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== == AC [armored cable] and MC [metal-clad cable] are "filled to the max" because they are manufactured [like everything else] under totally controlled conditions to just meet the mechanical requirements of production standards, without excess waste.

Cable "full" includes packing and protective material that electricians don't install in flexible metal conduit [FMC] - the raceway that looks like manufactured metal clad cable and armored cable - and air, which we do include. Remember that the metal sheath is WRAPPED on the conductors in a factory, under controlled conditions.

Cables are manufactured to closely engineered tolerances and must meet quality control tests in manufacture. The manufacturing standards must meet industry requirements and pass third-party testing for use standards.

Underwriters Laboratories (c) largely serves as the arbiter of quality in the American electrical industry.

On the other hand, field installations of conductors in conduits must allow for dirt, conductors that cross over each other during installation, variations in pulling conditions [big strong installer - little weak installer], yada, yada, yada ....

In the field, 40% is quite full enough, thanks...

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As always, if you are in doubt about what to do, the best advice anyone should give you is to call a licensed electrician to advise what work is needed.

Before you do any work yourself,

on electrical circuits, equipment or appliances,

always use a test meter to ensure the circuit is, in fact, de-energized.

IF YOU ARE NOT ALREADY SURE YOU CAN DO THIS JOB

SAFELY AND COMPETENTLY

REFER THIS WORK TO QUALIFIED PROFESSIONALS.

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Q: Why can pre-wired AC be filled to the max yet an empty MC can only be filled 40 percent?
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