🎉 Free launch period — every calculator, every feature unlocked, no account needed, through mid-November 2026. PDF reports carry a watermark for everyone during this period.
IEEE 118510 min read

Worked Example: Pulling Tension and Jam Ratio Through a 90° Conduit Bend

Tension and sidewall pressure both pass comfortably for this pull — but the jam ratio lands right inside the danger band, the one check that actually fails.

Scenario

Route50 ft straight, 50 ft straight, then a 90° bend of 2 ft radius
Cable weight3.3 lb/ft
Coefficient of friction0.35
Conduit ID4 in
Cable OD1.45 in
LimitsMax tension 5000 lbf, max sidewall pressure 300 lb/ft

Step-by-step calculation

Step 1: Accumulate tension across the first straight section

ΔT = f x w x L
0.35 x 3.3 x 50
T after segment 1 = 57.75 lbf

Step 2: Accumulate tension across the second straight section

Step 3: Apply the capstan equation through the 90° bend

T_out = T_in x e^(f x θ)
θ = 90° = 1.571 rad; T_out = 115.5 x e^(0.35 x 1.571)
Final tension = 200.1 lbf

Step 4: Compute sidewall bearing pressure at the bend

SWBP = T_out / bend radius
200.1 / 2
SWBP = 100.1 lb/ft

Step 5: Compute the jam ratio

Jam ratio = conduit ID / cable OD
4 / 1.45
Jam ratio = 2.76

Jam ratios between roughly 2.6 and 3.2 are the recognized danger band for three cables jamming against each other and the conduit wall.

Result summary

CheckRequirementActualStatus
Final pulling tension≤ 5000 lbf200.1 lbf✓ PASS
Sidewall bearing pressure≤ 300 lb/ft100.1 lb/ft✓ PASS
Jam ratioOutside 2.6–3.2 danger band2.76 — inside the danger band✗ FAIL
Tension and sidewall pressure both pass with large margins, but the jam ratio of 2.76 falls squarely inside the recognized 2.6–3.2 danger band — this pull needs a different conduit size (or a different cable configuration) even though the tension math looks fine.

Key insight: A pull can pass every tension-based check and still be a bad pull. Jam ratio is a purely geometric risk (three similarly-sized round objects wedging against a circular boundary) that has nothing to do with how much force is being applied — which is exactly why it's checked as a completely separate, independent criterion rather than folded into the tension limit.

Try it with your own numbers

Every input in this example is editable in the live calculator — free, no signup.

Open Cable Pulling Tension calculator →

Frequently asked questions

Why is 2.6–3.2 specifically the danger zone for jam ratio?

This range is where three same-size round cables lying inside a circular conduit can wedge tightly against each other and the conduit wall simultaneously — geometrically, ratios noticeably below 2.6 leave enough clearance to avoid a tight three-way wedge, and ratios above about 3.2 give the cables enough room to shift past each other rather than lock in place.

What fixes a jam-ratio failure?

Either increase the conduit size (pushing the ratio above roughly 3.2) or use a different cable configuration — for example, a single larger multiconductor cable instead of three separate single-conductor cables removes the three-cable jamming geometry entirely, since jam ratio specifically applies to the classic three-cable-in-round-conduit case.

More in Cables & Line Engineering

← Back to all worked examples