SD in M & E Co-ordination Topic 6 Electrical System

G Cable Management Systems

1.1 Introduction

This section discusses the various types of methods that cables can be protected against
mechanical damages. It is because of the complexity and hazards involved in the
installation of cables in the many types of buildings and their surroundings, there are
quite a number of different types of cables and wiring systems in use. Each is designed
to meet and withstand the elements encountered and at the same time, fit in with the
overall building construction in terms of convenience and appearance.

1.2 Conduit System

• A conduit is a tube or pipe in which cables are run.

• The conduit replaces the PVC sheathing of the cables.

• Provide a mechanical protection for the insulation of the cables.

• Three types of conduit: metal, flexible (metal) and non-metallic (PVC). See
Figure 1.2 (a).

Figure 1.2 (a) various type of conduits system

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Points to note

i) The conduit system for each circuit of an installation must be completely erected
before any cables are drawn in.

ii) Conduit system must not be used as protective conductor.

iii) All conduits system must be properly supported. In the case of rigid PVC
conduits, allowance must also be made for longitudinal expansion.

iv) Supports for conduit system must be purpose made saddles or clamps as shown
in Figure 1.2 (b). The spacing between supports is as per recommended in
Appendix 11, CP5: 1988, Table 11 C.

Nominal size of Maximum distance between supports

conduit Rigid Metal Rigid Insulating Pliable
Horizontal Vertical Horizontal Vertical Horizontal Vertical
Mm m M m m m m
< 16 0.75 1.0 0.75 1.0 0.3 0.5
≥ 16 <2 5 1.75 2.0 1.5 1.75 0.4 0.6
≥ 25 < 40 2.0 2.25 1.75 2.0 0.6 0.8
≥ 40 2.25 2.5 2.0 2.0 0.8 1.0

TABLE 11 C Spacing of Supports for Conduits

Figure 1.2 (b) Types of Conduit Fixings

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v) When conduit is bent, the radius of the bent must not be less than 2.5 times the
outside diameter of the conduits. See Figure 1.2 (c). The bending radius may
have to be increased to allow for the bending radius of cables as specified in
Table 52 C, CP5:1988.

Figure 1.2 (c) Bending Radius of Conduit bends

Table 52C
Minimum Internal Radii of Bend in Cables for Fixed Wiring

Insulation Finish Overall diameter Factor to be applied to

Rubber or p.v.c.
(circular, or circular
stranded copper or
aluminium conductors)
overall diameter + of
cable to determine
minimum internal
radius of bend.
Non-armoured Not exceeding 10mm 3(2)*
Exceeding 10mm but 4(3)*
not exceeding 25mm

Exceeding 25mm 6
Armoured Any 6
P.V.C. Armoured or Non- Any 8
(solid aluminium or armoured
shaded copper
conductors)
Impregnated paper Lead sheath Any 12
Mineral Copper or Aluminium Any 6
sheath with or without
p.v.c covering
+
For flat cables the factor is to be applied to the major axis
* The figure in brackets relates to single-core circular conductors of stranded construction installed in
conduit, ducting or trunking.

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vi) Non-inspection solid conduit elbows or tees are allowed only at:

• locations at the end of a conduit immediately behind a luminaire, outlet box

or conduit fitting of the inspection type or

• not more than 500 mm from a fitting which will allow permanent access,
provided that the total run of conduit between 2 points of permanent access
is 10 m or less and there is not more than 1 right angle ( or 2 45°) bend in the
run in addition to the solid elbow. See Figure 1.2 (d).

Figure 1.2 (d) Illustration of the Limitation in the use of solid elbows

vii) The number of cables drawn into a conduit may be determined by selecting the
size of conduit using the tables shown in Appendix 12, CP5:1998.

viii) The ends of conduit must be reamed and entries to boxes and accessories must be
bushed in order to prevent damage to cables.

ix) Conductor carrying current has a magnetic field around it. The a.c. current causes
the field to change direction continually and the field will cut across any metal
close to it. As a result e.m.f. is induced in the metal and give rise to eddy currents
(heating) in that metal. Running another conductor close to the first with its
current flowing in the opposite direction will cancel out the fields. Hence, cables
of a.c. circuits installed in steel conduit should have all phases and neutral
bunched in the same conduit.

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x) Non-metallic conduits must not be installed where extremes of ambient

temperature are likely to occur.

xi) Drainage points should be provided at the lowest point of a metallic conduit
installation to allow moisture due to condensation to drain away.

xi) Where conduits pass through floors or walls the opening through which they pass
must be made good to the full thickness and to give the required degree of the
fire resistance. See Figure 1.2 (e).

Figure 1.2 (e) Cable passing through walls or floors

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1.3 Trunking System

• Trunking is used to accommodate a large number of small cables or to install

cables that are too large to be drawn into conduit.

• More accessible than the conduits system.

• The trunking can be classified in to two types. They are ordinary wiring trunking
and bus-duct trunking. The ordinary trunking system is available in either metal
or PVC. See Figure 1.3 (a).

Figure 1.3 (a) Various types of trunking system

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• There are 2 main types of busbar trunking, the overhead type used for
distribution in industrial area, and rising-main trunking. See Figure 1.3 (b).

Figure 1.3 (b) Various form of bus-duct trunking

Points to note

• Trunking may be secured direct to a surface or suspended by means of brackets.

See Figure 1.3 (c).

Figure 1.3 (c) Supports for trunking

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• Where trunking passes through floors, wall or ceilings a fire barrier must be
provided. Additionally fire internal barriers must be fitted within the trunking in
which cables or conductors are installed, where these pass through fire
compartment walls or floors. See Figure 1.3 (d).

Figure 1.3 (d) internal fire barrier to prevent the spread of fire

• Entry to trunking must be so placed as to prevent water from entering.

• The size of trunking may be determined from the guidance notes as outline in
Appendix 12, CP5:1998, or can be obtained by allowing a space factor of 45%.

• Trunking is not allowed to be used as a circuit protective conductor. However,

copper straps should be fitted across joints to ensure electrical earth continuity

• In multi-compartment trunking, segregation of circuits as required by CP5:1998

must be complied. Electrical circuits can be divided into 3 categories:

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Category 1: all low-voltage circuits and supplied directly from the mains
supply (other than fire alarm or emergency lighting circuits).

Category 2: Circuits at extra-low-voltage for telephone, radio or television,

sound distribution, intruder alarms, bell and call and data
transmission circuits, which are supplied from a safety source.
(Other than fire alarm or emergency lighting circuits)

Category 3: A fire alarm circuit or an emergency lighting circuit.

In trunking, all 3 categories may be run together provided that either:

 category 2 cables have the same thickness of insulation as

category 1 cables or are separated by a barrier, and category 3
cables are separated from these by a fire-resistant barrier; or

 as above, but excluding the fire-resistant barrier provided that the

alarm circuit is wired in micc cable.

• All conductors of busbar trunking must be identifiable.

• All phases and neutral (if any) of a.c. circuits must be contained in the same
metal trunking.

• Bus-duct system must be installed so that the conductors are inaccessible to

unauthorized persons.

• Bus-bars must be free to expand and contract with variations in temperature.

(Figure 1.3 (e)).

Figure 1.3 (e) Flexible copper strips to allow for expansion

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1.4 Under floor trunking and cable ducts

• In some large building under construction it is sometimes found practical and

economical to provide a network of cables ducts or trunking in the concrete
floor.

• Enable alterations to be carried out with ease as in commercial buildings where

there are changes of tenancy often.

• Different types of under floor trunking are available.

1.4.1 Under Floor Trunking

Trunking of this type is installed directly onto the structural slab of new
buildings, and screed is poured over it until it is completely submerged. Access is
obtained only at junction boxes or where the trunking rises up the wall to go to a
distribution board or join up with skirting trunking. Figure 1.4.1 (a)

Figure 1.4.1 (a) Under floor Duct Distribution System

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• When properly designed this distribution system is a good method for

distributing telephone cables

• Could be designed with total access or with junction box access.

• System with total access throughout its entire length to enable easy installation
and maintenance of cables is known as the trench duct system. Figure 1.4.1 (b)

Figure 1.4.1 (b) Trench duct system

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• Duct should extend into the telephone riser and link to the floor trench (Figure
1.4.1 (c) and 1.4.1 (d)

Figure 1.4.1 (c) Under floor duct extended to the telephone riser

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PLAN VIEW OF RISER DUCT

Figure1.4.1 (d) Floor trench in centre of riser

• Should be designed to enable access with little or no disruption to the tenants.

Access to the system should be from the floor it is designed to serve and not
from adjacent floor.

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• Should be designed with the main junction boxes along the common corridor
area or passageway. Figure 1.4.1 (e)

Figure 1.4.1 (e) Main junction boxes along common corridor area or passageway

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• Should be free from internal roughness, sharp edges, moisture and dirt.

• Should be provided with floor outlets to lead the telephone cables out of the
ducts. Figure 1.4.1 (f)

Figure 1.4.1 (f) Types of distribution ducts and outlets

• For an underfloor duct system with junction box access, the thickness of the
floor screed on top of the ducts should not exceed 40 mm for ease in carrying
out cabling work.

• The size of the underfloor duct should be such that the cross-sectional area of
all the cables accommodated within a duct does not exceed 30% of the cross-
sectional area of the duct.

• Underfloor duct should be made of either high impact rigid PVC or galvanized
metal or steel of welded construction and of sufficient thickness.
• The duct should have a minimum internal height of 25mm.

• Nylon draw wire should be provided in the duct between every adjacent
junction box.

• Junction boxes should be provided at all junctions and bends. The distance
between 2 junction boxes in a straight run should preferably not exceed 6 m
Figure 1.4.1 (g)

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Figure1.4.1 (g ) Junction boxes installed 6 m apart

• Junction box cover should be secured to the junction box by means of screws
or other acceptable means. Figure 1.4.1 (h)

Figure1.4.1 (h) Exploded view of junction box

• All junction boxes and telephone outlets should be readily accessible at all
times. Wall or partitions should not be constructed on the top of them.
Figure 1.4.1(i)

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Figure 1.4.1 (i) Partition sitting on junction box

• For carpeted floors, appropriate slits should be made on the carpet at all
junction boxes and floor outlets to enable access to the floor ducts. Figure
1.4.1 (j) illustrates one method of providing the access to the junction box for
carpeted floors.

Figure 1.4.1 (j) Access to junction box for carpeted floor.

1.4.2 Raised Floor Duct Distribution

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• A raised floor distribution system is a floor assembly superimposed upon an

existing floor. Cables are distributed in the space between the 2 floors. Figure
1.4.2 (a)

Figure 1.4.2 (a) Raised Floor System

• Usually used in computer rooms and offices with high number of telephones.

• The floor assembly consists of a series of square modules of steel plates or

panels resting upon pedestals. Figure 1.4.2 (b)

Figure1.4.2 (b) Pedestals

• The raised floor panels should be supported on pedestals that are of a height
sufficient to ensure a clear working space of at least 25mm below the floor panel.

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• Trunking or cable tray should be provided to segregate telephone cables from

electrical cables and cables of other services placed below the raised floor.
Figure 1.4.2 (c)

Figure 1.4.2 (c) Typical section of raised floor

1.4.3 Cellular Floor Distribution System

• A cellular floor distribution system serves as s structural floor as well as a system

for distributing telephone cables and cables of other services. Figure 1.4.3 shows
the different compartments of a cellular floor system.

• The cellular floor distribution system comprises two main components:

 Distribution Cells
These are mainly constructed of steel but concrete distribution calls can
also be used.

 Header duct or Trench header

These are used to link the distribution cells to the telephone riser.

• The system basically has two-level system with the distribution cells on the
lower level and header duct or trench header on the upper level.

• The layout of the distribution system and the design of the structural floor and its
supported members should be integrated.

• Header duct is installed on top of the distribution cell. It provides permanent and
ready access to distribution cells which run at right angle to it.

• Junction boxes are provided on the header duct.

• Since the header duct is the link between the distribution calls and the telephone
riser, it is important that adequate capacity be provided.

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• Trench header is a metallic trough that is flushed with the finished floor. It
provides permanent and ready access to distribution calls that run at right angles
to it.

• Trench header is equipped with removable steel cover plates for its entire length.

• If the trench has two or more compartments to distribute cables of different

services such as power and telecommunication, the segregation is maintained
throughout the trench.

• The main trench header or header duct should be installed along the common
corridor of the building and made accessible at all times.

• No partition shall be constructed on top of the trench header or the duct junction
box of the header duct.

Figure 1.4.3 Sectional view of a cellular floor system.

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1.5 Cable Tray

• Common use for supporting PVC/PVC, PVC/SWA/PVC or MICC cables.

• Cable tray consists of perforated metal channel which allow cables to be fastened
to it by means of cleats or cable ties. See Figure 1.5.

Figure 1.5 Cable tray

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Sectional view of a cellular floor system

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