Selecting the right flexible conduit system can be a tricky task. Rob Sprason, Technical Sales Manager from Atkore Flexicon outlines how to get it right.

The choice of which type of flexible conduit system to use for a particular application is an important one. It is vital that the solution you opt for not only protects all areas of the cabling but provides the appropriate levels of protection for its specific environment.

However, as every electrician knows, there is so much choice available that it can be a confusing decision. One of the biggest challenges for electrical installers and contractors is time. The requirement to move onto the next task quickly will often see electricians defaulting to products they know well and have used multiple times.

Although flexible conduit might look the same visually, with similar colours and profiles, material properties can differ significantly. There are numerous products available on the market, often for a lower cost than seemingly comparable alternatives. While it can be tempting to select based on previous installation experience or personal preference, this can be a false economy, so it is essential to verify all recommended performance criteria to avoid inadvertently reducing the level of safety and increasing risk.

So, what are some of the factors you need to consider—and how can you ensure that you get it right every time?

Ongoing development

Historically, conduits and conduit fittings were only available in metal, but, over time, the development of engineered plastics saw more flexible, corrosion and water-resistant solutions enter the market.

These solutions could withstand large temperature ranges, offered improved chemical and oil resistance, and enjoyed a high level of mechanical strength. As the market acceptance for these systems grew, so nylon (polyamide) became an increasingly important material. However, metallic and composite systems also remain in demand because of their excellent mechanical strength and EMC screening possibilities.

Get the specification right

Specifying cable protection based on one property alone can be a costly mistake and the full range of environmental factors should be considered. These can include exposure to extremes of temperature, UV radiation, harsh chemicals and the likelihood of water or dust ingress.

In addition, fire performance, compression strength and impact or abrasion resistance, risk of explosion or even the resistance to build up of bacteria could need to be considered.

Nylon, metal or composite?

Where fatigue life or impact resistance is important, installers should consider nylon polyamide (PA) corrugated flexible conduits, which can offer high impact strength and recovery if crushed, combined with excellent temperature performance.

Polypropylene and PVC conduit systems are available; however, both systems are inferior to nylon polyamide (PA) when it comes to fire performance, resistance to solvents and abrasion, as well as UV properties in external applications when exposed to the damaging effects of the sun.

With no exposed metallic content, non-metallic conduits do not rust or corrode when subjected to water, thus maintaining performance and appearance over time. In addition, it is worth considering labour and installation time. Non-metallic systems are often quicker to install than metallic options as they are easier and faster to cut. Non-metallic fittings will typically be one piece and simply push on and twist to secure. This makes them easier to handle as well as providing a lighter weight system.

For installations subject to increased UV exposure, it is important when specifying non-metallic and polymer-coated metal conduit to consider that ultraviolet (UV) radiation will naturally degrade any plastic materials. Failure could result in materials cracking, an increase in brittleness, reduced flexibility and lower impact strength, thus compromising the performance of the system or equipment.

Metallic flexible conduit typically has a higher level of crush resistance, high mechanical strength and can provide excellent EMC screening properties. Metallic systems are ideal for applications that require a very high compression or pull-off strength, or where there is the need to protect cables from exposure in hazardous environments. They also offer excellent performance for extremes of temperatures, both high and low – with uncoated options such as stainless steel offering a performance range from +600°C through to -100°C.

Composite products, such as plastic sheathing on metal conduits, metal over-braiding or metal threads on plastic fittings can also offer the ideal combination of light weight and high strength.

Retrofitting with ease

In existing applications, retrofitting cable protection has, traditionally, been a more complex task, with the installer required to pull existing cabling through the open end of a conduit system.

Conduit system manufacturers are therefore developing enhanced retrofit options to make it easier and quicker to install cable protection in existing applications, such as interlocking slit conduit. The construction allows existing cabling to be inserted laterally via a slit opening, enabling the installer to wrap a flexible conduit around the cables retrospectively with minimal disruption and without the cable being exposed.

This also has the added advantage of being able to protect pre-terminated cables with connectors or plugs, which are too big to pull through a conduit system.

It is also important to consider the cable routing. Traditional slit conduit options can potentially expose cabling when bent or routed around corners, with reduced mechanical strength, whereas newer options can maintain continuous protection of the cabling irrespective of orientation or routing.

Specify a complete system

The specification process should also take into consideration the range of fittings available, especially where these can help reduce installation time.  Conventional fittings can take time to assemble and install, whereas newer designs feature innovations such as simple, one-piece push and twist conduit connection. These can offer significant time, simplicity and cost benefits, particularly where there are numerous cables to terminate.

Elsewhere, design improvements to help simplify cable management and routing over the lifetime of an installation are available. Junction boxes, such as Flexicon’s Connectabox, feature easy-to-connect entry points which can be used with non-metallic flexible conduit. These use push, twist and lock connectors to make a reliable connection in seconds, with the highest ingress protection of IP66, IP67, IP68 and IP69. This is without having to remove knockouts, drill holes, fit locknuts or even torque tighten any components.

In conclusion

When specifying the correct flexible conduit system, making the right choice is not merely a matter of convenience; it is essential for ensuring the reliability and efficiency of electrical installations. By embracing these principles, electricians can prioritise safety and performance and ensure the installation is fit for the future.

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With a focus on lighting up darkened areas and aiding inspections in confined spaces, Jefferson Tools introduces versatile and reliable LED lighting solutions for electricians.

Firstly, the Dual COB LED spotlight with floodlight function is well suited to comprehensive area illumination, ideal for both outdoor work and detailed inspections within dimly lit enclosures. Equipped with a COB LED bulb and a 220° rotating floodlight, this tool provides versatile lighting options complemented by its durability rated at IPX-4 and multifunctionality, including power bank capabilities.

The pocket-sized 300-lumen work light and 1,000 Lumens COB LED rechargeable inspection lamp are powerful solutions designed to illuminate confined spaces for detailed evaluations of electrical cupboards and other enclosed areas. They offer easy portability and long-lasting use.

Additionally, the 800-lumen work light with magnetic charging base stands ready to support demanding tasks. With its high-quality LED, adjustable tilt, and robust construction, it’s the go-to tool for electricians seeking reliable, heavy-duty lighting solutions. It is also rated IK07 for impact and IP65 for ingress protection.

For more information, click here

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Martindale Electric has launched the Drummond MTL15 test lamp and MTL15PD-S Kit which includes a test lamp and proving kit.

The new test lamp extends the application areas for Drummond test lamps to higher voltage installations. With AC/DC voltage indication thresholds of 50, 230, 400, and 690V plus a 1000V CAT IV safety rating, the test lamp is the ideal solution for proving dead in all installation categories.

Ensuring reliable indication of hazardous voltages, the new test lamp does not require batteries and has no ranges or switches. It is compatible with six existing interchangeable test probes accessories to aid safe and easy measurement in all application types – particularly where access is restricted. In addition to the two standard 62mm straight probes, a 62mm angle probe is also included.

The new kit encompasses the test lamp and proving device, all housed within the combination carry case which provides the simplest solution for implementing safe isolation practices onsite, in accordance with the Electricity at Work Regulations. For convenience and to save time, the proving unit can be used without having to remove it from the case. The PD690S voltage and power output is matched to the test lamp to illuminate all voltage bands and prove it is functioning correctly.

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HiKOKI Power Tools has launched the new Multitool, a great addition to any toolkit to elevate your work.

A master of adaptability, the Multitool accepts both Starlock and OIS blades with a tool-free blade exchange system. The swift swap capability allows for easy transition between accessories. The Multitool’s lightweight build and ergonomic grip mean you can navigate tight corners or stubborn jobs without sacrificing comfort or control.

The Multitool features HiKOKI’s UVP anti-vibration technology to ensure smooth operation while keeping vibrations to a minimum. Its compact control and ergonomic design make it ideal for hard-to-reach areas, ensuring intricate tasks in confined spaces can be tackled with precision.

Additionally, its low vibration body makes it comfortable to use, especially during extended run times. Adding to its user-friendly design is an integrated LED light, improving visibility in poorly lit areas.

Operating at a 3.6° oscillation angle and offering a no-load speed range of 6,000-20,000/min, the Multitool is adept at everything from cutting and scraping to sanding. It has an overall length of 327mm, a weight of 1.2kg (excluding the battery) and is backed up with three and five year warranties.

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Schneider Electric has developed the first of its kind, a modular circuit protection range tailored for the UK market – Acti9 Active.

Schneider Electric’s innovative solution has revolutionised the future of electrical installations across higher risk residential buildings, HMO’s, Office Buildings and care homes, catering to the evolving sustainable needs of electricians, facilities managers and design firms. Compliant with the Acti9 Isopar P distribution board, Acti9 Active is a scalable, modular circuit protection that builds with your business.

The all-in-one circuit protection device is known for its cutting-edge technology. Integrating residual current device (RCD), miniature circuit breaker (MCB), AFDD, and over-voltage protection, Acti9 Active delivers an exceptional level of protection that has been designed to meet the ever-growing needs of modern enterprises. With this product offer, Schneider Electric underlines the company’s commitment to supplying sustainable and energy efficient solutions to the electrical infrastructure sectors.

Acit9 has been a key player in supporting SMEs on their sustainability journey since its launch in 2012. Now, over a decade later, Acti9 Active has been developed with even more eco-friendly features. The modular upgrade includes energy efficient components that reduce environmental impact during the manufacturing process, but also through to the end-of-life recyclability. By opting for Acti9 Active, businesses can significantly contribute to their green initiatives, while supporting top-level electrical safety and distribution.

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Unicrimp has recently extended its comprehensive range of Q-Crimp accessories with the addition of three new Trade Tubs.

Comprising a variety of essential fixings and clips, the new tubs offer reliability and versatility to the installer and are ideal for any job – big or small.

These robust new tradesman tubs feature a resealable plastic lid and carry handle, and the tub itself is manufactured from recycled material.

The First Fix Kit Tub includes 400 x red wall plugs, 400 x 8×1 ½ screws and 100 x 20mm open grommets – bringing together all the elements in one handy tub to make back box essential installs that much easier for the contractor.

The Fire Alarm Installer Kit comprises 200 x Red 28 LSF P clips, 200 x red 32 LSF P clips and 100 x red 302 LSF saddle clips which are designed for use on mineral insulated or soft skin fire cables. They are manufactured from copper and are LSF powder coated.  They have been tested and approved to meet the requirements of BS476 Pt.6 and BS476 Pt.7 and they are designed to assist the installation of fire cable to meet the requirements of BS 5839-1:2027.

For additional support with projects, the Multipurpose Q-Fire Tub combines 70 x 25mm, 20 x 40mm and 10 x 50mm fire clips, 100 x 8×1 1/2 screws and 100 x red wall plugs. The various fire-rated clips sizes are suitable to be fixed to substrates or in PVC trunkings. They are 18th Edition compliant.  521.10.202 wiring regulations stipulate that cable support systems must be constructed with materials that will withstand premature collapse.

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THORNeco has announce the latest update to its Anna recessed LED panel. Designed with precision and engineered for excellence, the Anna recessed LED panel redefines workspace lighting with its exceptional quality, low glare, and fantastic energy efficiency.

The highly versatile Anna recessed LED panel comes equipped with the VARIO feature, which allows a choice of colour temperature using the easily accessible integrated CCT switch and the FLEX feature which allows for effortless adjustment of lumen output with just the flick of a switch.

Ideal for retrofit projects, this panel is a 1:1 replacement for 4 x 14 W T5 or 4 x 18 W T8 fluorescent panels, so it is possible to upgrade lighting without the hassle of major installations.

With UGR<19, Anna offers gentle, soft, and glare-free lighting ensuring a comfortable and productive workspace. While the efficacy up to 125 lm/W saves energy and reduces operational costs, making it an environmentally and economically sound choice.

Thanks to its integrated connector, Installers can save time and money with the panel’s easy, quick, and tool-free installation. The four pole push terminal accommodates up to 2.5mm2 wires, enabling loop-in loop-out wiring, and the detachable connector facilitates first fix wiring and high-voltage circuit testing while the luminaire is detached.

For more information, click here

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CMP Products recently welcomed regional managers and their sales teams from 14 different countries to its Cramlington headquarters for its annual global sales conference.

The company, which is part of the British Engines Group and actively sells its cable products across six continents, welcomed guests from the Americas, Canada, Singapore, Kazakhstan, Australia, South Africa, South Korea, France, German, Netherlands, India, Dubai, Saudi Arabia and the UK.

Vince Patterson, CEO of CMP Products, said: “As a business with a truly global reach we’re all very used to communicating and working remotely from one another, but the benefit of getting together for a week every year to discuss all aspects of the business simply can’t be underestimated.”

“We share everything from ideas and best practice through to new training techniques and company plans in a setting that enables everyone to provide valuable input into the ongoing development of the company.”

This year’s conference, which ran from February 26th to March 1st, included live demonstrations of a number of upcoming products; a factory tour to showcase new technology and machinery; and a review of global marketing activity for the year ahead. Meanwhile, regional teams provided presentations on the company’s five-year growth plans and other commercial activity. It was attended by 40 people, comprising all six regional sales managers and their full sales support teams.

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As the 2050 net-zero deadline becomes ever nearer there is increasing focus on the whole supply chain when it comes to more sustainable solutions and embodied energy. As a result, there is a rise in electricians asking wholesalers about the environmental credentials of products. Natasha King, Product Manager at Manrose, discusses these developments and how the company is committed to making ventilation sustainable.

Wholesalers are increasingly stocking more sustainable products on their shelves to meet customer demand. According to the latest study by NielsenIQ over half (55%) of UK consumers say living sustainably is important for society and they try to make sustainable choices when they can. Meanwhile, the Building Regulations are also driving a trend towards more sustainable products. Amended Part L (Conservation of Fuel & Power) and Part F (Means of Ventilation) of the Building Regulations published in 2021, required new homes in England to reduce carbon emissions by 30% from June 2022. The new Future Homes Standard looks set to reduce carbon emission by a further 75-80% for new homes built from 2025. As a result of these trends, electricians are looking for more sustainable products when they visit wholesalers as the whole supply chain comes under scrutiny. In response manufacturers are taking the subject seriously and working to provide sustainable solutions.

At Manrose the company is committed to making ventilation more sustainable and is undergoing a manufacturing transformation by moving from using virgin to recycled plastic. Improving sustainability is its main aim through continuously improving its processes to reduce waste throughout its products’ lifecycle and significantly increasing the use of recycled plastic from the circular economy in manufacturing its products.

Targets

To show its commitment to a net-zero carbon future, Manrose has set itself sustainability targets, each geared towards achieving significant improvements by the end of FY2025, which will significantly cut carbon emissions​. The company has transformed its manufacturing to reduce carbon by investing in R&D and manufacturing technology to develop ventilation products from recycled sources with 90% of the plastic used in its facilities to be from recycled sources by the end of FY2025, without compromising on quality or reliability. By investing in new, more efficient plant within its facilities, is also reducing the embodied carbon on the components it moulds. For example, an investment in a new injection moulding machine at its Reading site is 30% more energy efficient than the previous generation.

Transformation

The transformation from virgin to recycled plastic was a huge change for Manrose and a true innovation, marking a step-change in ventilation manufacturing. This involved defining new processes following significant R&D, this included extensive material and product trials and testing, CFD analysis, FEA analysis, and FMEA analysis. There was also investment in specialist manufacturing equipment and extrusion capability to increase ducting output and optimise PVC material usage.

Changing from using virgin plastic and moving to recycled sources required changes throughout the manufacturing process. This included a tooling redesign for the moulds. Tooling changes needed to ensure the impact and tensile strengths were retained and the material flowed into the moulds consistently, to ensure Manrose’s renowned reliability. The investment in specialist manufacturing equipment allowed Manrose to produce its ventilation products without affecting their function or performance.

The move to using recycled material was the next step for Manrose since previously the company had reduced its single-use plastic waste and produced ductwork from recycled plastic. But this latest innovation moves to the core product, ventilation, learning to work with recycled material, developing and manufacturing a robust product performing to the same high standards as those made from virgin material, meeting safety standards.

Product trends

So, what do these changes mean for wholesalers? As we approach 2025, there is set to be a further shift to more energy efficient ventilation, so it is wise for wholesalers to make the move to stock this option now. Manrose’s low watt ventilation products are energy efficient, therefore reducing energy usage. By 2025, 70% of Manrose’s sales will be in this category.

Wholesalers will also witness a swing towards ventilation products manufactured from recycled materials rather than virgin plastic. Manrose has already manufactured over 500,000 complete ventilation units where chassis and facias are produced from 100% recycled ABS. Manrose’s customers have always known the company for its reliability and now it is helping make ventilation more sustainable for them too.

Another change for wholesalers will be a move from stocking white to grey ducting made from recycled material. Manrose’s grey PVC ducting is made from 100% recycled PVC window frames that have been diverted from landfill. Meanwhile, plastics extracted from old fridges are used to create Manrose’s ducting components.

Saving carbon

Choosing low watt ventilation products can reduce a building’s carbon emissions but the next step after energy efficiency is to look at embodied energy. Wholesalers also need to consider the embodied carbon of products too. Embodied carbon is the carbon footprint of a product (inclusive of all the components/materials it contains) measured in kg CO2e. There is currently no legal definition of what it comprises, but this will change and wholesalers need to be aware of it now.

Another area to consider regarding reducing carbon is the use of recycled material. Not only does recycled plastic prevent the use of virgin materials, but it also has a lower embodied carbon, this can reduce embodied carbon by a third.

With the 2050 net-zero deadline approaching fast, now is the time for wholesalers to ensure they are up-to-date with the latest sustainable products so they have the ventilation customers want. Despite the Government appearing to slow down on its route to net-zero, the UK still has the legal target to meet. Wholesalers are a vital part of the supply chain and those that are ahead of the game will help meet the net-zero target and also benefit from customer demand.

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Darren Binns, National Sales Manager for Jefferson Tools, looks at why it is worth seeking out a ‘pro’ brand to save you money, time and aggravation in the long run.

The choice between professional and DIY tools can be a decision with far-reaching consequences. While cost can be a pivotal factor, the allure of ‘pro’ tools goes way beyond the initial expense – their many advantages can elevate these top-tier tools to a league of their own.

One of the most common arguments against professional tools is their higher initial cost compared to DIY alternatives. It’s true that professional tools often come with a heftier price tag and at first glance this can be a stumbling block for budget-conscious individuals. But while the upfront cost of professional tools may be higher, their longevity and performance can more than justify the investment. High-quality, professional tools are built to withstand the rigours of regular use, making them more durable and less likely to require replacement or repair. On the other hand, DIY tools, often designed for occasional use, may wear out quickly and necessitate frequent replacements, adding up to significant costs over time.

Precision and efficiency

When it comes to precision and efficiency, professional tools shine brightly. Their design, construction and materials are engineered to meet exacting standards, ensuring accuracy and performance.

Tailored to meet the exacting demands of professionals, these tools ensure consistent, top-tier results. Whether it’s the surgical precision of a table saw or the unyielding torque of a socket wrench, professional-grade tools elevate accuracy and reliability to new heights. This not only translates to superior quality work but also slashes downtime by minimising the need for adjustments and callbacks, ultimately supercharging productivity.

Durability and trust

A common frustration with DIY tools is their susceptibility to wear and tear, potentially leading to breakdowns and replacements that interrupt projects and drain resources. Professional tools on the other hand, are built for resilience and long-term service. This reliability is a key element that distinguishes professional tools from their DIY counterparts.

Professionals often rely on their tools for their livelihoods which makes the consistency and dependability of professional-grade tools paramount. Downtime can be a significant cost for professionals, but quality control measures, rigorous testing and robust manufacturing standards ensure that professional tools are dependable, helping to prevent delays in project completion which can result from tool malfunctions or breakdowns.

Top-tier pro tool manufacturers prioritise customer satisfaction, evident in their robust warranties and accessible support. This assurance not only instils confidence but also proves cost-effective over time. With reliable warranty coverage and responsive support, the expense of repairs and replacements dwindle, amplifying the overall worth of professional-grade tools.

Safety

Safety should never be compromised when it comes to tools, and pro tools offer several advantages in this regard. They are engineered with safety in mind, with features such as ergonomic designs, precise controls and enhanced safety mechanisms – professional tools often have more built-in safety features to help prevent accidents.

When it comes to tools, brand reputation holds weight. Established professional tool brands have earned their stripes through a legacy of excellence, known for quality, dependability, and top-notch performance. Opting for a trusted brand ensures your investment lives up to its promises, much like our commitment at Jefferson Tools.

While DIY tools may serve occasional needs or tight budgets, those who rely on their tools for professional work will find the investment in professional-grade tools to be a wise decision, ultimately enhancing their productivity and overall success. When it comes to tools, it’s not just about the cost; it’s about the value they bring to your work and your livelihood.

For more information on Jefferson Tools and to download the latest catalogue visit, click here

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