Blog

One-Pull’s Bundled Cable Outside Diameter Calculator

Posted on by Mike Zimm

Saving time is always a top priority for busy construction project managers and procurement specialists. When your to-do list and your inbox are both full, finding small productivity enhancers can make a big difference in your day.

Take, for example, when ordering bundled cable. Project managers need to know the estimated outside diameter (OD) of XHHW-2 or THHN wire bundles to determine if they will fit inside existing conduits and trays, or confirm which conduit size to use on the job site. PMs typically rely on engineers or vendors to make those calculations. That means making calls or sending emails, then waiting for a response.

At One-Pull, we’re always looking for ways to save our customers time. By providing a real-time answer to “what is the diameter of my wire bundle?” our Bundled Cable Outside Diameter Calculator tool does just that.

Configuration Types and Fill Rates—

Will My Cable Bundle Fit?

The calculator is located on the Resources page of our One-Pull website. Users simply input their wire insulation type, gauge, and the number of conductors, then select their configuration type. The calculator instantly outputs the outside diameter of the specified cable bundle in inches. Users also have the option of receiving a detailed, downloadable spreadsheet containing their bundled cable OD calculations.

This immediate calculation is beneficial for project managers who must keep conduit fill rates in mind when designing their cable bundles. Conduit fill is the amount of conduit occupied by a cable or cable bundle, based on the conduit’s inside diameter and the outside diameter of the cable or cable bundle.

Recommended fill rates are determined by the National Electrical Code® (NEC), and non-compliance can lead to costly rewiring or even an unsafe installation. Our One-Pull Bundled Cable Outside Diameter Calculator helps project managers quickly determine fill rates and confirm compliance with NEC specifications.

Spiral Versus Straight Cable Bundles

The One-Pull calculator also highlights a key difference between spiral cable bundles and their straight bundle counterparts. Spiral bundles are smaller and take up less room in the conduit than straight bundles.

Spiral cable bundles are also more flexible than straight bundles, which can be critical when pulling cable through bends or on long home run pulls.

One-Pull — Saving You Time and Money

Saving our customers time and money on every project is central to One Pull’s mission. Here are other ways we’ll work with you to deliver on that promise:

Custom printing. Terminating cable is time and labor-intensive, especially if contractors have to label and test every conductor. One-Pull minimizes those requirements by printing unique identifiers on each wire. We can also tailor printing for specific customer needs by adding custom numbering schemes, branding, or other text.

Wire striping. Striping helps contractors to quickly identify individual conductors by visual inspection. One-Pull’s striping is available in multiple colors as a linear tracer or in a spiral tracer stripe that wraps around the conductor.

Short lead times. One-Pull’s lead times are the fastest in the industry for custom cable bundles, with targets of five days or less.

Same-day quotes. Our highly-trained customer service team responds quickly to all email and telephone inquiries and provides same-day quotes to help meet tight customer deadlines.

At One-Pull, we know your time is valuable. That’s why, whether you’re gathering information, looking for a quote, or installing our bundled cable solutions, we’ll get you the answers you need, when you need them.

Just like with our Bundled Cable Outside Diameter Calculator.

The Value Prop of Pre-Cut, Pre-Labeled, Bundled Cable

Posted on by Mike Zimm

Across the wire and cable industry, a common assertion is that bundled, pre-cut, pre-labeled cable solutions can save contractors and installers up to 40% in labor costs.

At One-Pull, we know that assumptions aren’t enough for our customers. So we conducted a controlled time and motion study to quantify the time savings achieved when installing bundled cable compared to pulling, cutting and tagging multiple conductors on-site.

Even we were surprised by the results.

How Does Bundled, Pre-Cut, Pre-Labeled Cable Slash Costs?

Pulling cable is a labor-intensive, multi-step process. Installers must pull conductors from separate spools, feed them through conduit or a cable tray, then label and terminate each wire. Bundled, pre-cut, pre-labeled cable eliminates or simplifies several steps in this process.

Pre-Printed Cable Eliminates Labeling

With single conductors, installers have to label wire multiple times. First, they label individual spools. Next, once they pull the wire through the conduit, contractors separately label each conductor after referencing it back to the associated spool. If they don’t, they’ll need to ring out each wire, a very time-consuming process.

Finally, when installers terminate the conductor onto the breaker panel, they’ll typically have extra wire left over. When they trim that extra wire, often they’ll remove the label as well — so those wires must be relabeled.

Pre-printed cable eliminates the need for all this labor-intensive and time-consuming labeling. With pre-printed conductors, the custom printing repeats every few inches on each wire. No matter where contractors trim and terminate the cable, the identification is always in the right place.

Easier, Faster Pulls


While most of the time savings associated with a bundled cable are realized in both a straight or a spiral configuration, when pulling through conduit a spiral bundle has significant advantages over both singles and a straight bundle.

Spiral vs. Straight Cable Bundle Configurations

Contractors often use straight bundled cable configurations for home runs and assemblies laid in place. The un-spiraled structure also helps minimize heat build-up in power wires 12 AWG or larger.

The compact binding in spiral configurations maintains its shape and provides greater flexibility. Spiral cable bundled are often used for long pulls in conduit or where numerous bends in the conduit could cause hang-ups. Spiral-wrapped bundles pull much easier through conduit, requiring much less force.

In our time and motion study, we measured the force required to pull both 50 conductor straight and spiral bundles through the same conduit. The straight bundle needed three people to pull — two pushing from the spool end and one pulling from the terminating end of the conduit. It was slow and difficult to pull — one team member used gloves to help protect his hands when pulling on the pull string to complete the task.

By comparison, the spiral bundle needed only two people — one at each end. The pull required much less effort and was completed significantly faster.

Pre-Cut Cable — Another Time-Saver

When contractors are installing hundreds or thousands of cables, every minute they can save quickly adds up. Pre-cut cables eliminate trimming time for installers and minimize expensive copper waste, both which can yield boost the bottom line.

Other Benefits of Bundled, Pre-Cut, Pre-Labeled Cable

While the cost savings are significant, using bundled, pre-cut, pre-labeled cable offers other important benefits to contractors and installers:

Error reduction

Mislabeling conductors is a serious job site concern. Installers can incur critical delays if they’re forced to ring out or re-terminate mislabeled cables.

Less Cluttered Job Sites

Manually-bundled cables can leave the job site littered with debris — hundreds of empty spools and piles of trimmed cable ends. While a cluttered job site can represent a safety risk, there are also costs associated with disposing of cable debris. Using pre-cut cable also minimizes leftover wire that has no residual value and must be scrapped. 

Fatigue Reduction

Contractors are always concerned about repetitive strain injuries and employee safety. Our time and motion study confirmed that it took much greater force to pull manual cable bundles than pre-cut, spiral bundles. These extra efforts can translate into worker fatigue, injuries, and even employee time off.

The Bottom Line — Big Savings

To zero in on the savings potential of bundled, pre-cut, pre-labeled cable solutions, we conducted our time and motion study in a carefully controlled environment. We pulled both 25 and 50-conductor bundles and repeated each step of the process several times.

The result? We determined that contractors using bundled cable solutions is over 8 times faster compared to manually pulling single conductors.

Of course, no two projects or job sites are the same, and not every One-Pull customer may achieve the same results. However, contractors looking to save labor costs and boost margins would be wise to explore the benefits of bundled, pre-cut, pre-labeled cable for themselves.

One-Pull’s lead times are 3-5 days — the shortest in the industry — and our expert customer service team is standing by to answer your questions and provide a same-day quote.

Determining the Cost of Conveyor System Installation

Posted on by Mike Zimm

Conveyor systems  increase efficiency and productivity in manufacturing. When considering installing a conveyor system, it is essential to be aware of all the components that determine the pricing.  

Installing a conveyer belt system goes beyond equipment acquisition. A conveyor system carries three costs— two of which are rarely taken into consideration. Besides the initial costs that are easiest to understand and quantify, there are operational and maintenance costs. Being aware of and understanding these associated costs enables companies to decide whether installing a conveyor system is financially feasible.  

Since conveyor system installation costs vary, this article does not provide specific prices associated with conveyor belts. However, it gives a breakdown of what factors go into determining the overall costs.  

We look into the three costs mentioned above and how they factor into an automated conveyor system installation. 

 

1. Initial Costs

When it comes to a conveyor belt system installation, the initial costs  include the price of the equipment, installation, and controls.  

Conveyor systems come in a range of prices depending on their intended use. They vary depending on the needs and scope of the project. Certain types of conveyor systems are more expensive than others. For example, a regular conveyor belt is used for a general process or a manufacturing step can be found at lower prices. Belt conveyors, on the other hand, are the most commonly used since they are cost-effective.

Another less expensive option would be acquiring used conveyor belts or modular conveyer belts. Modular belts are small and semi-portable. They come in pieces and are assembled on site. While less expensive, they are subject to wear and are not heavy duty.  

Labor costs should also be taken into consideration when looking at initial costs. While hiring a specialty electrical contractor adds to the labor costs, it could ensure a safe and successful installation. Improper installation can lead to performance issues which is why getting the right contractor is important. Such contractors are well-trained to handle new equipment designs and safety procedures. The electrical contractor can also oversee ongoing maintenance contributing to more efficient production. In the long run, this not only reduces injuries but also saves money. 

 

2. Maintenance

A well-maintained conveyor system is critical to its success. High breakage of materials could lead to longer processing times which in turn delays orders.  

Different types of conveyor systems require different levels of maintenance. Vacuum conveyors, for example, have a very high maintenance cost.  

While everyday maintenance is critical, it does not significantly increase the overall cost compared to maintenance resulting from poorly functioning equipment.  

Purchasing a cheaper conveyer system to lower initial costs, regardless of the durability of the equipment, could mean constantly having to buy and install replacement parts. This could quickly add up, bringing the cost even higher than the initial cost or even the cost of a more expensive but durable conveyor belt system. Therefore, it may be more cost-effective to purchase more expensive but more reliable equipment than initially cheaper equipment with a higher risk of failure. 

Replacing parts of a conveyor system requires expertise which could mean hiring specialized labor. This adds to the labor costs and overall cost of the conveyor system.  

 

Learn more about conveyer systems in our quick guide to material handling systems. 

 

3. Operational

 While more manufacturing machinery is becoming automated, running a conveyer belt still requires some form of human oversight. This is an operational cost in the form of associated human labor costs. This goes beyond wages as it includes administrative costs of maintaining operators for the conveyer equipment. 

Maintenance and repair costs are also factored into the overall operational cost of the conveyor system. 

Besides maintenance, repair, and labor costs, another operational cost associated with conveyor systems is the energy consumption cost. 

A facility’s energy costs will vary based on the type of energy source, location, and electricity peak demands. Being a high energy consumption equipment, conveyor systems could significantly raise the energy costs of a facility. Hence one should consider the energy needs of a conveyor system prior to installing one to make sure that they are ready for the associated energy costs.   

 

In summary, to determine the overall cost of a conveyer system, always take this calculation into consideration: 

TCO (total cost of ownership) = IC (initial cost) + OC (operational costs) + MC (maintenance costs)/ useful life of the system. 

 

 

Check out  5 U.S. companies that are leading the charge in the manufacturing of automated conveyor belt systems. 

 

The ABCs of Custom Printed Cable

Posted on by Mike Zimm

Every contractor is looking for ways to reduce costs and save time on the job. And when it comes to wire and cable, material costs are just the beginning. Separately labeling and ringing out each conductor takes time, and labor costs can quickly add up. However, custom printed cable can simplify the identification of individual conductors, speed termination times, and slash labor costs.

What Is Cable Printing?

Cable printing adds a unique, printed identifier to the jacket of each wire conductor. For example, with standard alpha-numeric printing, the first conductor would be labeled ‘ONE-1’, the second ‘TWO-2’, and so forth. In this way, contractors can differentiate every conductor within a cable bundle, even if they’re all the same type and jacket color.

At One-Pull, we use a durable inkjet printing process to mark each conductor in black or high contrast bright white, repeating the printing every two inches along the conductor’s entire length. One-Pull can further customize printing to include multiple alpha-numeric characters, symbols, words, and even complete sentences.

 

Cable Striping — Another Visual Aid for Contractors

Another way to identify conductors within a cable bundle is with striping. Different colored stripes on each conductor help contractors visually differentiate between multiple wires in a cable bundle. As with our alpha-numeric printing, One-Pull uses a specialized inkjet printer to add the striping, either as a linear tracer running along the wire’s length or in a spiral stripe that wraps around the wire. Our striping is available in various colors, including common color codes like E1, E2, K1, and K2.

 

The Benefits of Custom Cable Printing:

Time Savings, and More
Custom cable printing offers many benefits to project managers and facility operators:
Reduces termination time and labor costs. Printing eliminates the need to test or ‘ring out’ each conductor, saving contractors considerable time. A common alternative, cable tagging, is much more time and labor-intensive. Printing on the entire cable allows simple conductor identification, no matter where the conductor is cut and terminated along the wire length.

Simplifies troubleshooting and daily operations. If a production facility experiences a connection failure or wire break, cable printing helps staff quickly identify and repair the damaged or disconnected conductor.
Similarly, cable printing expedites the ‘moves and changes’ process in production environments if conductors need to be relocated and re-terminated.

Promotes brand identity. With custom printing, suppliers and contractors can add company names and tag lines to wire and cable, helping them establish and reinforce their brand.

Enhances safety and deters theft. Cable printing can help keep workers safe by providing proximity or hazard notifications (e.g., ‘Gas Line Below — Warning’). Custom printing can also reduce or eliminate cable theft.

Supports industry-specific requirements. Some industries have specific requirements for cable printing. For example, complex environments like wastewater treatment plants often use unique printed codes to facilitate control panel connection throughout the plant. Government project RFPs may also include specific wire marking requirements.

One-Pull Custom Cable Printing: a Fast, Cost-Effective Solution

The incremental cost of custom cable printing is minimal, particularly when compared to the costs of manually tagging each wire. Printing, combined with One-Pull’s bundled cable solutions, provides contractors with a compelling return on investment by reducing installation times, labor costs, and onsite material waste.

As well, ordering printed cable from One-Pull won’t hold up progress on the job site. Our lead time target for custom printed cable bundles is 3-5 days — the shortest in the industry.

For many contractors and project managers, custom cable bundling and printing offer compelling financial and operational advantages. One-Pull’s expert team can answer all of your questions about custom printing, provide a same-day quote, and deliver your custom cable cost-effectively — when and where you need it

How Bundled Cable Helps Electrical Contractors Boost Margins

Posted on by Mike Zimm

Here at One-Pull Wire Solutions, we’re known for technical innovation that helps electrical contractors reduce costs, save time, and improve productivity.

One-Pull manufactures custom bundled and labeled cables used extensively in industrial applications like conveyor belt systems and automated control wiring. Each cable bundle can incorporate up to 300 separate conductors, and each wire can be custom-labeled every two inches to simplify identification and termination.

Our One-Pull bundled cabling solutions can yield up to 40% in labor cost savings by reducing set-up, tagging, pulling times, and ring-out requirements. One-Pull bundled cables are also built to custom lengths to meet individual customer specifications, minimizing wire waste and excess customer inventory.

A Combination of Industry Leaders

In 2019, One-Pull acquired Quik-Pull, another leading custom cable manufacturer well-known to electrical contractors and distributors for its bundled cable solutions. As a result, our expanded product line now includes spiral configurations, insulated multi-conductor wire bundles, and custom tray cable (UL-listed for direct burial) — all available nationally through One-Pull’s distributor partners.

The Benefits of Bundled Cables

Bundled cables address a significant challenge electrical contractors often face on the job site. Single conductors must be pulled from individual spools, then tagged and taped together before pulling through conduit. In contrast, One-Pull’s bundled cable comes on single spools and is cut to the exact lengths specified for the job — speeding up the installation and reducing material waste.

Our bundled cables come in many configurations. The most common are:

Straight configurations — consist of individual conductors that can be broken out at intermediate points along the run. This configuration is generally used for #12 AWG wire sizes and above to minimize heat build-up. It works well for cable bundles used in trays, troughs, and other wire management systems that do not use conduit.

Spiral configurations — are commonly used for ‘home runs’ pulled through conduits or raceways. This configuration retains the cable’s roundness and flexibility through our equipment’s twisting capabilities, making it easier to pull cable over long distances and through conduit.

Staggered configurations — are optimal for wiring that must be broken out at particular points along the run. Staggered configuration bundles have all the breakouts measured, cut, and ready to be installed, eliminating the need to measure specific lengths and terminations on the job site.

 

Reducing Labor Costs with Custom Printing and Striping

Once pulled, terminating cable can be slow, painstaking work. Each conductor must be separately labeled, and contractors often have to test or ‘ring out’ each wire to ensure they’re terminating the right conductor.

One-Pull eliminates manual labeling and ring-out requirements by printing unique identifiers on each conductor. We use durable inkjet printing to affix alpha-numeric characters, symbols, words, and sentences on each wire.

Our printing is entirely customizable. Common options include conductor coding, technical print, standard numbering, and custom branding. Each conductor is marked every two inches, and print is available in black or high contrast bright white.

Striping is another way to help reduce termination labor costs. Striping helps to quickly identify conductors by differentiating the same color conductors through a visual inspection. Striping is available in multiple colors, including existing color codes like E1, E2, K1, and K2.

Striping may be applied as a linear tracer running parallel to the wire or in a spiral tracer stripe that wraps around the conductor as it runs along the length of the wire.

Short Lead Times for Busy Contractors

Time is a precious commodity for project managers, estimators, and electrical contractors. At One-Pull, our lead time target is five days or less — the shortest in the industry for custom cable bundles.

We know that the clock starts running when you pick up the phone. Our expert customer service team will quickly answer all of your questions and provide a same-day quote. And, when it comes to shipping, we’ll recommend cost-effective options to deliver your cable when and where you need it.

No Substitute for Experience

We’re proud of our low employee turnover, and many of our team members have been with us for over a decade. That experience, combined with an ongoing focus on updating our industry knowledge and technical expertise, ensures our team can serve as trusted advisors to our customers, whatever their requirements.

Here at One-Pull, we look forward to helping you choose the right bundled cable solutions to reduce your project costs and boost your productivity.

Want to learn more about what our products can do for your next project? Contact us, and a representative will get back to you shortly.

Navigating the Ins and Outs of Plenum Cable

Posted on by Mike Zimm

When choosing cable, contractors must know the difference between plenum and non-plenum spaces. Making the wrong choice can mean a needless expense, or worse, run afoul of building codes and create a safety issue.

Drop ceilings and raised floors are spaces commonly used to run data and electrical cables. In many cases, but not all, these spaces are designated as plenum, mandating the use of specially-designed cable for safety purposes.

What is a Plenum?

A plenum space is a raceway, duct, or air space that forms part of the air-handling component of a heating, ventilation, and air conditioning (HVAC) system. While drop ceilings and raised floors are often considered plenum, some drop ceilings are built tight enough to restrict airflow and may not be deemed plenum spaces.

Due to the high rate of airflow, plenum spaces can represent a significant fire hazard. If standard (non-plenum) cable is used in plenum spaces, the cable insulation can spread a fire quickly and release toxic smoke and fumes throughout the building. 

Plenum Versus Non-Plenum Cable

The physical differences between plenum and non-plenum cable are straightforward. It’s all in the jacket — the outer sheath that protects the cable’s core.

Plenum cables have specially treated jackets to inhibit flame progression and eliminate the harmful smoke normally released by burning plastic. The plenum cable jacket is usually made with a low-smoke PVC (polyvinyl chloride) or FEP (fluorinated ethylene polymer) and sometimes uses a Teflon coating (PTFE).

In the U.S., the construction and composition of plenum cable are regulated under the National Fire Protection Association standard NFPA 90A, an evaluation that includes extensive fire safety testing.

Picking the Right Cable for Your Job

Plenum cable is more expensive (up to 2x) than its non-plenum counterpart, so using plenum cable when it’s not needed can eat into margins and impact profitability. Unfortunately, it’s not always easy for contractors to determine whether plenum cable is required.

Typically project engineers will review local building codes to help determine which cable to specify. If the codebook is unclear, consulting with local inspectors will validate whether plenum-rated cable should be used in a particular environment.

Can Plenum Cable Be Bundled?

Pre-cut, bundled cables can slash set-up, tagging, and pulling times while reducing material waste. In many cases, using bundled cabling can save contractors up to 40% in labor costs. Bundled cables also require less space to pull through and make for cleaner, more manageable terminations.

Plenum-rated cable can be bundled using special, fire-rated Kevlar binding. This binding holds the conductors tightly together (with enough room to breathe) while limiting sagging or catching wires when pulled.

It’s important to note that it’s not always possible to print on plenum cable, depending on the type of jacket used. Printing is used to speed conductor identification and termination by printing a unique identifier on each wire. However, the inkjet printing typically employed for bundled cable may not ‘stick’ to plenum cable jackets, especially those containing Teflon.

One-Pull: Helping You Choose Your Best Options

Our One-Pull team of experts can help you determine if bundled cable is the right fit for your plenum and non-plenum requirements. One-Pull will completely customize your cable bundles (including printing) and provide short and custom runs with no minimum length requirements.

Since 1979, One-Pull has been producing bundled cable solutions for electrical contractors and industrial applications. With same-day quoting and the best lead times in the industry (typically five days or less), we’re committed to saving our customers time — and money.

To learn more about how One-Pull products can save you time and money, contact us and a representative will get back to you shortly.

The Differences Between Bundled Cable and SIMpull Coilpaks

Posted on by Mike Zimm

 

Electrical contractors often ask us what are the differences between our Quik-Pullbundled cable products and SIMpull Coilpaks. When speaking with electrical contractors, I explain that whether bundled cable is better suited for a project than SIMpull Coilpaks often depends on the type of construction, the number of conductors being pulled, and the total wire footage.  

Here I will run through the advantages of both products and the types of projects where one is a better cost-saving solution. 

SIMpull Coilpaks

Stocked at most electrical distributors, SIMpull Coilpaksare available in different sizes and colors (in fact you can order from Home Depot or Lowes).  

 

Advantages of SIMpull Coilpaks 

Easy setup 

The SIMpull Coilpaks come in individual packs which can then be easily pulled from the package. Among the benefits are that the Coilpaks can be quickly set up on SIMPull cart (sold separately), which contains a payoff with 8 shelves that hold the individual Coilpaks. Though the Coilpaks can be used without the cart, it is good to have a cart for larger pulls. For smaller pulls (such as less than 5 conductors), the containers can be stacked on top of one another. The conductors are  then pulled from the center of the packages.  

 Widely available 

Once the Coilpaks are set up on the cart’s payoff, the electrical workers can easily combine the conductors which the workers then proceed to pull to the connection. Since Coilpaks are not custom made, they are stocked at most distributors. This makes them easy to find, purchase, and bring to a job site. 

Good solution for short home runs  

When I speak with electrical construction crews, I often tell them that SIMpull is a good solution for repetitive home runs that do not involve dozens of conductors (individual Coilpaks can include up to four conductors inside each pack).  

 

Disadvantages of SIMPull Coilpaks 

Despite the advantages there are some drawbacks that limit Coilpaks utility on different types of projects..  

Leftover material 

Since they are not custom made, there is typically leftover wire. No electrical contractor wants to have a surplus inventory of different lengths and gauge size of THHN wire just sitting around in their office. Especially at a time when copper prices are high, scrap wire on the job site can make a noticeable dent in the electrical contractor’s profit margins.  

Conductor limit 

Since there’s also a maximum of 8 Coilpaks on the payoff cart, the product is not as well suited for large wire bundle installations where the contractor needs to install more than dozens of conductors per home run.  

Length limit 

The longest Coilpak is 14 solid which comes up to 2500 feet per pack so any longer runs limit where the Coilpak can be used. 

The cart cost is expensive 

There’s also the cost of setup: if you don’t have a cart, it’s good to have one for a multi-conductor pull. Purchasing a SIMPull cart costs over $1,500.  

No custom printing 

If the electrical workers are using the same color conductors, they’ll have to do the tagging themselves. Without the custom printing, electrical workers have to spend the time marking and tagging, adding to the set-up and extending their time on the job site.

 

Bundled Cable

Blue Red Black Bundled Cable

Premanufactured bundled cable is an effective labor saving solutions for many different types of electrical construction projects. 

 Advantages of Bundled Cable 

Prefabricated wire bundles expedite installation 

Since every bundled cable order is manufactured to customer specification, the setup and installation is faster than using a SIMpull Coilpak. Bundled cable, on the other hand, is pre-made and shipped on a single reel  so that once it is setup on a job, the pulling can begin seamlessly.  

Custom printing saves time on tagging and identifying 

Bundled cable comes with custom alpha-numeric printing every 2” on the individual conductors. As a result the electrical workers save time on the marking, tagging, and identifying portion of the installation.  

Manufactured to specification avoids surplus footage 

Since every order is manufactured to the customer’s specification, scrap footage is greatly reduced or eliminated. 

Large wire length and conductor count 

Whereas Coilpaks carts have a payoff tree limited to 8 Coilpaks and the footage of individual Coilpaks are capped at 2,500 feet, bundled cable doesn’t. With bundled cable, it is possible to bundle over 50 conductors. Furthermore, our machinery can bundle up to 5,000 feet per conductor. 

 

Disadvantages 

Bundled cable is not the right product for every multi-conductor installation. There are certainly projects where I recommend SIMpull Coilpaks as a good alternative.  

Upfront planning required for purchasing bundled cable 

Since the wire is prebundled and labeled, the upfront sticker cost can appear higher for bundled cable than using Coilpaks. However, when you include the time on the job site to do the marking and tagging the overall value of the bundled solution comes into focus.  

Longer lead time than Coilpaks 

Coilpaks can be purchased and brought to a job site within hours (assuming it is stocked at a store relatively close to the job site).  

On the other hand, bundled cable can’t be purchased the same day it is ordered since every order is custom bundled. The lead time is typically 3 to 5 days from order receipt to shipment. Therefore if an electrical contractor needs an immediate solution on the job site, Coilpaks would be a better option.

Summary 

To conclude, there are advantages and disadvantages to both products. Whenever I speak with an electrical contractor who is unfamiliar with custom bundled wiring and asks how it differs from SIMpull Coilpaks, I lay out the pros and cons of both products.  

In short, bundled cable requires a bit more upfront planning and may appear to cost more. But for the right project, the savings occur on the job since it saves considerable time and let’s the contractor get their labor team on to the next project. 

To learn more about our bundled cable products advantages, contact us for more information. 

 

5 Electrical Contractor Specialties

Posted on by Mike Zimm

Electrical contractors are generally classified by the type of electrical work they do. There are various specialties that an electrical contractor can decide to pursue. Understanding these different specialties is essential as they require not only specialized knowledge but licenses. Specialization, as most would think, does not limit the scope of work that an electrical contractor can do. On the contrary, a contractor is most likely going to be more competitive with specialization. 

Developing a specialty field requires one immersing themselves in all of its aspects to understand all facets of the new venture. This translates to a contractor being knowledgeable and well-trained, thereby increasing their competitiveness on job bids.  

As electrical contractors progress in their career, they may find themselves working mainly in particular areas that they may eventually decide to focus on. However, this does not mean exclusively working in these areas of interest and not others.  

The following are some of the specializations that exist for electrical contractors: 

 

1. Fire Alarm Systems

Fire alarms use a complicated connection from the mainboard to fire detectors distributed all over buildings—both commercial and residential. Because of this, an electrical contractor must be highly knowledgeable and skilled in working with fire alarm systems.  

Contractors dealing with fire alarm installations would normally be certified by the National Institute for Certification in Engineering Technologies (NICET) in fire alarm systems. This is so because a high level of proficiency in fire alarm codes is required. A qualified contractor should be able to provide advice on both the installation and maintenance of the system. Engineers working with electrical contractors in this specialty often want a contractor who understands the importance of a fire alarm system and how to install them in a code-compliant manner. 

Fire alarm systems are low voltage wiring systems. For this reason, electrical contractors working to install these systems may sometimes be referred to as low voltage contractors. 

 

 

2.  Solar Panel Installations

Solar installations are not a one-size-fits-all solution. These installations are can be dangerous and complicated work that is linked with high voltage transmission.  Experienced and well-trained electrical contractors familiar with the industry are needed to provide the installation and maintenance needs of solar projects. These contractors are required to undergo specialized and extensive training for different facilities. While this sounds daunting, the solar industry is booming and the demand for electrical contractors in the solar industry is higher than ever. This presents an opportunity for electrical contractors wanting to specialize in the solar industry.   

A big hurdle in solar installations is the high up-front cost. However, this is an opportunity for electrical contractors to be competitive while maintaining high–profit margins. Incorporating value-add solutions makes a contractor’s bid stand out as it ensures reduced installation costs. 

Being a competitive electrical contractor in the solar industry goes beyond cost-savings; it also means being suited to install solar systems for a wide variety of locations and buildings and being able to provide recommendations tailored to the project requirements.   

 

Check out our value-add solutions that help electrical contractors save time and money on their solar projects. 

 

3. Oil and Gas Industry

Just like the solar industry, the oil and gas industry has been growing. Electrical contractors working in these sectors are often required to put effective electrical systems in place that can handle the energy requirements without compromising on safety and reliability. Safety comes in when extracting, processing, and treating natural gas. 

Electrical contractors in this industry need to be familiar with the electrical equipment essential to the industry. Such equipment includes:  

  •  Signal, alarms, and surveillance— these are essential for the safety of employees working in the plants 
  •  Motor Controls— critical for circuit protection and power management hence required for the proper working of electrical safety systems 
  • Lighting— proper lighting is necessary for performance, quality, and safety in the industry. 
  • Instrumentation— used to monitor critical processes on offshore oil and gas platforms in power production plants and petrochemical installations. 

 

 

4. Water Treatment Plants 

Water plant installation takes a special type of electrical contractor. This is because water treatment plants are complex and technically advanced.  

Electrical contractors choosing to specialize in these water treatment plants are often qualified in motor control, PLC, and instrumentation installation and wiring. Knowledge of controls, wiring methods, and SCADA systems are all essential components for a qualified electrical contractor to perform and execute water treatment projects in a safe and timely manner.  

Electrical contractors in this specialization provide a wide range of services including but not limited to: 

  • Wiring and installation of chlorination equipment 
  • Using and handling sewage treatment facility equipment 
  • Monitoring system panels and power installations. 

Wastewater treatment plants use a broad array of equipment and instrumentation systems. Having some familiarity and expertise in using this equipment could make an electrical contractor stand out. 

 

 

5. Process Automation

Industrial process automation helps optimize processes and streamline workload. Electrical contractors in process automation deal with installations of automated conveyor systems, integrated machinery, and automated process control systems. As the use of automated systems continues to increase in the  construction and manufacturing industries, there is a constant demand for specialized contractors.  

Electrical contractors specializing in process automation get to work in a variety of projects including: 

  • Chemical plants 
  • Agriculture facilities 
  • Food production 
  • Manufacturing plants 
  • Construction 
  • Distribution Centers 

 

Learn more about the best construction estimation software for electrical contractors.  

 

Lead Time and Shipping Time for Making Quik-Pull Bundled Cable?

Posted on by Mike Zimm

Along with questions about available wire types, customers frequently ask how long it takes to manufacture and ship Quik-Pull bundled cable.  

Lead time and shipping date are crucial for our customers. Ideally, we work with project managers and estimators during the project planning phase to get the precise measurements and lengths for their wire bundles.  

With advanced planning, manufacturing and shipping usually takes 3-5 business days.  

Sometimes customers realize they need bundled cable to reduce their labor overage and overmanning costs only after an electrical construction project has begun. When that happens, the customer wants their Quik-Pull bundled cable on the job site ASAP. While this is uncommon, when it does occur our sales team works with our manufacturing production team to accommodate a need for an expedited order. 

Though the vast majority of our orders ship within 3-5 business days, the situation is different for large, 50 conductor plus orders that are over 100,000 feet.  

For example, bundled cable runs for utility scale solar farms are often hundreds of thousands of feet.  As a result, the lead times are longer for utility scale solar farm projects.  

Though every project has its own unique challenges, we are committed to manufacturing and shipping to our customers as quickly as possible.

 Want to learn more about whether our bundled cable is a good fit for an upcoming project? Contact us to learn more. 

What Types of Wire Can Be Used in Wire Bundles?

Posted on by Mike Zimm

One of the most common questions we receive is what types of wire can be used in our bundled cable configurations. As for wire type, the answer is simple: any kind of control wire. 

Our most requested cable bundles contain access control wires such as THHN, TFFN, XHHW-2, Cat5, Cat6, data cable, and fire alarm cable. Additionally, we have a bundling line dedicated exclusively to PV wire for utility solar farm projects.  

From a customer standpoint, the most critical question is whether it will be more efficient to pull the wire bundled together than to pull as individual singles. Usually this is the case but only up to a certain gauge type. Our equipment is capable of bundling wire as small as 18AWG up to 6AWG. Our wire bundles reach a maximum 6AWG because once the wire becomes very heavy, it loses its flexibility. As a result it cannot be easily pulled through conduit. 

Finally, customers will sometimes ask whether we can print, bundle, and cut wire they already have on hand.  

Absolutely we can.  

Customers can ship the wire to our manufacturing facility if they want us to mark and bundle wire they have already purchased. Electrical contractors often remark how the custom alpha-numeric on each conductor makes it easier and faster for their team to identify the wire. 

Want to learn more about our custom wire bundles? Check out our “how we make bundled cable” video.