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Old 08-18-2016, 02:45 AM   #1
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Strange EMT Coupling, Old Rusty Conduit, and TW Wiring


Hello!

A few days ago I was going through some electrical conduit in a large building, a barn. The building has two sections, the older section with all the original conduit and wiring, and then a newer section with newer conduit and wiring. The original building was built sometime in the 40's and then had the original electrical added later, probably 60's. It is all old EMT with TW wiring. It is in pretty good shape. The newer back section was added in the 70's or 80's. They added a 150 foot length of 1" EMT with nine 10 AWG Stranded THHN conductors. This work looks to have been done very nicely when installed, except for one particular area. There is a very odd coupling about 10 feet into the 150 run from the front to back. Take a look.







I have never seen anything like this before. The coupler looks to be intentionally cut like that to fit exactly like that. The conductors inside still have room, but why would someone do this? Has anyone seen anything like this? As you can tell even from those pictures and more pictures below, the conduit is moderately rusty. It has not yet rusted through though. This tubing is the newer tubing from somewhere around the 70's. I bought some cold galvanizing spray to fix some of the moderate areas, but should some of the worse areas be replaced like these?





Believe it or not, this is the newer section. In the winter, the warm air inside creates condensation on the inside of the roof, causing the pipes to become soaked in water. Strangely enough, the oldest conduit is in the best of shape because it was not mounted on the beams like in the above pictures, rather horizontally on the support posts. If we do replace this EMT with more EMT, what should we do to it to prevent this kind of rusting?

One last thing, all of the older wiring in the older part of the barn is all TW wire, thousands of feet of it. It looks to be in really good condition actually. The PVC is not brittle or dry rotted and is still pliable. It still carries power just fine with no shorts anywhere. Is it fine to keep it or does it absolutely need to be replaced?

Thanks for reading this far, any advice on anything would be greatly appreciated!

Last edited by adam759; 08-18-2016 at 02:51 AM.
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Old 08-18-2016, 12:18 PM   #2
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Re: Strange EMT Coupling, Old Rusty Conduit, and TW Wiring


In the first pictures, its a EMT connector that has pulled apart. EMT set screw connector to be precise. Just pull the conduits apart a little and reinsert the pipe into the end its out of.
The second set of pictures looks like old EMT conduit and personally i see nothing wrong with it. The guy that bent the conduit did a decent job.
Although EMT is galvanized, it will still rust. Your pictures prove it.

All of your issues are esthetic. Rusted pipe and connectors and or couplings pulled apart.
All these are easy repairs and if it was my barn, they would remain.
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Old 08-18-2016, 12:24 PM   #3
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Re: Strange EMT Coupling, Old Rusty Conduit, and TW Wiring


I too think the EMT has slipped out of the coupling, but it looks lkeil it may have cracked the coupling.
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Answers based on the National Electrical Code. Local amendments may apply. Check with your local building officials.
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Old 08-18-2016, 06:40 PM   #4
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Re: Strange EMT Coupling, Old Rusty Conduit, and TW Wiring


replacing that coupling is gunna be a PITA
Having to splice all them wires
Are there any ways of fixing it without
having to re-splice all them wires ?
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Old 08-18-2016, 07:40 PM   #5
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Re: Strange EMT Coupling, Old Rusty Conduit, and TW Wiring


Well, about 10 feet down the run is a junction box. All the wires are spliced in there already, so it won't be that difficult of I have to remove the emt all together. Still, it looks to me physically inspecting it that it was cut with a saw to fit like that.

Anyways, would it help to spray cold galvanizing on the rusted EMT? And is TW wire still ok and up to code?
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Old 08-18-2016, 09:24 PM   #6
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Re: Strange EMT Coupling, Old Rusty Conduit, and TW Wiring


If the wiring looks in good condition leave it alone.
once the coupling is fixed and in place
spray some fish oil around the joint
that will stop rust dead in it's tracks.
smells awful, but works real well.


Last edited by dmxtothemax; 08-18-2016 at 09:27 PM.
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