How many 500 kcmil THHN fit in 2-1/2" EMT?
3500 kcmil THHN/THWN-2 wires in 2-1/2" Electrical metallic tubing
5.858 sq in × 40 % = 2.3432 sq in allowed. ÷ 0.7073 sq in per wire = 3.31, so 3.
This pull in numbers
- 3 wires fill
- 36.2 % of 2-1/2" EMT
- Limit for three or more
- 40 %
- For 4 or more
- 3" EMT, up to 5
- Pipe to wire diameter
- 2.88 to 1
- In THW insulation
- 3 fit
- In XHHW-2 insulation
- 3 fit
The pipe is 2.88 times the wire's diameter, inside the 2.8 to 3.2 range where three wires can wedge side by side on a pull. If you pull exactly three, go up a size or pull with care.
Before you pull 3
- The ground counts. Every wire in the pipe counts toward fill, the green or bare ground and the neutrals too. 3 is the total, not the hots.
- Bends. A full pipe pulls hard. Keep to 360° of bends between pull points, less for a tight fill.
500 kcmil THHN in other 2-1/2" conduit
| Conduit | Inside area | Most 500 kcmil THHN |
|---|---|---|
| Electrical metallic tubing | 5.858 | 3 |
| Intermediate metal conduit | 5.135 | 3 |
| Rigid metal conduit (RMC, GRC) | 4.866 | 2 |
| Rigid PVC conduit, Schedule 40 | 4.695 | 2 |
| Rigid PVC conduit, Schedule 80 | 4.119 | 1 |
| Flexible metal conduit (FMC, Greenfield) | 4.909 | 2 |
| Liquidtight flexible metal conduit (LFMC) | 4.881 | 2 |
500 kcmil THHN in other EMT sizes
Other wire sizes in 2-1/2" EMT
#12: 176#10: 111#8: 64#6: 46#4: 28#3: 24#2: 20#1: 15#1/0: 12#2/0: 10#3/0: 8#4/0: 7250 kcmil: 6300 kcmil: 5350 kcmil: 4500 kcmil: 3