You know what they say about assuming, right?
Wire pulling practices are often based on methods that worked on previous projects, but some of those long-held assumptions are being challenged as large-scale projects continue to push the limits of teams, tools and techniques. Many of these changes are being driven by hyperscale and data center projects, where contractors are encountering longer runs, different installation methods and stricter project requirements.
Here are four wire pulling assumptions worth taking a second look at.
Assumption #1
Longer Cable Runs Require More Splices
For years, longer cable runs often meant adding splice points along the route. That’s not always the case today.
Larger projects are driving longer medium-voltage cable runs exceeding 1,200 to 1,500 feet without splicing.
Why does that matter? Every splice is an extra step in the installation process and another connection that can fail down the road. Reducing splice points reduces the amount of field work required and minimizes the chance of failed connections down the road.
What contractors should reconsider: Before assuming a long run requires multiple splices, evaluate calculations, equipment and layout to see if a single run cable pull is possible.
Assumption #2
Pulling Wire Through Conduit is the Default Choice for Every Installation
Pulling wire through conduit is the default way of doing things for many contractors, but a lot of large-scale projects are going in a different direction.
Hyperscale wire projects are moving away from conduit and toward tray and trench installations because they’re viewed as more cost effective. Rather than hanging conduit and installing separate conduit runs for each cable, they can combine multiple cables in a single cable tray or trench.
What contractors should reconsider: Look beyond the material costs when you're evaluating installation methods. Cable tray and trench systems may reduce conduit installation work, but they also introduce different planning, equipment and pulling requirements.
Assumption #3
The Same Wire Pulling Tools and Techniques Work Everywhere
Moving from conduit to cable tray or trench changes more than where the cable goes. It can change how the entire pull needs to be set up.
Unlike pulling wire through conduit, cable tray installations can require specialized rollers to guide cable through 90s and offsets. Crews may also need different bracing methods or standalone pulling equipment instead of traditional tuggers that brace up against conduit.
What contractors should reconsider: Don't choose your wire pulling equipment based solely on what worked on the last job. Start with the cable route and installation method, then determine the rollers, pulling equipment and setup needed to complete the pull.
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Assumption #4
Wire Pull Calculations are a Best Practice
Most contractors understand the value of pre-planning wire pulls by calculating pulling tension, conduit fill, sidewall pressure, etc. What’s changing is how often they are becoming a requirement.
Some large projects require engineered wire pull calculations and drawings as part of the specification.
As more project owners require engineering documentation, it may not be enough for contractors to do the calculations themselves. Understanding specification requirements earlier in the process can help avoid surprises later.
What contractors should reconsider: Before starting a project, verify whether pull calculations are recommended or formally required by the specification.
Stay Ahead of What’s Changing
Longer cable runs, alternative installation methods and changing project requirements are challenging assumptions that have guided wire installations for years.
That's why pre-planning is more important than ever. Working with a contractor services specialist can help identify the most efficient installation approach for your application, before challenges affect the project.
If you'd like to see some of these solutions in action, consider scheduling a visit to one of Van Meter's Wire Innovation Centers. You can test equipment, learn to use wire pull calculators and gain hands-on experience in a controlled environment.
The assumptions behind wire pulling may be changing, but the value of having the right plan before the pull begins will always stay the same.