Tips or tools to running 44 circuits through overhead square duct with turns?

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Does anyone tips or tools to running 44 circuits through overhead square duct with 2 or 3 turns? I'm an engineer and a want-to-be electrician.
I did this a few years back--when I was very young-- and even then it wasn't easy. The wire would get skinned by the 5" metal square duct ribs and we would have to re-run the circuits.

Do they sell any special cuffs or sleeves to make pulling the conductors easier?

I'm definitely not a skilled electrician but the last time I did a 100 foot conduit run and ran 4 circuits, I unraveled the wire from the spools and took the twelve conductors and tied them between two trucks and took all the slack and kinks out of them to make a nice and smooth and straight bundle. Maybe it was my imagination, but I thought it helped.
 
you may be able to find a small roller wheel that you could mount on those inside corners, when I have had to navigate them in buildings, not in ductwork but sharp corners, I take an appropriately-sized piece of PVC conduit, cut 1/4 out of it lengthwise, then attach it to the corner in question
 
Wireways are intended to have the conductors laid in, not pulled in.
Metal Wireways. Sheet metal troughs with hinged or removable covers for housing and protecting electrical wires and cable and in which conductors are laid in place after the raceway has been installed as a complete system.
Click to expand...
 
Also 44 circuits will require that the ampacity of the conductors be adjusted to 35% of the value shown in Table 310.15(B)(16).
 
would it make more sense to put a pnl at the terminus of the duct and just run a feeder to it?
and route the 44 ckts from it
 
I haven't done that in awhile but we used to wrap ribs with cardboard & duct tape, same with outer edges. THHN is a must for this kind of pull & fortunately it is the most common wire today. TW would be ripped to shreds.

Your bundling is good too. I've done similar, taping every 2-3 feet, then remove tape after getting into duct or as it goes into a conduit. Plenty of wire lube helps too.

A large Greenlee pulley at the feed point would help too.
 
The total run is 80' not 100'-- my mistake
44 circuits = 132 conductors = 10,560 feet of wire (80 foot run)=200 pounds of wire

Someone said that wire is usually placed in trays, not pulled, and I guess that person is right. I have four ladders along the run at key points, bit some pulling is necessary.

Cardboard at the corners and ribs is a great idea. I saw plastic sleeves on the internet somewhere but they were for large conduits.

The big pinch point is getting them into the Panels. There's a 6" round conduit opening at each panel and they are already pretty clogged. Its a set of big panels and it already looks like the tags are going to come off the conductors when we pull them through, so maybe we have to pull each conductor through that opening individually so we can track it.

Problem is when you have too many people involved, you actually have more chance of making a mistake. I think four people at most would be best.

Can a get a link to the Greenlee pulley?

Having a big feeder is a good idea but transitioning to small 12 AWG conductors involves--more panels!
 
Installer said:
The total run is 80' not 100'-- my mistake
44 circuits = 132 conductors = 10,560 feet of wire (80 foot run)=200 pounds of wire
Click to expand...
What size conductors and what it the load current?

Someone said that wire is usually placed in trays, not pulled, and I guess that person is right. I have four ladders along the run at key points, bit some pulling is necessary. ...
Click to expand...
Is this a wireway (square duct) or cable tray (tray)? Single conductors smaller than 1/0 are not permitted in cable tray.
 
so, 44 ckts of h,n,g #12 on 20 A cb's I assume
total ampacity = 44 x 20 x 0.35 = 300 A

you could run
6 x 3/0
3 x 350

has to be cheaper
even buying a new panel
 
review don's posts (#4 & #8).
There are some key questions that need to be answers as he pointed out, with than many conductors the ampacity on #12 is 10.5 amps (assuming a 90° conductor)
 
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