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Technical Aspects & Features
COSTS LESS – INSTALLS FASTER – UL LISTED 800-334-6825 • www.sapagroup.com
Rigid
Aluminum
Conduit
2
Agenda
•! Introductions
•! Rigid Conduit –! Advantages
–! Elements of Design
•! Rigid Aluminum Conduit
–! Material Cost Advantage
–! Electrical Characteristics
–! Corrosion Characteristics
–! Installation Characteristics
–! Sapa Support Structure
•! Follow Up –! Email Survey
–! Job Calculations
3
Sapa is...
•! The Largest Extruder in North America
–! 16 Plant Locations, 10 Paint Lines, 4 Anodizing Lines
–! 550+ Million Pounds Produced Every Year
•! The Leading Producer of Rigid Aluminum Conduit
–! Over 35 Years Experience Producing RAC
–! Main Extrusion Facility in Burlington, NC
–! 33 Representatives Nationwide
–! 20 Stocking Warehouses Nationwide
–! Nearly 1 Million Pounds of Material In-Stock, Ready to Ship
–! Coast to Coast Distribution
4
Rigid Conduit: Aluminum and Steel
•! Advantages
–! Mechanical & Flame Protection
–! Safety for personnel
–! Easy Pull, Smooth, Snag-Free pathway for cables
–! Pull-boxes to enable straight pulls
–! Easy means for replacing conductors or pulling in additional ones
•! Elements of Design
–! Adequate strength in relation to size for self-support over reasonable lengths
–! Capability of being cut and threaded readily and bent smoothly with normal field methods and tools
–! Provision and maintenance of good electrical conductance through the conduit proper and across all threaded joints
5
RAC Material Cost Advantage
•! Market Price Review
•! RS Means Data –! Less Expensive Material
–! Less Expensive Install
Percent Material Savings
Aluminum vs Galvanized
Is the money going in…or coming out?
6
COMMERCIAL GRADE MALLEABLE IRON COMMERCIAL GRADE ALUMINUM
BodyStyle
AppletonModel
StockNo. Each
AppletonModel
StockNo. Each
C C50M 5XC46 6.53 C50A 5XC42 5.15
C C75M 5XC47 7.87 C75A 5XC43 6.32
C C100M 5XC48 11.80 C100A 5XC44 9.49
C C125M 5KF15 20.39 C125A 5KF14 13.39
C C150M 5KF17 26.50 C150A 5KF16 18.82
C C200M 5XC49 44.35 C200A 5XC45 31.40
TB TB50M 5KG58 8.83 TB50A 5KG57 10.78
TB TB75M 5KG64 10.77 TB75A 5KG63 12.84
TB TB100M 5KG42 15.48 TB100A 5KG41 15.54
TB TB125M 5KG44 23.32 TB125A 5KG43 24.09
TB TB150M 5KG46 30.65 TB150A 5KG45 31.40
TB TB200M 5KG50 48.25 TB200A 5KG49 49.20
COVER KK50 5XC82 1.44 KK50A 5XC78 1.44
COVER KK75 5XC83 3.26 KK75A 5XC79 2.05
COVER KK100 5XC84 4.54 KK100A 5XC80 2.59
COVER KK125&150 5KF63 7.92 KK125&150A 5KF64 3.16
COVER — — — — — —
COVER K200 5XC85 9.49 K200A 5XC81 5.32
T T75M 5XC71 9.83 T75A 5XC67 8.02
T T100M 5XC72 14.80 T100A 5XC68 11.02
T T125M 5KG26 22.01 T125A 5KG25 11.02
T T150M 5KG28 28.70 T150A 5KG27 14.73
T T200M 5XC73 44.95 T200A 5XC69 37.10
RAC Material Cost Advantage
7
Rigid Aluminum Conduit
•! Weight Factor
–! 1/3 Weight of Steel
–! Field Practicality
•! Standard 10’ Lengths
•! 4” Steel = 98 lbs
•! 4” Aluminum = 34 lbs
–! Fewer Supports Needed
•! Saves Money
–! Installs Faster
•! Labor Rate
8
Installation Labor Rates
SIZE METAL 12' 16' 20'
1 1/4" Aluminum 4.9 5.9 8.5
Steel 6.5 7.8 11.5
1 1/2" Aluminum 5.4 6.5 9.0
Steel 8.0 9.6 13.5
2" Aluminum 7.0 8.5 10.5
Steel 11.0 13.2 16.5
2 1/2" Aluminum 9.8 11.5 14.0
Steel 15.5 18.3 22.0
3" Aluminum 11.7 14.0 16.5
Steel 18.5 22.0 26.0
3 1/2" Aluminum 12.8 16.5 19.0
Steel 22.0 26.0 30.0
4" Aluminum 17.5 21.0 23.5
Steel 30.0 36.0 40.0
5" Aluminum 24.0 29.0 31.5
Steel 41.0 49.0 54.0
6" Aluminum 31.0 37.0 40.0
Steel 53.0 63.0 68.0
RIGID CONDUIT CEILING HEIGHT
Comparative Installation Labor
SERVICE LINES AND FEEDERS - MAN HOURS PER 100 FT.
36%
9
RAC Electrical Characteristics
•! Electrical Resistance
–! 1/4 of Steel
–! When Installed with Couplings, Elbows & Boxes - 5 times greater conductivity
•! Protective Capability
–! Ground Fault
–! Lower Resistance
10
RAC Electrical Characteristics
•! Short Circuit Capability
–! 2” Aluminum & Steel
–! 10 Second Test
–! 22,200 amperes RMS
–! Steel
•! Buckling & Glowing
•! 4 1/2 Times as Hot
•! Couplings Smoked Profusely and Threads Damaged
–! Aluminum
•! Showed no signs of the heavy current passage
•! Gummed Labels Remained
0 2 4 6 8 10
Seconds
1600
1200
800
400
Steel
Aluminum
Tem
pera
ture
11
Rigid Aluminum Conduit
•! Composition
–! 6063-T1 Alloy
–! Lower Copper content to increase corrosion resistance
Percentage Limits per Industry Standards
Aluminum Conduit Typical
Percentages Copper 0.10 max 0.02 Silicon 0.20 to 0.6 0.40 Iron 0.35 max 0.20 Magnesium 0.45 to 0.9 0.70 Manganese 0.10 max 0.01 Chromium 0.10 max 0.01 Titanium 0.10 max 0.01 Zinc 0.10 max 0.02 Others 0.15 max Trace Aluminum Remainder Remainder
Composition of Aluminum Conduit Alloy
•! Code Compliance
–! Federal Specification WW-C-540c
–! Underwriters’ Laboratories UL-6A, latest revision
–! American National Standards Institute (ANSI) C80.5
–! Canadian Standard Association CSA C 22.2 No. 45
12
RAC Corrosion Characteristics
•! Composition
–! Lower Copper & Iron than Standard 6063
–! Enhances Resistance
•! Compare to Galvanized
–! Galvanizing Continuously Wearing Out
–! Scratches in Galvanized Surface - Huge Problem
–! Aluminum Oxidation is Continuously Building Up
•! Historic Examples
Washington Monument - Aluminum Cap - 73 Years Later
- 5 thousandths of an Inch
Empire State Building - Decorative Facades - 30 Years Later
- No Corrosive Effects
13
RAC Corrosion Characteristics
Atmospheric Corrosion of Solid Metals over a 10 Year Period
Atmosphere Location Aluminum Copper Zinc** Lead
Desert Phoenix, AZ 0.000 0.005 0.010 0.009
Rural State College, PA 0.001 0.023 0.042 0.019
Coastal Key West, FL 0.004 0.020 0.021 0.022
Coastal La Jolla, CA 0.028 0.052 0.068 0.016
Industrial New York, NY 0.031 0.047 0.190 0.017
Industrial Altoona, PA 0.025 0.046 0.190 0.027
Corrosion rate shown in average mils per year. Table based on ASTM data (Committee report).
*Aluminum 1100. Aluminum conduit is usually made from aluminum alloy 6063, generally considered to be equivalent in corrosion resistance to aluminum 1100.
**Prime western zinc.
14
RAC Installation Characteristics
•! Non-Sparking
–! Gas, Vapor, Dust
–! No Special Tools
•! Explosion Proof –! Sealed Against Entry of
Explosive or Corrosive Gases, Vapors, and Fluids
15
RAC Installation Characteristics
•! Fittings - Interchangeable –! NEC 344.10(A)
–! Either Aluminum or Galv
•! Cutting & Threading –! Standard Cutting Tools
–! Standard Dies
–! Fast, Easy Cuts & Threads
•! Bending –! Standard Equipment
–! Much Easier than Steel
–! EMT Benders on Sizes <1”
•! Pulling –! Comparable to Steel
–! Chart on Next Slide
16
RAC Installation Characteristics
•! Pulling Test –! 3 New #2 Cables
–! Pulled Through 90° Bends in 1 1/4” Conduit
* Rigid Aluminum - No Anti-friction Coatings
** Average of Tests With 9 Galvanized Steel Conduits. Cable Breakage at the 4th 90° Bend Occurred in 4.
First 90°
Bend
Second 90°
Bend
Third 90°
Bend
Fourth 90°
Bend
900 lbs
300 lbs
100 lbs
700 lbs
500 lbs
Conduit A*
Conduit B*
Conduit C*
Conduit D* Conduit E*
Conduit F*
Conduit G*
GRC Conduit **
Anti-Friction Aluminum
17
Partial Client List
OIL REFINERIES
Chevron Clark Exxon Mobile Marathon Oil Phillips 66 Premcor Clean Fuels Shell Sonoco Tosco Valero
TELECOM
AT&T Bell Atlantic Chesapeake Telecom Digital Teleport FL Telecon Lucent Pacific Bell Verizon
TRANSPORTATION
American Airlines Amtrak Ford Motors General Motors Kaman Aerospace Lockheed Martin Long Island Railroad Michelin Tire Mitsubishi Norfolk So Railway Northwest Airlines
ADM Biltmore Winery Brach’s Confection Coca-Cola Con Agra Dairy Farmers of America Domino Sugar Farmland Foods General Mills Hillshire Farms Iams Kellogg Kraft Foods Land O Lakes
FOOD PROCESSING
Louis Rich Co Meridian Vineyards Nabisco Nestle Ocean Spray Pepsi Purdue Farms Pilgrims Pride Pillsbury Quaker Oats Ralston Purina Sysco Food Services Tombstone Pizza Tyson Foods
ELECTRIC/POWER PLANTS
Beaver Valley Nuclear Browns Ferry Nuclear Con Edison Nuclear Conesville Gen Station Cooper Power Station Crow Wing Coop Decatur Energy Center Farmers Elec Coop Gaston Steam Plant GE ComEd Substation Hayes Energy Houston Light & Power
Larosita Power Louisville Gas & Elec Mustang Power Plant Ohio Power Orion Power Phantom Power Roanoke Valley Energy Rockport Plant San Juan Gen Station Trinity Valley Electric Texas Utilities Virginia Power
PAPER/TEXTILES
American Tissue Boise Cascade E I Dupont Fox River Paper Frontier Spinning Georgia Pacific International Paper Kimberly Clark Mead Paper Milliken National Textiles Premier Box Board Republic Paper Unifi Weyerhauser Yakima Forest Products
CHEMICAL
BASF Beaumont Hospital Coastal Chemical Dow Corning Dupont Chemical Eastman Chemical Eli Lilly GE Medical Hilton Davis Merck Mobile Chemical Owens Corning Pfizer Procter & Gamble Soluter Chemical Ticona Polymers Union Carbide
WASTE WATER/WATER TREATMENT
Alexandria WWTP Appleton WWTP Ashland WWTP Aspen WWTP Bonita Springs Bonnieview Pump Station Carson Water Treatment Ocala Water Treatment Clarksville WWTP Coral Springs Water Treat Gettysburg Water Treat Gypsum WWTP
LA Sanitation District Lodi WWTP Mohawk View WWTP Myrtle Beach WWTP New Britain WWTP Sand Springs WWTP Trinidad WWTP Walnut Creek WWTP Wichita WWTP Widefield WWTP Wylie WWTP Yonkers WWTP
NON-INDUSTRIAL
Austin Civic Center Bechtel Clemson University Dallas/Ft Worth Airport Fluor Daniel Goldman Sacs IBM
Miami Int’l Airport MIT NASA Sam’s Club UCLA Kaufman Hall University of Houston Wal-Mart
18
Case Studies
•! Kansas Bridge Project
•! Alabama Pulp & Paper Mill
•! Oklahoma Electrical Utility Pole Risers
•! Dallas-Fort Worth Airport
•! North Carolina Textile Plant
19
Kansas Bridge Project
•! The Project –! Wichita, KS Five Mile Bridge
–! Carrying Telecommunication Lines
•! The Challenge –! 6” Conduit Running 5 Miles
–! Maintain Structural Integrity of the Bridge
•! The Solution –! Fewer Hangers & Holes Drilled
–! Fewer Workers & Faster Completion
•! The Payback –! Material Savings = $70,000
–! Labor Savings = $210,000 7000 hours @ $30 hr
–! Total Savings = $280,000
20
Alabama Pulp & Paper Mill
•! The Project –! Selma, AL Pulp & Paper Mill
–! Carrying Power Lines
•! The Challenge
–! Highly Corrosive Environment
–! Intricate Network of Conduit
•! The Solution
–! Non-Corrosive Aluminum
–! Easy to Work With
•! The Payback
–! Material Savings = $90,000 300,000 feet of various sizes
–! Labor Savings = $22,500 750 hours @ $30 hr
–! Total Savings = $112,500
21
Oklahoma Electrical Utility Pole Risers
•! The Project –! Oklahoma Power Co-Op
–! 15’ Riser - 600 Volts
•! The Challenge –! Long Lengths in Various Sizes
–! Extreme Outdoor Exposure
•! The Solution –! Custom Sized 15’ Lengths
–! Enable 1 Person to Handle Safely
•! The Payback –! Material Savings = $50,000
60,000 feet of various sizes
–! Labor Savings = $6,300 210 hours @ $30 hr
–! Total Savings = $56,300
22
Dallas-Fort Worth Airport
•! The Project –! Dallas-Fort Worth Airport
–! Carrying Telecommunication Lines
•! The Challenge –! Transport & Install Large Sizes
throughout an Intricate Network
•! The Solution –! Light Weight
–! Easy to Work With
•! The Payback –! Material Savings = $18,000
17,000 feet of various sizes
–! Labor Savings = $3,680 115 hours @ $32 hr
–! Total Savings = $21,680
23
North Carolina Textile Plant
•! The Project –! North Carolina Textile Plant
–! Carrying Power Lines
•! The Challenge –! Ceiling Mounted 3” Conduit
–! Plant Layout Required Stair Climbing
•! The Solution –! Light Weight & Easy
to Maneuver
–! Easy to Work With
•! The Payback –! Material Savings = $34,000
– Labor Savings = $9,240 220 hours @ $42 hr
–! Total Savings = $43,240
24
Summary
So…what does all this mean to me?
•! Material Cost Benefits
•! Installation Savings
•! Time & Money
•! Enhanced Performance
•! A Better Product
25
Frequently Asked Questions
•! Does Rigid Aluminum Conduit Meet the Same Code Requirements As Rigid Steel Conduit? - YES
–! Sapa Rigid Aluminum Conduit Meets Federal Spec WW-C-540C, UL-6A, ANSI C80.5, and Canada’s CSA C 22.2 No. 45
•! Can I Use Galvanized Fittings With Rigid Aluminum Conduit? - YES –! NEC 344.10(A) Allows the Use of Either Aluminum or Galv
•! Will Cutting & Threading Aluminum Be Harder Than Steel? - NO –! Use Your Standard Cutting Tools & Dies and You’ll Get Fast, Easy Cuts & Threads
•! Any Differences for Bending Aluminum Conduit? - NO –! Use Your Standard Equipment, but It Will Be Much Easier
–! You Can Even Use an EMT Bender on Sizes <1”
•! Is It Harder to Pull Cables Through Aluminum Conduit? - NO –! Independent Tests Show That Aluminum & Steel Are Comparable, Details Are Available.
•! Why Is Rigid Aluminum Conduit Less Expensive Than Steel? –! The Combination of Extrusion Technology and the Weight of the Material.
–! Aluminum Extrusion Is Much More Productive Than the Steel Counterpart.
–! Since Aluminum Weighs 1/3 As Much As Steel, You Can Cover 3 Times the Distance With the Same Amount of Weight. 1 Pound of Aluminum = 3 Pounds of Steel
•! Are There Any Applications Where You Would Not Want to Use Aluminum? - YES –! When Buried in Concrete or Soil, We Recommend Using PVC Coated Rigid Aluminum Conduit.
–! Certain Chlorine-based Chemicals May Reduce the Life of Steel or Aluminum Conduit, in These Applications We Recommend Using PVC Coated Rigid Aluminum Conduit.
