1 1/2" EMT has 1.610" inside and 2.036 in² of area, so the 40 % fill limit is 0.814 in². It holds 84 × 14, 61 × 12, 38 × 10, 22 × 8 or 16 × 6 AWG THHN. A 60 A EV run (two 6 AWG and a 10 AWG ground) fills it 6 %: it fits.
03 · Conduit fill · Chapter 9 Tables 1, 4 & 5
USE:
1 1/2" EMT · 2.6% FILL · PASS
4 conductors take 0.0532 in² of the 2.036 in² inside 1 1/2" EMT: 2.6 % against the 40 % allowed.
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| Actions | |||||
|---|---|---|---|---|---|
| 1.9 % | 0.7756 in² | 58 | 36 | ||
| 2.6 % | 0.7612 in² | 57 | 36 | ||
| 4.1 % | 0.7300 in² | 54 | 34 | ||
| 6.4 % | 0.6835 in² | 51 | 32 | ||
| 8.5 % | 0.6412 in² | 48 | 30 | ||
| 13.9 % | 0.5306 in² | 39 | 25 | ||
| 16.1 % | 0.4859 in² | 36 | 23 | ||
| 19.6 % | 0.4163 in² | 31 | 19 | ||
| 25.5 % | 0.2951 in² | 22 | 13 | ||
| 29.8 % | 0.2072 in² | 15 | 9 | ||
| 35.2 % | 0.0968 in² | 7 | 4 | ||
| 42.0 % over | over by 0.0400 in² | — | — | ||
| 2.0 % | 0.7745 in² | 58 | 36 | ||
| 6.0 % | 0.6919 in² | 52 | 32 | ||
| 3.3 % | 0.7479 in² | 56 | 35 | ||
| 4.6 % | 0.7213 in² | 54 | 34 | ||
| 6.1 % | 0.6901 in² | 51 | 32 | ||
| 8.4 % | 0.6436 in² | 48 | 30 | ||
| 10.6 % | 0.5990 in² | 45 | 28 |
gnd: Table 250.122 ground. 1 1/2" EMT allows 0.814 in² at 40 %.
05 / Field guide
1 1/2" EMT has 1.610" inside and 2.036 in² of area, so the 40 % fill limit is 0.814 in². It holds 84 × 14, 61 × 12, 38 × 10, 22 × 8 or 16 × 6 AWG THHN. A 60 A EV run (two 6 AWG and a 10 AWG ground) fills it 6 %: it fits.
1 1/2" EMT (Article 358) has 2.036 in² inside. One conductor may fill 53 % (1.079 in²), two 31 % (0.631 in²), three or more 40 % (0.814 in²). A nipple 24" or shorter may take 60 % (1.221 in²): 92 × 12 AWG.
fill % = Σ Table 5 areas ÷ 2.036 in²
1 1/2" EMT is 1.740" outside and 1.610" inside, a 0.065" wall; the steel is an equipment grounding path (250.118).
Secure 1 1/2" EMT within 3 ft of each box and support it at least every 10 ft (358.30). At 116 lb per 100 ft, each 10 ft span hangs 11.6 lb of pipe. A 60 A EV run leaves room for 52 more 12 AWG THHN; a 60 A subpanel feeder leaves room for 48.
For a mix, add the areas. Two 6 AWG and a 10 AWG ground (a 60 A EV run) take 0.1225 in², 6.0 %; three 3 AWG and an 8 AWG (a 100 A subpanel) take 0.3285 in², 16.1 %.
Questions
61 THHN conductors at the 40 % limit (0.814 in² ÷ 0.0133 in²); 61 current-carrying 12 AWG are derated to 35 % (310.15(C)(1)).
38 THHN, or 33 XHHW (thicker insulation, 0.0243 in² against 0.0211 in²).
Within 3 ft of every box or fitting and at least every 10 ft along the run (NEC 358.30): a 50 ft straight run takes 6 straps, a 100 ft run 11. Keep the bends between pull points to 360° or less (358.26).
Three 6 AWG THHN and a 10 AWG ground take 0.1732 in², 8.5 % of 2.036 in²: that fits the 40 % limit.
1.610 inch nominal (NEC Chapter 9 Table 4), 1.740 inch outside. Use the inside area, 2.036 in², for fill.
3/0 AWG THHN: three fit within 40 %.
EMT is the reference: 1 1/2" EMT has 2.036 in² inside.