Our Pipe Fill Calculator has quickly become one of the most popular tools in Sparky’s CircKit — and we’re taking it to the next level. One of the most requested features has arrived: support for multiple insulation types in a single calculation.
But that’s just the beginning.
The updated tool features our new step-based interface, following the same intuitive flow used in our Hazardous Locations, Transformers, and Motors tools. When you open the calculator, you’ll first choose between the Basic (classic) interface or the new Advanced interface. For this walkthrough, we’ll focus on the Advanced mode — the Basic mode remains unchanged, except for inline derating, for those who prefer simplicity.
As of right now, this is only available on iOS, but will be available to Android users in the coming months.
Step 1: Select Conduit Type and Ambient Temperature
Start by choosing your conduit type (EMT, PVC, Rigid, etc.). Next, select the ambient temperature for your installation. This ensures accurate derating when adding conductors in the following step.
Step 2: Add Insulation Types
You’ll then be prompted to add all insulation types that will be pulled into the conduit.
Step 3: Add and Adjust Wires
Once you’ve selected your insulation types, you’ll see them listed on the next screen.
Tapping an insulation name expands a dropdown menu of all available wire sizes (for example, T90 Solid supports 14–10 AWG, while T90 Stranded supports 14 AWG–1000 KCM).
Use the +/- buttons to add or remove wires. As you build your run, Sparky’s CircKit automatically derates the ampacities using Table 5, accounting for both ambient temperature and wire count.
You can toggle between copper and aluminum by tapping the coloured circle beside each entry. To keep things consistent, the tool uses the 75 °C column of Tables 3 and 4. When finished, simply tap Next.
Step 4: Review Results
Your results screen displays the recommended conduit size along with fill percentages and colour indicators:
- Green — within code limits
- Orange — within 5% of the limit
- Red — over the limit
For example, running a single 750 KCM RW90 Stranded Unjacketed 600 V conductor through EMT will show:
- 1¼″ = Red (72%)
- 1½″ = Orange (52.75%)
- Larger sizes = Green
Sparky’s CircKit automatically adjusts the code limits based on the number of conductors — 53% for single, 30% for two, and 40% for three or more.
Step 5: Save and Reuse
You can tap the “Save as Note” icon to store any calculation for later, and even tag it to a job for quick access (stay tuned for more details in our next post).
After using this new workflow once, we’re confident you’ll never go back to pen-and-paper or any other calculator again.