance continuity and firm mechanical assembly.

3.2.12. Dissimilar Metals: Use of dissimilar metals is to be avoided throughout the system to eliminate possibility of electrolysis. Where dissimilar metals are in contact, treat surfaces with corrosion inhibiting compound before assembling.

3.2.13. Miscellaneous fittings such as reduces, chase nipples, 3-piece unions, split couplings and plugs that have been specifically designed and manufactured for their particular application are to be installed as necessary.

3.2.14. Conduits are to be tested with a mandrel. Conduits that reject a mandrel are to be replaced.

Restore conduit and surrounding surfaces to original condition.

3.3. CONDUITS AND WIREWAYS APPLICATIONS AND INSTALLATION, GENERAL

3.3.1. Conduits and wire-ways installations are to be as described below, unless otherwise shown on the drawings or described in the particular section of the Specification.

3.3.2. Rigid heavy gauge steel conduit is to be used for all exposed installations comprising lighting, power, low current, communication and signal system wiring, including mechanical equipment rooms, electrical equipment rooms, and service areas. Use rigid steel conduit in areas classified as hazardous explosive area. Flexible conduit is not acceptable.

3.3.3. Light gauge steel conduit (EMT) is to be used for exposed installations over false ceilings when the false ceiling is used as a return plenum.

3.3.4. Light gauge steel conduit (EMT) is to be used for exposed and above false ceiling wiring installations used in conjunction with exit and escape route lighting.

3.3.5. Conduit termination in sheet metal enclosures is to be fastened by lockouts, and terminate with bushing. Install locknuts inside and outside enclosure.

3.3.6. Rigid heavy gauge PVC conduit is to be used for lighting and power circuits, low current, communication and signal system wiring, where embedded in concrete masonry earth, under floor, except where otherwise shown on the Drawings or described in the particular section of the

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Specification.

3.3.7. Flexible conduit of same material as corresponding conduit system is to be used for connection to motors, vibrating and non-rigidly fixed equipment and to fixtures installed in false ceilings.

3.3.8. Flexible steel conduit is to be used in movable partitions and from outlet boxes to fixture over false ceilings when used as a return plenum. Conduits are to be liquid tight in damp areas.

3.3.9. Liquid-tight flexible steel galvanized conduit is to be used in one or more of the following conditions:

3.3.9.1. Exterior location.

3.3.9.2. Moist or humid atmospheres where condensate can be expected to accumulate.

3.3.9.3. Corrosive atmosphere.

3.3.9.4. Subjected to water spray or dripping oil, water or grease.

3.3.10. Exposure to Damage: Conduit considered being subject to undue risk of damage by shock or corrosion is to be brought to the attention of the Engineer. Copper silicone alloy tubes may be used in corrosive atmospheres.

3.3.11. Crossing: Conduits are not to cross pipe shafts, vents or openings.

3.3.12. Clearances: Install conduits at least, 150 mm clear of and preferably above pipes of other non-electrical services. (Hot water pipes, etc.). Wherever possible, install horizontal conduit and wire-ways runs above water and steam piping.

3.3.13. Sleeves: Obtain approval for positioning sleeves where conduits pass through reinforces concrete.

Additional opening may be allowed in finished slabs, but are to be drilled. Fix sleeves rigidly to maintain position and alignment during construction work.

3.3.14. Waterproof Construction: Conduits are not to cross waterproof construction unless permitted by Engineer. Specially designed and approved fittings are to be used.

3.3.15. Expansion Fittings: Provide in each conduit and wire-ways run every 30 meters, or wherever structural expansion joints are crossed.

3.3.16. Make good all holes for conduits passing through walls, floors and ceilings with cement or similar fire-resisting material to full thickness.

3.3.17. Bends: Conduit runs between outlet and outlet, fitting and fitting or outlet and fitting are not to contain more than the equivalent of 2 quarter bends (180 degree total).

3.3.18. Bending is to be made without damaging conduit or tubing and without reducing internal diameter. Methods of field bending are to be approved.

3.3.19. Cut ends are to be reamed to remove burrs and sharp edges.

3.3.20. Conduits entering cold stores are to be made vapor tight, so that vapor from outside cannot enter conduit.

3.3.21. Draining: Arrange conduits so that condensed moisture can drain to screwed plug at lowest point.

3.3.22. Before wiring, conduits are to be swabbed through. Do not draw cables into any section of system until conduit and draw boxes are fixed in position, and the raceway installation is completed.

3.3.23. Capping: Conduits are to be properly capped until wiring conductors are drawn in.

3.3.24. Conduit and fittings installed outdoors are to be watertight and highly resistant to corrosion.

Use appropriate fittings, threaded and hubbed boxes, gaskets with screw on covers and the like.

3.3.25. Terminations: Do not terminate or fasten rigid conduits to motor frame or base.

3.3.26. Length and radius of flexible conduit used for motors and vibrating equipment are to permit

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bending of feeder cables without damage to conductor or insulation.

3.3.27. Flexible conduit for slide rail mounted motor is to have sufficient slack to allow for movement of motor over entire slide rail length.

3.3.28. Pulling Wire: Install 3 mm galvanized stranded steel wire or equivalent strength cord with wooden blocks fastened at ends, in empty service conduits (power, low current and signal).

3.3.29. Standard elbows are to be used for all conduits.

3.3.30. Tags: Fit to conduits entering or leaving floors, walls or ceilings for identification of conduit and circuits. Tags are also to be placed at suitable intervals throughout the system.

3.3.31. Non-ferrous conduit is to be installed for circuits operating above 60 Hz.

3.4. STEEL CONDUIT

3.4.1. Termination: Conduit entering sheet metal enclosure or outlet boxes, when not terminated in a threaded hub, is to be securely held in place by two lock-nuts, placed inside and outside enclosure, and terminated with an insulating bushing.

3.4.2. Running Threads: Do not use running threads at joints and terminations, but use 3-piece unions or split couplings.

3.4.3. Additional threaded cuts on galvanized steel conduits are to be painted with zinc based coating resistant to corrosion.

3.4.4. Damage to protective coating of conduits is to be repaired to original degree of protection.

3.4.5. Outdoor Mounted Steel Conduit: Apply anti-corrosion coating of zinc-chromate based paint and two weather resistant finish coats of enamel, of approved colour, or other equal and approved coating.

3.4.6. Galvanized conduit run in screed is to be painted with heavy coat of emulsified bitumen.

3.4.7. Galvanized steel conduits buried in ground or placed in wet or damp locations are to be coated with two heavy coats of hot bitumen. Conduits are to be covered by at least 600 mm of earth if buried in planting soil and by 300 mm if under walkway.

3.4.8. Plugs: Use hardwood or threaded iron plugs for blanking ends of steel conduit not used.

3.5. PVC CONDUIT

3.5.1. Coupling of conduit and/or termination into spouted fittings are to be made watertight and permanent using special cement.

3.5.2. Termination: Connect conduits terminating in switchgear, fuse-boards, trunking, adaptable boxes or other non-spouted enclosures etc. with smooth bore male PVC bushes and sockets.

3.5.3. Ends of conduit and conduit fittings are to be cleaned and jointed using PVC cement recommended by manufacturer.

3.5.4. Semi-Permanent Adhesive: Use in joints requiring expansion couplers.

3.6. EMBEDDED CONDUIT

3.6.1. Conduits In Concrete Slabs: Place conduits parallel or at right angles to main reinforcing steel, between bottom reinforcing and top reinforcing steel. Fasten conduits to reinforcing steel by positive wire, fasteners at the proper distance from the concrete face. Embedded conduit diameter is not to exceed 113 of slab thickness. Special cases shall be referred to Engineer.

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3.6.2. Conduits In Partitions or Side Walls: Horizontal or cross runs are to be avoided.

3.6.3. Pull-boxes are not to be used. If unavoidable, pull-boxes may be approved if located inconspicuously.

3.6.4. Conduits in floor of beds on grade: Encase in concrete, minimum thickness 50 mm or to thickness allowed by architectural detail.

3.6.5. PVC conduits in reinforced concrete structures are generally to be installed after placing reinforcement and before concreting, if protected against damage, or are to be placed in grooves formed in the concrete, if approved.

3.7. EXPOSED CONDUIT

3.7.1. All electrical installation for power cables and feeders shall run in either EMT or IMC (Intermediate Metal Conduit) as needed.

3.7.2. No PVC run is permitted exposed in the electrical or generators room.

3.7.3. Conduits on ceilings & walls are to be run neatly, horizontally or vertically.

3.7.4. Supports: Use approved clamps, hangers or clips fastened by machine screws to expansion sleeves in inserts or to lead anchors.

3.7.5. Spacing of clamps or clips for supporting steel conduits is not to be greater than:

Conduit Size (mm) Maximum Spacing between Supports (Meters)

1. 20 3.00

2. 25 3.60

3. 32-38 4.25

4. 50-63 5.00

5. 75 and larger 6.00

3.7.6. Bends and Fittings: Firmly fasten conduit at each side of bends and within 900 mm of each outlet box, junction box, cabinet or fitting.

3.7.7. Outlets: Do not run more than the permissible numbers of conduits to any surface wall outlet.

3.7.8. Exposed conduit work is to be installed so as not to interfere with ceiling inserts, lights or ventilation ducts or outlets.

3.8. CABLE TRUNKING

3.8.1. Installation: Secure trunking of all sizes at intervals not exceeding 1200 mm. Joints are not to overhang a fixing by more than 500 mm.

3.8.2. Trunking passing through walls and ceilings is to have the cover fixed solidly for 25 mrn either side of walls and for 150 mm either side of floors and ceilings.

3.8.3. Vertical sections of trunking over 900 mm long are to have staggered insulated tie-off studs to support weight of cables.

3.8.4. Cabling Provisions: Separation of power, low current and control circuits is to be by two channel trunking or by barriers inserted in trunking before installation of cables. Cable retaining straps are to

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be provided at not more than 600 mm centers. Openings in front of trunking are to facilitate drawing-in cables.

3.8.5. Coupling: Trunking parts are to be mechanically and electrically coupled without causing abrasion to wiring.

3.8.6. Earthing: Do not use metal trunking as earth continuity conductor. Provide protective conductor.

3.9. PROTECTION

3.9.1. Provide final protection and maintain conditions, in a manner acceptable to manufacturer and

Installer that ensure coatings and finishes are without damage or deterioration at the time of Substantial Completion.

3.9.1.1. Repair damage to galvanized finishes with zinc-rich paint recommended by manufacturer.

3.9.1.2. Repair damage to PVC or paint finishes with matching touchup coating recommended by manufacturer.

3.10. CLEANING

3.10.1. On completion of installation, including outlet fittings and devices, inspect exposed finish.

Remove burrs, dirt, and construction debris and repair damaged finish, including chips, scratches, and abrasions.

END OF SPECIFICATION