Section 19
Appendix
NEMA Classifications
Standardized NEMA classifications are routinely
associated with a myriad of electrically
manufactured components. To assist the Field
Engineer, common, NEMA classification
descriptions are accompanied below to aid in
ordering or selecting the proper class of desired
material.
Plugs and Receptacles
Straight Blade
Straight blade plugs and receptacles are most
commonly associated with general-purpose non-
locking use and application. Voltages, poles, wires,
amperage, and grounding vary. NEMA has broken
these classifications down by amperage (15 - 60),
male/female use (R - receptacle; female, P - plug;
male), voltage, number of poles and wire/grounding
configurations. Common to each are:
• An initial identifying number followed by:
• A secondary number and a corresponding:
• Letter
Example: 5-15R would represent -
1 No initial letter in front of the number indicates
general-purpose use.
2 5 = Group (Voltage, number of poles, wire and
grounding configuration)
3 15 = Amperage
4 R = Receptacle
To purchase the mating (male plug) with the typical
configuration supplant R with (P).
Locking type plugs and receptacles are similar with
the addition of an initial letter (L) before the initial
number. This letter represents a Locking-type.
Locking types are the most common used plug or
receptacle used in industrial complexes outside a
normally “controlled environment”. A controlled
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
environment is akin to offices, interior building,
control rooms.
These locking-type plugs and receptacles are also
most commonly used for small hand power tools or
equipment. Also, for safety reasons used on power
cords or light stringers.
When ordering most receptacles for industrial
application color, grade, and either side or back
wired must also be considered.
Standard colors must commonly used are:
• Brown - in plant areas most commonly used.
• Ivory - used in most offices, hallways, rooms.
• White - specific request normally.
• Gray - associated commonly with hospital
grade.
• Orange - industrial facilities use this color for
“isolated” receptacle applications.
• Red - fire detection or protection devices or
with small fractional (125v) horsepower motors
or equipment (hot water heaters).
Common grades include:
• Commercial
• Residential
• Industrial
• Standard
• Hospital
Specialty receptacles include:
• GFCI
• Wiremold or Strips
• Surge suppressors
• Combination switch, light, receptacle
• Carpeted or concrete floor or flush mounted
Enclosures (Boxes, Panelboards)
Common NEMA types associated with the
installation of these electrical commodities and
material purchase orders include: NEMA class:
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1. Primarily associated with dry-indoor general
use or application. Normally, is associated with
screw cover commodity installation and/or
application. Offers protection against
accidental contact of internal components where
unusual service or environmental conditions do
not exist. Is the least utilized NEMA class for
industrial interior installation. When used is
associated most commonly with cable pull
boxes or condulets.
2. General indoor application where an additional
degree of protection from the areas environment
is required. This NEMA class is not commonly
used in most industrial facility.
3. Outdoor environment offering a degree of
protection against windblown particles, rain,
sleet, and ice.
3R Outdoor environment offering a “greater
degree”
of protection from falling rain and sleet.
Undamaged from accumulation of ice. Of, the
two (classes of 3) this class is most utilized.
4 Indoor or outdoor use. Offers protection from
windblown dust and rain, splashing and/or hose
directed water, also undamaged from
accumulation of ice on the enclosure.
NEMA 4 rated enclosures are the most
commonly installed in industrial plants, where
the existence of corrosive chemicals or hazards
are not present.
Common construction is provided with “door
hinges”, is gasketed, and is provided with
enclosure “lips” or metal ledges enabling
internal components to remain protected from
the elements.
Note: when raceway etc. is installed to this
NEMA classified commodity the installation
must be installed so the NEMA 4 classification
(integrity) is maintained (e.g. “conduit hubs”,
approved cable connectors).
4X Indoor or outdoor use where a degree of
protection against corrosion or corrosive
atmospheres or environments exist.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
Most commonly is made of fiberglass
construction and is utilized to “house”
indoor/outdoor instruments that are not totally
self sealed or where exposed wiring exists.
Also, the integrity rating must be maintained
similar to NEMA 4 enclosures.
6 Intended uses are submersible applications.
7 Rated for hazardous classified areas. Class I.
Specific selection and use must also comply
with Class I Group and Division.
9 Rated for hazardous classified areas. Class II.
Specific selection and use must also comply
with Class II Groups.
12 Indoor applications where a degree of
protection against dust, falling dirt, and
dripping non-corrosive liquids are present.
Is the most installed enclosure type in an
industrial indoor setting.
Available with door hinges or removable
gasketed clamp on covers.
13 Indoor applications offering a degree of
protection similar to NEMA 12 except with the
additional protection against oil and spraying
water.
Electrical Craft General
Perceptions and Understanding
A common complaint made by craft electricians is
that most design or field engineers have no concept
of what is required to be used (materials, tools) or
how electricians perform electrical work (conduit
bending, equipment setting logistics). As an aid to
the field engineer this section will “dwell” into the
mindset of an electrician of how they perform or do
“business” relative to electrical installation tasks,
duties, and responsibilities.
Electricians, either union or non-union, individual
skills or talent vary widely and their capability is
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predicated upon on-the-job training, type of job(s),
class or formal education (union apprentice
program, vocational, college), licenses or degrees
held (master electrician, contractors license,
engineering), and experience in-the-trade (age,
tenure). The popular engineering conceptions and
perceptions of an electrician are “overpaid and
uneducated”, incompetent overbearing “know-it-
all’s”, “is paid just to install and “not to think” is
thrown out the proverbial window based on the
actual facts. However, what is true about
electricians is they will perform to “your
expectations” and thankfully take the money no
matter “how many times it takes to do it” (install the
design or perform the test).
To further belittle the “point”, the electricians
perception of engineering is in reality “closer to the
point”. Engineer’s by nature feel “we know all the
answers” before the question is asked. An
Engineer’s mentality is such that “they refuse to ask
for advice” or “admit wrong”. The solution is not
meeting in the middle but rather to appreciate the
duties and responsibilities of the “performer” whose
task it is to “install in 3 dimension want engineers
visualize in 2 dimension (drawings)”. A field
engineer and designers philosophy should be:
“make it easy on the craft and you’ll make it easy on
yourself”.
Craft Electrician Organizational Structure
The common electrician is one individual of a team
of electricians. Consistent with all construction
projects is a craft labor “order” or organizational
structure. This structure has a central craft
electrical field superintendent and/or subsequent
area subordinate superintendents. Below this
management structure lies the craft structure.
Dependent on job (union or non) or required
local/national jurisdictional labor agreements, or a
projects overall electrician manpower size and the
installation phase their could be the following
electrical craft heirarchy:
• Site labor (or craft) representative(s) (shop
stewards) associated with union sites.
• Electrician “Bull” General Foreman (super GF).
This individual, or position may not exist on all
sites, is directly over all the other “area General
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
or labor electrical Foremen’s”. This individual
could also assume the additional duties of a
“superintendent”.
• Area General Foreman (GF). Common practice
is to have an area GF for a pre-determined
number of craft foreman’s. This individual
could also be the “bull GF”, act as the craft
labor representative, or also be the/a
“superintendent”.
• Labor Foreman. This individual is the
“cornerstone” of the electrical department. This
individual could also be termed a “working
foreman” whereby duties are split between
being a foreman and an electrician.
• Lead Electrician. This individual(s) or position
may not exist in a crew of electricians but, the
position represents the “lead electrician” who
normally assumes “temporary” foreman status
in the abscence of a foreman (vacation, sick). Is
usually the foreman’s most trusted or skilled
individual. Can be relied upon to perform tasks
without much direction, help, guidance, or
monitoring.
• Electrician. Works alone or with others, is a
member of a crew of electricians under a
foreman. Is most commonly “paired” with
another electrician(s) or is assigned to a “class”
(union) of apprentices or helpers (non-union).
• Apprentices or Helpers.
Apprentices, involving union work sites, are
basically “electricians in training”, and have
not formally completed an union sponsored
“apprenticeship” educational program. This
program comprises basically of “on-the-job
experience” with “formal union educational
classes” and could include outside schooling
(vo-tech, college). The typical apprentice
program is 4 or 5 years. In construction
terminology apprentices are noted by “their
years in the program” (e.g. 4-year apprentice).
Apprentices, paid less than electricians,
conceivably are fully capable, (4 or 5-year
apprentices especially), of performing all the
assigned work tasks and duties of a “certified
electrician” and are usually in “high demand”
by union contractors.
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Helpers, associated with non-unions, are akin
to apprentices and are usually associated by a
“classification number” 1 - 5. Five (5)
representing the highest qualified. 4 or 5th
class helpers are also capable of performing,
most electrical tasks, but principly are classified
as “helpers” because they might have failed the
required hiring “code test” or examination.
Note: Non-union labor is pre-screened at a hiring
office. Electricians must be able to pass a test and
other significant prerequisites. Upon, working on a
site the electricians and helpers are evaluated by
foreman, general foreman, and supervision to
determine if their qualified to perform the duties of
their position.
Union labor is hired via an “union local or hall”.
Union electricians are those that have successfully
completed their locals apprenticeship program.
The Craft Foreman
The Field Engineer will primarily interface daily
with electrician foreman(s). Understanding their
duties; responsibilities, strengthes, weaknesses,
attitudes, trustfulness, and competency of each
foreman, than “tailoring” your dealings with each,
will result in a harmonious, relaxed, trustful, and
co-dependent relationship between field engineer
and the electricians, not just the foreman.
Foreman Responsibilities (Union or Non)
1. Directly interface between their assigned
electricians, the GF, field engineers, other
discipline foremen or trades, safety, or quality
inspectors. Indirectly interface with project
supervision, management, client, plant
operations, maintenance, or design engineering.
2. Properly plan, assign, and oversee the execution
of daily electrical installation work tasks.
3. Perform and give electrician(s) direction and
installation advice, act as “baby-sitter” and/or
“mother” to them, listen to their labor disputes
or problems, resolve internal “crew” personality
conflicts, manload work to task(s) considering
electricians skill level and capability, plan for
work arounds due to unscheduled delays,
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
manpower shortages, material or tool
unavailability, reassign electricians to support
other foremens or respond to “must do now”
“hot job” work tasks.
4. Give or attend “daily or weekly safety tool box
meetings”, order or request material and
equipment from the laydown or warehouse, due
bulk material takeoffs for their assigned work
areas, perform daily craft time sheets against
commodity cost codes and/or schedules, status
daily or weekly installation quantities or
reports.
5. Resolve installation concerns or problems,
monitor and/or inspect electrician work and
performance.
6. Review design or vendor drawings, notify field
engineering of problems that they cannot
resolve concerning design issues, material
deliveries or specialty tool needs, interferences,
constructability,
7. Perform responsible area housekeeping cleanup
or walkdowns, prepare, submit, acquire
necessary safety permits and/or ensure PPE,
MSDS, is available or in place, install, modify,
or troubleshoot temporary power problems,
requests, or demands.
8. Determines who in their crew gets “laidoff”,
“ROF” (reduction of/in force, “pink slip”),
recommends or “writes up” project violators for
warnings or firing, attempts to resolve payroll
or time disputes, is involved in “fact finding” or
cause and analysis investigations relative to
safety, labor disputes (back pay, loss of wages,
“law suits”), determines or recommends raise
increases or promotions (apprentices/helpers).
9. Performs physical work where the need or
situation demands. Gets demoted, “cut back”,
evaluated, laid off.
A common rule of thumb is to have one-foreman for
every “crew” of 10 - 14 electrician/helpers.
Electrician foreman(s) could be responsible for
“crews” associated with or comprise combinations
of:
• Raceway crews
• Cable pulling crews
• Equipment setting crews
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• Material receipt, storage, cable or laydown yard,
tool or material issue rooms
• Termination crews
• Start-up or client checkout support crews
• Temporary Power or site services
Engineers that do not have craft experience can not
fully appreciate the demands of this “pivotal”
position. Nor; understand that foremen selection is
not “an exact science” and that most qualified
electricians prefer not to be, will be, or want to be,
promoted to a foreman because:
• Additional “pay”, nominal at best over an
electrician, is not worth the pressure of the
position.
• “Sometimes a good private (electrician) makes
a bad sargent (foreman)”.
• Is incapable of making mass or critical
decisions or has temperment or personality
problems (weak or strong).
• Does not perfer to deal or interface with
management, supervision, hiring/firing/lay offs.
• Is content “just being an electrician”.
• Isn’t truly qualified to fill the foreman position.
Rigid Conduit General Expanded (Section 7)
Bending rigid conduit is an exact science and not all
electricians are capable of bending conduit without
some degree of “trial-and-error”. Bending of
conduit can best be summarized by the pipe sizes
that get field bended. Sizes of conduit range from
1/2” to 6”. One-half inch (1/2”) conduit is not
standard installation practice for industrial facilities
and is normally limited to temporary raceway
installations or flexible conduit applications to
instrument devices. Rigid conduits of 3/4” to 2” are
the most commonly designed and/or installed and
are known as “small bore pipe/conduit”. The more
common “large bore pipe/conduit” sizes designed
and installed are 3” or 4”. Sizes 5” and 6” require
specialty equipment, bending skill, and are vastly
more expensive to install or purchase. Less
common designed or installed conduit “trade sizes”
include:
• 1-1/4”
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
• 2-1/2”
• 3-1/2”
Note: A designed raceway system should avoid
mass usage of these sizes mostly due to the
additional material required (couplings, bushings,
hubs, locknuts, etc) expenses that drive up a projects
or electrical commodities budget needlessly.
Conduits in these sizes are mass purchased in
“bundles” of hundreds of feet due to their common
design and installation use. Conduit is normally
manufactured in 10’ length’s, is supplied with both
ends pre-threaded, galvanized, and is provided with
a single (one) coupling. It is noteworthy to mention
that the opposite end of the conduit is provided with
a “uniquely identified colored plastic cap” which
directly corresponds to the conduits “trade size”
thereby enabling quick distinction from the more
confusing sizes (e.g. 1-1/4”, 1-1/2”, 2”) when stored
in the laydown area.
Another factor that must be equally weighed in
raceway design and installation methodology is the
conduit weight. Though not a significant factor for
the smaller trade sizes it “becomes a factor” for the
larger. A typical 2” conduit (10’ long) weighs 37#,
3” conduit 77#, 4” conduit 109#. What appears as
one-man engineered raceway design has become a
two-man task just for safety or personnel injury
protection reasons not even considering travel from
bending table to work area or lifting and positioning
the conduit into place.
Rigid Conduit Bending Equipment, Labor, and
Material (TIC) Approach
Engineers don’t realize the material or equipment
costs associated with their raceway and/or cable
designs. To achieve a successful TIC (Total
Installed Cost) approach the designer and field
engineer must weigh the “hidden” construction
equipment, tool, material, and/or labor costs that are
associated with electrical raceway designs. A trade
electricians inside joke is “one design engineer can
feed ten (10) electricians families”. To offset this,
the designer and field engineer can reduce costs
drammatically at the design onset, during
construction, and via lessons learned for future
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designs and installations. By illustrating the
equipment costs associated with basic conduit
bending or cable pulling equipment the field
engineer and designer can appreciate the cost and
labor savings that can be achieved by “rethinking”
or “revisiting” a design or a design approach:
• Common Hand Bender (Hickey) - $75 average
cost. Good for bending 3/4 and 1” conduit.
• Mechanical (tripod) Bender (Chicago Bender) -
1. $800 average cost. Good for 1/2 - 1” only.
2. $1000 average cost. Good for 1-1/4 - 1-1/2”
only.
• Electric Speed Bender (Sidewinder) - $5500
average cost. Good for 3/4 - 2”.
• One-shot Table Power Bender (motor and
stand) - $10,000. Good for sizes through 4”.
• Cable Tugger - $5000.
• Cable sheaves - $150 - $500.
What costs are not illustrated are maintenance,
required accessories, spare or replacement parts,
equipment quantities a project needs, labor hours in
equipment setup or temporary power needs, storage,
or transportation to-and-from work areas.
Conduit TIC (Total Installed Cost)
Many designers and field engineers don’t care how
conduit is installed or bended. The attitude is “just
put it in”, “just bend it”, or “bend around it”.
Conversely; project controls, supervision, the
electrician, the client, and the “code” do care. The
conduit installation is one of the most visible
electrical commodities noticed when personnel
traverse throughout an industrial or construction
site. The installation reflects “directly” back to the
installer (contractor, electrician) and consequently
reflects what the designer “designed”. The clients
perception of the raceway (conduit) installation
influences their perceptions of the overall electrical
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
design. Primarily because, “thats usually the only
thing most un-involved persons visibly notice”.
Achieving TIC Conduit Installation
Applicable code or site standards generally require a
maximum of 360° in conduit bends without a “pull
point” (unless specified otherwise by project
guidelines). In addition, other factors influence the
total degree of bends between pull points (poor
engineering design, conduit run or distance, radius
of bends, project unit rates, quantity or type cables).
Exposed raceway designs, and installations, that are
installed in continuous straight length’s are a
“luxury” only the electrician, supervision, and
project controls can appreciate. These straight
conduit runs must make up for the “commodity
manhour unit rates” assigned to the raceway
installation. Consistent to most construction cost
budgets their is usually only one or two unit rates
assigned to conduit installation, though may be sub-
defined by area, location, or building etc. They are:
• All raceway sizes - For one unit rate project.
Or: For two unit rate projects:
• 2” and smaller
• 3” and larger
Note: Some projects may assign a separate cost
code for lighting, communications, etc.
In addition, the raceway supports are included in
those established unit rates.
Historically, conduit unit rates are not going
higher but lower, and the designer and field
engineer must “help” supervision and the
electrician to achieve those project rates.
Conduit Installation versus Design TIC
From the Designers viewpoint: “I’ve done my part
by issuing the layout and let the craftsman do
there’s by installing it”. “The electrician will know
what I mean”. If, those viewpoints were correct
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there’d be no design issues, changes, revisions, or
problems just installation one’s.
The Field Engineer’s viewpoint: “Just install it
to/by the drawing”. If, that viewpoint was correct
the craft wouldn’t ask questions or request solutions
and just conceivably wouldn’t need the field
engineer.
Supervisions viewpoint: “Your performance is
unacceptable”. “Your behind schedule”. “Do it
over or tear it out”. “Get it done!”. “Why did you
put it there or do that?”. “I need this done now!”.
Project Controls or Managements viewpoint:
“Where do you stand?”. “Your holding up the
schedule/system”. “Your PF (performance) is over
1”. “Your over budget”. “Why aren’t you done the
quantities say you are?”.
Foreman’s viewpoint: “Here’s the cards, here’s
how I want to see it installed, here’s the equipment
material/tools, and I need it done as fast as
possible”. Or, another approach “I need at least 70’
per day”.
Electricians Predicament: “I wasn’t aware that
was a hazardous classified area”. “That’s where the
drawing/card said it was going too!”. “There’s no
way I can get that many conduits into that panel!”.
“There’s no way we can pull these cables into that
conduit”. “I didn’t realize that pipe/duct was going
there”. “Why didn’t the drawing show those
conduits before I had the scafford removed?” “Why
am I installing a 3” for a 3c-12 cable?” “There’s no
steel for us to support the conduit”. “You can’t do
that its against the code!”.
It is understood that no design will be installed
without problems or changes after issuance. It is
also understood that all scenarios cannot be
considered or prevented. But; to truly achieve
electrical reduced installation and material or
design total installed costs the field engineer and
designer must realize it begins (design scope,
drawing input and review, constructability issues,
equipment, material and tool management costs or
considerations) and ultimately ends with them as
well (design changes, revisions, rework, schedule
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
delays, cost overruns, material or equipment
purchases, as builts, recalculations, lessons learned).
Electrical Welding Activities
Electricians require welding certification on all
projects, similar to the other trades, before their
authorized to perform any electrical welding
activities (e.g. tray, conduit, equipment supports, or
equipment setting installations, bus duct).
Electrician welders are first required to pass welding
tests by performing test welds to the sites governing
applicable welding procedures applicable to the type
welding activities these welders will be performing
on the site.
The sites Welding Engineering Department (or
Welding Engineer(s) oversees the performance of
these welder(s) while performing their welding tests
(called test samples). Upon, passage these welders
are than authorized to perform welding activities
only for the procedures they tested or passed on.
Most all electrical welding activities are carbon steel
or “structural” welds in nature. The welders
commonly are only certified to perform SMAW
(Shielded Metal Arc Welding aka “stick”welding)
and routinely is “limited” to “fillet” type structural
welds.
Note: Aluminum welding for tray or bus duct
welding requires certification to that applicable
welding procedure.
A “fillet” weld is simply two-metal members at a
“perpendicular” or left/right angle plain whereby the
deposited weld metal “fuses” the two-mating metals
together.
Other forms of welding processes requiring
certification for usage include:
• GTAW - Gas Tungsten Arc Welding (TIG)
• GMAW - Gas Metal Arc Welding (MIG)
Weld metal is deposited using “electrodes” or more
commonly referred to as weld rod. Welding
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electrodes principly used to support electrical
welding activity include:
• E6010
• E7018
Many other forms welding processes and electrodes
are available for use. The Field Engineer should be
apprised that the AWS code (American Welding
Society) is the governing body for the structural type
welding activities that most electrical welding is
performed too and should consult the sites Welding
Engineering Department and/or this Code Book for
more detailed welding information.
The Field Engineer should also be apprised that
“pre-heating” the “to be welded” metal surface may
be required when welding activities are performed
during winter or where outdoor ambient
temperatures and metal surfaces are routinely below
50°F.
Inclusive, with the AWS code, are standardized
welding symbols. These weld symbols, in essence,
“tell” the welder what type weld the designer (or
governing drawing/document) is requesting to be
performed.
The typical welding symbol comprises of an “arrow”
that literally points to specific location on the
document/drawing that requires weld metal to be
deposited. Associated directly with this standard
arrow symbol are other “symbols” or descriptive
information which provides additional specific
welding information.
For more comprehensive information relative to
welding symbols and their specific interpretations
reference the AWS Code Handbook Vol. 1.
Note: Some projects require weld inspections on all
welding activities regardless of discipline (e.g.
nuclear power plants), while some projects may only
require “surveillance” or “percentages” of welds to
be inspected. Consequently, “weld maps” and/or
inspection records must be keep up and current.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
Welding Inspection
Welding inspection (by inspectors) must also be
certified to perform welding inspections. Welding
inspectors are certified to perform NDE (Non-
Destructive Examination) on welded work.
Inspector certifications are routinely by
“certification levels” and by NDE test.
Common electrical welding activities that could
require welding inspection basically, unless
specified by project otherwise, require just a “visual”
inspection.
Visual inspection (inspector) specialty tools and
equipment utilized most commonly are:
• Welding guages
• Undercut guage
• Visual-light scope
• Inspection mirror(s)
Welding defects identified must be reworked before
weld can be accepted. Common “visual” welding
defects that are indentified include:
• Weld Cracks
• Excessive slag
• Excessive Undercut
• Not enough weld deposited or weld not per weld
detail/symbol.
• Porosity
• Excessive grinding
Additional NDE inspections that could be required
on electrical welding activities include:
• LP/PT - Liquid dye-penetrant
• MP - Magnetic particle
• RT - Radiographic
• UT - Ultrasonic
For a detailed explanation of acceptable welding
conditions or descriptions of the above consult the
AWS code or the sites Welding Engineering
Department.
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Weld metal areas should be treated with a suitable
protective coating (paint or galvanized compound)
upon completion of weld inspection or repair.
Standard welding accessories utilized to support
welding activities or welding machines use include:
• Weld Rod Ovens
• Weld Rod “buckets” or portable rod ovens.
• Weld Rod
• Welders stencils
• Fahrenheit temperature (hot melt) sticks
• Air or electric Grinders
• Carbon or stainless steel wire brushes
• Welders chipping hammer
• Welder face shield/hood and rated eye/vision
glass
• Weld or flash screens
• Welders slag half-jacket
• Welders gloves
Welding Documentation
Welding documentation on some projects are
required to be with the welder, controlled,
maintained, available for inspection, and turned
over with the completion of the welding task or
applicable mechanical/electrical system. Typical
welding documentation that may be required is:
• Weld Rod (electrode) material withdrawal, user,
or component used on documentation.
• Welding machine or rod oven calibration
inspection procedures and records.
• Weld maps, detailed welding or weld history
documents and design drawings.
• Inspection signoffs, repairs, rework
documentation.
• Current revision of the welding procedure for
each welding procedure utilized.
• Material traceability records.
Electrical Tools of the Trade
Hand Tools
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
The Field Engineer should have a “working
knowledge” of what are the common “tools and
equipment used” by electricians. Field Engineer’s
may be required (maintenance or plant upgrade
projects) to purchase or prepare “tool lists” before
each project is started. These tool lists should
include specialty tools and equipment unique for a
specific task (e.g. “ramset gun”, “hot box” for PVC
bending) that may require purchasing or “rental” for
the project or site.
Generic Power Tools
• Welding machines and accessories (stinger,
whip, rod oven, ground clamp and cable, foot
peddle). Welding stud gun.
• Concrete/masonary - “rotor hammer” drill and
accessories (adapters, “bits”, chuck, chuck key,
puff ball). Core Bore machine (GFCI drill stop,
water tank, hoses, extentions, bits).
• Drills - battery (charger), pistol grip, magnetic,
presses, punches, right angle, “nibbler”, table,
power screwdriver.
• Saws - table, portable bandsaw, jig/saber,
circular, sawzall, reciprocating, hole (blades).
• Grinders - pencil, 4” electric side or angle (w/
guard), etchers, compressed air, sanders.
• Wet/Dry vacuum (hoses).
• Powder actuated nail and/or stud guns.
Rental Equipment Options
• Ditch Witch
• Backhoe
• Bucket truck
• Concrete/asphalt saw-cutter
• Soil Tamper or compactor
• Portable generator or light stand
• Compressor
Specialty Equipment
• Scissor lift
• One-man lift
• Manlifts
• JLG rig
• Bucket truck
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• Dollys/carts
• Mechanical lift jacks
• Ladders - aluminum step/extention
• Scaffolds - rolling, stationary, platform,
suspension.
Gangbox or Tool Pouch Tools
• Wrenches - strap, 14” or 24” chain, pipe,
metric, speed, adjustable/crescent/ratchet (4”,
6”, 8”, 12”), box/combination (5/16” - 7/8”),
folding “allen”, “crows feet (5/16” - 7/8”),
430/440 channel locks, in-lb or ft-lb. torgue
wrenches.
• Pliers - 9”end/sidecutters, “dykes”, needle or
long nose, midget pointed, bolt re-threader,
locking, vise grips.
• Strippers/cutters - wire, MC/coax, bolt, cable
cutters/rippers, scissors, nibblers, utility or
razor knives, cable “skinners”, cable cutting or
jacket stripping knives, hacksaw.
• Sockets - 3/8” & 1/2” drive ratchet set (5/16” to
1-9/16”), deep well sockets, crow feet, 3/8” and
1/2” extention bars, male to female adapters,
metric set, bolt re-threaders, adjustables, sliding
tee or speed handles, hex bit.
• Screwdrivers - “cushion” straight blades,
holding, cabinet or fine tip, #1, #2 Phillips,
“stubby”, ratchet type, magnetic, “tweaking”,
reamers, scratch awls, scribes, “tap sets” and
handle, nut drivers (1/8” - 9/16”), center punch,
“star”, one-way, flexible ratchet, hex key kits.
• Hammers - 2 lb. Ball pein, 20 oz. claw, 2 -4 lb.,
sledge, mandrell/mallets, nail claws, nail sets.
• Squares - 9” torpedo level, 2 - 4’ levels, 12”
combination, framing squares, magnetic
protractors, plumb bob, chalk box, 6’ folding
rule, 16 - 25’ 3/4” or 1” steel tapes, 100’ tapes.
• Files - carbon and stainless, “bastard”, round,
flat, rasps, cold, wood, or floor chisels, pry/crow
bars, punches, wire brushes.
• C-clamps, screw/pin extractors, Knock-out
sets/punches, caulking guns.
• Gang boxes upright/chest style, footlockers, tool
pouches, belts, tool chests or boxes.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
Material Consumables
Supplementing the various tool needs are the
material consumables used by electricians.
Consumables predominantly used by electricians
generically include:
• Adhesives and solvents - locktite, RTV silicone,
denatured ethyl or isopropyl alcohol, cutting,
tap, or threading oil(s), contact cleaner or
cement, cold-galvanizing compound(s), cable
soap, paints/brushes.
• Arbors and bits - 3/8 - 1/2” brushes, high speed
metal bits, carbide bits, tap bits, hole, masonary.
• Blades - saw, knive, grinding discs, “flapper
wheels”, or sanding grits, soapstone.
• Cans - oily waste 6 gal., oily waste 10 gal. foot
peddle, 2 qrt/gal. metal safety, plastic buckets,
55 gal. drums/barrels.
• Cloth - lint free, “rags”, emery, canary board,
“herculite”, fire blanket, “visqueen”, rubber
gasket material.
• Rope - measuring tape or pull string, manila or
hemp, 1/4 - 1” polypropylene, safety pennants
or flagging/rope.
• Tape - phasing, double sided adhesive cloth,
masking, grafoil, rubber splicing or linerless.
• Shrink tubing.
• Test leads - mini-or maxi grabbers, banana
jacks.
Safety
• Water jugs
• Danger tags or warning labels
• Voltage testers
• Circuit tracers
• Eye/Ear/Nose-Mouth/Head protection
Anchors and Bolts
Installation of these materials is common
throughout all phases of electrical construction. The
Field Engineer should ensure that the correct
installation anchor/bolt/screw was used for the
applicable application.
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Anchors - standard applications for anchors are
used in concrete, block or drywall, or steel.
Common illustrations of uses include:
• Cinch, self-drilling, or wedge anchors.
• Drop-in anchors.
• Embedded screw-anchor.
• Toggle bolts.
• One-piece nail in, flange, or plastic anchors.
• Powder actuated nails or studs.
• Anchor bolts
Bolts and Screws
Bolts and screws, are installed to support electrical
commodity installation work activities, and must
comply with applicable site specifications, details,
procedures, guidelines, and be fabricated in
compliance to national standards. Purchase and/or
use of “off the shelf” bolts and screws may result in
expensive rework due to the Field Engineer not
being cognizant of the sites applicable requirements
on the proper purchase and use of the bolts and/or
bolted hardware.
Note: Some sites (e.g. nuclear power plants) place
stringent requirements on the use, purchase, grade,
and traceability of bolts, screws, nuts, etcetra. The
Field Engineer should not assume “all bolts and/or
screws are the same”.
Bolts commonly used in all industrial facilities are:
• High-strength carbon steel. (e.g. ASTM A-325
or A-307).
• Pre-Galvanized or coated (e.g. poly-vinyl, zinc).
• Stainless Steel (e.g. 316).
• Silicone Bronze.
• Brass.
Bolts are typically purchased in bulks, when not
supplied/provided as part of a vendor package. To
adequately ensure the correct bolts and quantities
are purchased the field engineer should:
• Consult applicable design or vendor documents.
• Specifications, drawing notes and details.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
• Client specifics or preferences.
• Applicable regulatory or site requirements.
• Min-max quantities or present in-
stock/warehouse stores and bins.
• Consult manufacturer catalogs, guidelines or
requirements.
• Perform material take-offs and estimates.
Bolts, nuts, and some screws, that are typically used
range in sizes from:
• 1/4” - 20. (1/2” to 2”)
• 5/16” - 18. (1/2” to 4”)
• 3/8” - 16. (3/4” to 5”)
• 1/2” - 13. (15/16” to 7”)
• 5/8” - 11. (1” to 7”)
• 1” - 8. (1-1/4” to 9”)
From the above, the corresponding - # (e.g. 20)
represents the bolts/screws “threads per-inch”.
Bolts also contain “identifying” markings on the
“head” of the bolt. These markings are an
“industry” standard to aid to uniquely identify the
“bolts characteristics” (e.g. class, type, grade).
Note: Consult available standards (ASTM) or site
structural or mechanical specifications or procedures
that aid in defining the “markings” associated with
each bolt.
When ordering bolts the field engineer should
specify:
Sample order: 1/2” - 13 Hex Bolts, 100 Qty.
• Bolt description (e.g. heavy hex head, hex head,
slotted)
• Grade, Type, Class (e.g. ASTM A-307 Grade
B)
• Thread type (e.g. coarse, fine, metric)
• Length (e.g. ..... x ..... )
• By the suppliers “unit of measure”. (e.g. box,
package, etc., this may mean you will receive
100 eaches, if you order 1 box) avoid ordering
in-eaches as the material requisition will cost
significantly more than the material your
ordering and you may get 100 boxes.
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• Catalog number (this may avoid providing some • Cut off excessive bolt or bolt rod threads that
of the above information) could cause accidental injury.
• Remarks (e.g. nuclear grade, system number,
equipment usage specifics) Screw Usage

Installation of screws are akin to bolts but generally

Installation Practices their use is more defined or specific. Common
screw installation practices include:
Bolts are commonly installed with nuts and/or
washers, unless details or bolt manufacturer specify • Mounting of lamacoid labels to exterior of
or dictate otherwise. boxes.
• Instrument mounting or devices details in
Standard installation practices associated with bolts cabinets, panels, boxes (fuse or terminal blocks,
or bolting hardware applications include: relays, switches).
• Use a calibrated torque wrench where detail or
• In conjunction with some anchors or framing
members (sheet metal, open channel strut
installation application warrants - switchgear
members, tray covers, barriers, raceway
cable termination lug attaches to bus bar, floor
clamps).
mounted equipment setting, general raceway or
tray support installation practices.
• Wrench tight - rule of thumb used for non- Screws are also available in sizes less than 1/4”.
torqued bolt installations is 1/4 turn past Common sizes associated with machine screws are:
wrench or hand tight without “deforming the
bolt”. Coarse TPI Drill
• Full thread engagement. Rule of thumb used is
“minimum one (1) thread exposed after • 1/4 - 20 # 7
torquing or wrench tight installation”. • 10-32 # 21
• Double nut - installation of all-threaded bolt • 10-24 # 25
rod(s) used for supports through open raceway • 8-32 # 29
channel(s) should have a “second” nut. Use of • 6-32 # 36
a second nut for open channel applications • 4-40 # 43
allows the channel to be adjusted vertically
without reworking the entire rod. Double nuts Also, associated with screws are “tap sets” to
are also used in some steel column or framing perform a “drill and tap”. To successfully perform a
applications. “drill and tap” the tap set and drill (bit) must
• Install a square flat “spacer” washer(s) behind correspond directly to the screw type and threads
boxes that are mounted directly on walls (e.g. fine or coarse) not just the threads per-inch.
(moisture barrier).
• Avoid using an excessive number of spacer
washers (rule of thumb is two).
• Use lock washers in combination with a flat
washers.
• Avoid using “hex head” bolts or nuts where
cable(s) could get “snagged” or hung up thereby
ripping the outer jacket. Use “slotted round
head” bolts for installation of ground cable
clamps or for tray joiner fittings.

Rev. 0 Electrical Handbook 19-12

 Bechtel Corporation 1997. 11/26/97