BONDO TECHNICAL TRAINING INSTITUTE

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

ELECTRICAL POWER OPTION

MODULE ONE

TRUNKING SYSTEM INSTALLATION

ISCED UNIT CODE: 0713 251 24A

TVET CDACC UNIT CODE: ENG/CU/EI/CR/02/3/MA

UNIT DURATION: 100 HOURS

TRAINER: MR. BENARD OKOTH

Relationship to Occupational Standards

This unit addresses the Unit of Competency: Install Trunking system.

Unit Description
This unit covers competences required in installing trunking system. It involves
identifying trunking accessories, preparing trunking work pieces, mounting trunking
work pieces, installing electrical cables and accessories and perform test and inspection.

Summary of Learning Outcomes

By the end of this unit, the learner should be able to:

1. Identify trunking accessories

2. Prepare trunking work pieces
3. Mount trunking work pieces

4. Install electrical cables and accessories

5. Perform Test and Inspection

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 LEARNING OUTCOME 1

IDENTIFY TRUNKING ACCESSORIES

1.0 Theory Notes

 Workplace Safety

Importance of Workplace Safety

 Prevents accidents, injuries, and fatalities.

 Protects tools, equipment, and electrical installations from damage.  Ensures
compliance with BS 7671, EPRA, and KPLC standards.

Basic Workshop Rules

 Always wear appropriate PPE (safety boots, gloves, goggles, overalls).

 Keep work area clean and free from obstructions.
 Do not operate tools/machines without authorization.
 Report defective tools or equipment immediately.  No food or drinks inside the
workshop.

Types of PPE (Personal Protective Equipment)

 Safety helmet – protection from falling objects.

 Goggles – eye protection when cutting trunking.
 Gloves – protection from sharp edges.
 Overalls – body protection.
 Safety shoes – protection from heavy objects and electric shock.

 Types of Trunking

PVC Trunking

 Lightweight, easy to cut, corrosion resistant.

 Commonly used for residential and light commercial wiring.

Metallic Trunking

 Made of steel/aluminium.
 Provides mechanical protection and earthing continuity.  Suitable for industrial
installations.

Galvanized Iron (GI) Trunking

 Strong and durable.

 Resistant to corrosion.
 Used in harsh environments.

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 Trunking Sizes (Standard)

 16 mm × 16 mm – small wiring jobs (lighting).

 25 mm × 16 mm – small power/light combination.
 25 mm × 25 mm – power wiring with few conductors.
 40 mm × 25 mm – larger installations (sockets, cooker points).

 Trunking Accessories

 Sockets – 13A BS 1363 type commonly used in Kenya.

 Switches – one-way, two-way, intermediate.
 Lamp Holders – pendant, batten, or fluorescent.
 Joint Boxes – used for joining multiple conductors.
 Pattress Boxes – mounting for switches/sockets.
 Circuit Breakers (MCBs) – automatic overload/short-circuit protection.
 Consumer Control Unit (CCU) – main distribution point in a building.
 Cut-outs (1Φ) – KPLC service protection fuse.  Energy Meters (1Φ) –
measure electricity consumption.  Earth Rods – provide earthing system for
safety.
 Switch Fuse (1Φ) – combines switch and protective fuse.

 Housekeeping

 Clean workbench and tools after practicals.

 Return tools to storage.
 Collect and dispose of PVC/metal cuttings safely.

 Practical Activities

 Safety Demonstration

Instructor demonstrates proper PPE use.

Learners identify unsafe vs. safe workshop practices.

 Trunking Identification

Learners are given samples of PVC, metallic, and GI trunking to identify.

 Trunking Size Demonstration

Learners measure trunking samples (16×16, 25×16, 25×25, 40×25).

 Accessory Identification Exercise

Learners are provided with sockets, switches, lamp holders, etc., and asked to classify
each.

 Housekeeping Task

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Learners practice cleaning, collecting waste, and storing tools.

 Assessment Methods

A. Written Assessment (Sample Questions)

1. State three importance of workplace safety in electrical installation.

2. Differentiate between PVC and metallic trunking.
3. List four trunking sizes and state one application for each.
4. Match the accessory with its function:

a) CCU
b) Earth rod
c) Cut-out
d) Energy meter

B. Practical Assessment (Checklist)

 Correctly identifies trunking types (PVC, metallic, GI).

 Measures and states trunking sizes accurately.
 Identifies at least 8 trunking accessories correctly.  Demonstrates correct PPE
use.

C. Oral Assessment (Trainer Questions)

1. Why is PPE important when cutting metallic trunking?

2. How does a CCU differ from a switch fuse?
3. Explain why KPLC requires an earth rod in every installation.

LEARNING OUTCOME 2 PREPARE TRUNKING WORK

PIECES
2.0 Theory Notes

Electrical Tools and Equipment

 Cutting Tools

 Hacksaw – for cutting PVC/metallic trunking to length.

 Side cutters – for cutting wires and small accessories.
 Chisel – for trimming edges or wall chase corrections.

 Fastening Tools

 Screwdrivers (flat, star/Philips) – for fixing screws in sockets, pattress boxes.

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 Hammer – for driving nails, rawl plugs.
 Pliers – for gripping and tightening.
 Spanners – for tightening bolts and nuts.

 Measuring Tools

 Steel tape measure – for accurate measurement of trunking runs. 

Ruler – for marking shorter lengths.

 Marking Tools

 Pencil/marker – for indicating cutting or drilling points.

 Chalk line – for drawing straight lines over longer distances.

 Measuring Instruments

 Vernier calipers – for precision measurement of trunking thickness.  Spirit level

– for ensuring trunking runs are horizontal/vertical.

Measurements in Trunking Preparation

 Accuracy is vital to avoid material wastage.

 Always measure twice, cut once.
 Allow extra length (5–10 mm) for adjustments.

 Observe British Standard (BS 7671) spacing for supports (not more than 300 mm
for PVC trunking).

Housekeeping Activities

 General cleanliness of workplace.

 Return tools to toolboxes after use.
 Store unused trunking pieces for future use.  Collect waste cuttings for safe
disposal.

Practical Activities

 Tool Identification Exercise

Learners handle and identify cutting, fastening, measuring, and marking tools.

 Measuring Practice

Learners measure trunking length for a given drawing.

Practice marking cutting points with pencil and chalk line.

 Cutting Demonstration

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Instructor demonstrates correct hacksaw cutting technique.

Learners cut PVC and metallic trunking to specified dimensions.

 Edge Finishing

Learners file sharp edges after cutting metallic trunking.

 Housekeeping Practice

Learners clean workspace, return tools, and dispose of waste cuttings.

Assessment Methods

A. Written Assessment (Sample Questions)

1. List four cutting tools used in trunking preparation.

2. State two differences between measuring tools and measuring instruments.
3. Explain why it is important to measure twice before cutting once.
4. According to BS 7671, what is the maximum spacing allowed for PVC trunking
supports?

B. Practical Assessment (Checklist)

 Correctly identifies all trunking preparation tools.

 Accurately measures trunking runs using tape measure.
 Cuts trunking pieces to specified dimensions.
 Finishes cut edges smoothly and safely.  Demonstrates proper housekeeping.

C. Oral Assessment (Trainer Questions)

1. Why must sharp edges of metallic trunking be filed after cutting?

2. What tool is most suitable for drawing a long straight line across a wall?
3. How can poor housekeeping affect safety in the workshop?

LEARNING OUTCOME 3 MOUNT TRUNKING WORK PIECES

3.0 Theory Notes

 Concept of Trunking Mounting

Mounting involves fixing trunking runs on walls, ceilings, or floors to hold and
protect [Link] mounting ensures:

 Mechanical protection of cables.

 Safe routing without obstruction.
 Compliance with wiring standards (BS 7671, IEC).  Neat and professional
appearance.

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 Angles of Trunking Mounting

 Horizontal mounting – trunking fixed parallel to the floor/ceiling.

 Vertical mounting – trunking fixed from floor to ceiling (e.g., risers).
 Oblique mounting – trunking fixed at an angle, usually to avoid obstacles or
follow building design.

 Methods of Mounting Trunking

 Using screws and rawl plugs – for walls (brick, concrete).

 Using saddles/clips – to support round conduit sections.
 Welding or bolting – for metallic trunking in industrial setups.
 Adhesives (limited use) – for light PVC trunking in temporary installations.

 Steps in Trunking Mounting

 Study drawing/layout plan.

 Mark out the trunking path on wall/ceiling with chalk line.
 Drill fixing holes at required intervals.
 Fix trunking base securely to surface.
 Ensure alignment using spirit level.
 Fit trunking lid after cables are laid.

 Fixing Electrical Equipment on Trunking

 Pattress boxes for sockets, switches, and outlets are mounted directly onto
trunking or adjoining wall surface.
 Clamps and saddles hold equipment firmly.

 Height standards:

 Switches: 1.5 m above finished floor level (AFFL).

 Socket outlets: 300 mm AFFL (domestic), 400–450 mm (commercial).

 Safety Considerations in Mounting

 Use insulated tools when working near live circuits.

 Ensure trunking edges are filed smooth to prevent cable damage.  Avoid over-
tightening screws (may crack PVC trunking).
 Maintain proper spacing of fixings (≤ 300 mm for PVC, ≤ 600 mm for metallic).

 Practical Activities

 Wall Marking Exercise

Learners use chalk line and tape measure to mark out trunking runs.

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 Drilling and Fixing

Learners drill holes at required spacing, fix rawl plugs, and screw trunking base to
wall.

 Angle Practice

Learners practice mounting trunking horizontally, vertically, and obliquely.

 Equipment Fixing

Learners mount pattress boxes, socket outlets, and switches at recommended heights.

 Alignment Checking

Use spirit level to ensure all runs are straight and neatly installed.

Assessment Methods

 Written Assessment (Sample Questions)

1. List three angles at which trunking can be mounted.

2. State two methods used for fixing trunking to walls.
3. What is the recommended height for a socket outlet in domestic wiring?
4. Why should a spirit level be used during trunking mounting?

 Practical Assessment (Checklist)

 Correctly marks out trunking runs using chalk line.

 Drills fixing holes at correct intervals.  Fixes trunking base firmly and neatly.
 Mounts pattress boxes, sockets, and switches at correct heights.
 Ensures alignment with spirit level.
 Observes all safety precautions.

 Oral Assessment (Trainer Questions)

1. What could happen if trunking is not properly aligned?

2. Why should screws not be over-tightened when fixing PVC trunking?
3. Explain the importance of maintaining standard mounting heights for equipment.

LEARNING OUTCOME 4 INSTALL ELECTRICAL CABLES

AND ACCESSORIES

4.0 Theory Notes

 Cable Colour Code Identification (British Standard / Kenya – EPRA/KPLC)

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Single-phase wiring (240 V, 50 Hz):

 Live (Line): Brown/Red

 Neutral: Blue/Black
 Earth/Protective conductor: Green/Yellow

Three-phase wiring (400 V, 50 Hz – for extension into advanced work):

 L1 = Brown
 L2 = Black
 L3 = Grey
 Neutral = Blue
 Earth = Green/Yellow

 Common Cable Sizes and Uses

 1.0 mm² → Lighting circuits (small load).

 1.5 mm² → Standard lighting with multiple points.
 2.5 mm² → Socket outlets (ring and radial).
 4.0 mm² → Cooker units, shower heaters.
 6.0 mm² → Water heaters, heavy appliances.

 Cable Laying Techniques

 Single-core cables: Laid inside trunking, conduit, or clipped direct.

 Bending radius: Minimum 6× cable diameter (to avoid damage).
 Grouping: Avoid overcrowding trunking (heat buildup).  Securing: Clips,
saddles, or trunking covers.

 Single-Phase Intake Point Installation

Components at the service entry point:

 Cut-out (1ɸ): Fused disconnector provided by KPLC.

 Energy Meter (1ɸ): Records consumption.
 Consumer Control Unit (CCU) / Distribution Board: Holds MCBs and RCDs.
 Earth Rod & Earth Conductor: For earthing system.  Switch Fuse (1ɸ): For
main isolation and protection.

Diagram: Single-phase intake showing cut-out → meter → CCU → final circuits.

 Electrical Final Circuits Installation

Lighting Circuits

 One-way Switching: One switch controls one lamp.

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 Diagram : Switch (L) → Lamp → Neutral.

 Two-way Switching: Two switches control one lamp (e.g., staircase).Two SPDT
switches interconnected, lamp at output.

 Intermediate Switching: Three or more switches control one lamp (e.g., long
corridor).Two-way switches at ends, intermediate switch in between.

 Looping-in Methods:

At ceiling rose, at joint box, or at switch.

Ensures fewer joints and easier fault finding.

 Power Circuits

Radial Circuit: Cables run from distribution board to sockets sequentially.

 Used in small installations.

 Cable size: 2.5 mm² (fused at 20 A).
 Diagram 4.5: CCU → sockets (linearly).

Ring Circuit: Cables form a loop from the CCU and back again.

 Used in domestic/commercial setups.

 Cable size: 2.5 mm² (fused at 32 A).
 Advantage: Shares load across two paths.

Diagram : CCU → sockets → return to CCU.

Cooker Units: Heavy-duty circuit, usually 4.0–6.0 mm² cable, controlled by cooker
switch.

Water Heaters: Dedicated radial circuit, 4.0–6.0 mm², with isolating switch.

 Safety Precautions During Installation 

Always isolate supply before working.

 Use proper PPE (gloves, goggles, insulated tools).

 Test cables for continuity and insulation resistance before energizing.
 Avoid sharp bends, overheating, or overloading.
 Keep proper circuit identification (labels on DB/CCU).

 Practical Activities

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Cable Identification Exercise

Learners identify different cable sizes and colour codes.

Trunking Cable Laying

Learners lay single-core cables into trunking, observing bend radius and neat
arrangement.

Single-phase Intake Simulation

Assemble a demonstration board with cut-out, meter (dummy), CCU, earth rod
simulation.

Lighting Circuits Practice Wire

and test:

 One-way switch and lamp.

 Two-way staircase control.
 Intermediate (3-point control).

Power Circuits Practice

 Construct a radial socket circuit.

 Construct a ring final circuit.
 Install a cooker unit and water heater circuit.

Housekeeping Exercise

Students clean and restore work area, properly store tools and cables.

3.0 Assessment Methods

A. Written Assessment (Sample Questions)

1. State the colour code for live, neutral, and earth conductors in single-phase
wiring.
2. What is the main advantage of a ring circuit over a radial circuit?
3. Name two looping-in methods used in lighting circuits.
4. Draw a schematic of a two-way switching circuit.
5. List the components of a single-phase intake point.
B. Practical Assessment (Checklist)

 Correctly identifies cable sizes and colour codes.

 Neatly lays cables in trunking with correct bend radius.
 Assembles intake point with correct sequence (cut-out → meter → CCU).
 Successfully wires one-way, two-way, and intermediate circuits.

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 Demonstrates radial and ring circuits with proper protection devices.  Observes
all safety precautions and PPE use.

C. Oral Assessment (Trainer Questions)

1. Why is it dangerous to overcrowd cables in trunking?

2. Explain why the earth conductor must never be omitted.
3. What would happen if live and neutral conductors were reversed at a socket?
4. Why is a cooker circuit installed with larger cable sizes compared to lighting?

LEARNING OUTCOME 5

PERFORM TEST AND INSPECTION

5.0 Theory Notes

 Purpose of Testing and Inspection

 Ensure safety before energizing the installation.

 Confirm installation complies with BS 7671, EPRA, and KPLC regulations.
 Detect and correct wiring faults (short circuits, reversed polarity, open circuits). 
Provide documentation for certification and handover.

 Visual Inspection

Before performing electrical tests, check for:

 Correct trunking installation (neat, no damage).

 Proper cable terminations (tight, no exposed copper).
 Correct polarity (live to switches, neutral to lamps).
 Adequate circuit protection devices (MCBs, RCDs).
 Presence of earth continuity (earthing connected).
 Labels and identification of circuits at CCU/DB.  Compliance with standard
mounting heights.

 Electrical Tests

Continuity Test

Ensures all conductors are continuous without breaks.

Especially important for:

 Protective earth (CPC) conductors.  Ring final circuits.

Instrument: Low-resistance ohmmeter / continuity tester.

Polarity Test

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Confirms that live conductors are correctly connected to switches and fuses, and
neutrals to the return paths.

Example: Switch must break the live, not the neutral.

Instrument: Test lamp, multimeter, or continuity tester.

Ring Test (for Ring Final Circuits)

Ensures the two ends of the ring are correctly connected back to the distribution board.

Steps:

 Disconnect ring conductors at CCU.

 Test continuity of line, neutral, and earth loops.
 Cross-connect and check end-to-end resistances.  Confirms no open ends in the
ring.

(Optional for advanced learners) Insulation Resistance Test

Ensures insulation between conductors is sound.

 Uses a megger (500 V DC).

 Minimum acceptable value: 1 MΩ.

 Safety During Testing

 Always isolate installation before testing.

 Discharge capacitors before insulation resistance test.
 Use test lamps/multimeters safely (check instrument ratings).
 Ensure proper PPE.
 Never energize a circuit until all tests are passed.

 Practical Activities

 Visual Inspection Exercise

Students inspect a sample trunking installation and record observations.

 Continuity Test

Use a continuity tester to check a lighting circuit and a socket circuit.

 Polarity Test

Wire a simple one-way switch and lamp, then confirm correct polarity.

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 Ring Circuit Test

Construct a ring final circuit on a board and perform end-to-end ring continuity
checks.

 (Optional Advanced) Insulation Resistance Test

Demonstration with a megger on a short test rig.

Assessment Methods

A. Written Assessment (Sample Questions)

1. State two reasons why testing and inspection are important.

2. What instrument is used for a continuity test?
3. Why must the switch always be connected in the live conductor?
4. What is the minimum insulation resistance value recommended for wiring?
5. Explain the main difference between a ring test and a continuity test.

B. Practical Assessment (Checklist)

 Conducts a proper visual inspection and identifies faults.

 Performs continuity test using correct instrument.
 Carries out polarity test and interprets results.
 Correctly tests a ring circuit for continuity.
 Observes all safety precautions during testing.

C. Oral Assessment (Trainer Questions)

1. What could happen if polarity is reversed at a lamp holder?

2. Why is continuity of earth conductors critical?
3. How can you tell if a ring circuit has an open end?
4. Why must insulation resistance be measured at 500 V and not lower?

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 APPENDIX

Lesson Plan Matrix

Learning Content Training
Outcome Summary Methods Tools/Resources
Hours Assessment

1. Identify 10 Safety, Lecture, PPE, Written, oral,

trunking demo, trunking practical
trunking
accessories types & sizes, practical samples, tools
accessories

2. Prepare 10 Tools, Demo, Cutting/fastening Written, oral,

trunking measurement, practice tools, measuringpractical
work preparation instruments
pieces

3. Mount 30 Marking, Demo, Trunking, fixings, Written, oral,

trunking angles, guided drill, spirit level practical
work mounting, practice
pieces housekeeping

4. Install 40 Colour codes, Lecture, Cables, CCU, Written, oral,

electrical cable sizes, demo, sockets, switches, practical
cables & cable laying, hands-on distribution boards
accessories final circuits

5. Test and 10
Visual Demo, Tester, multimeter, Written, oral,
Inspection
inspection, practice, insulation tester practical,
continuity, project (Megger) project
polarity, ring
test

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