In The Name of Allah, The Most Compassionate, The Most Merciful.ASO FAM SIL etal goed gLS gall pl SI LGtL5I 65 gag Jing 50 aU SII + Eo HES fiw yo dwoll Adil anol Laps Qilyy Ligydo ply SII ILI lol jilly lel! jJaso¥! lie goats agdl JS LI oat sgbly dg figs SpbaIl atsly peal ologlell rast JIB fio J alg ht} Gael igre fayae Leivoe Lied wild, Lelival ode alg, (0 9955 gly Latte Liojall LeSy Aabolg AI Laci gods glad bags gl puidily Logeaeg dyglaill lve! Ap HLs¥l opal) J 5S daly go Lgl ayad! copial fy ical JSLi gly ably Luly SI cs delaily byguane 125 pal Lilaiio deild yf Lda re pL tif olopliawe HUES, Lgliig SLI wulg5 debi obebiol yo SII oaks ASLagllg (Gell gan! 9 Ayiaell a ely tll [SL gH, Bech, ch BI) Lgtey oeLiasy! Lgelgil alas} ple A pwargll 45 jl) lg. Mp dLalS2l) de bi¥l os 219 Q,LEII slyaog sybian . oh Ly Sg gly ca Bg Bag tll po eh Lynas Il C”ANKA ‘ame SGS_ | susie 005Introduction Thanks to God and to our esteemed customers for their continuous support which has enabled us to come up with this fifth edition catalogue. We have done our best to accommodate their requirements and suggestions coupled with our long experience to introduce the information in the shortest and easiest way possible hoping to save user's time and effort. AL-ASHOURY, as it has always committed itself to keep leading the market, is now adding new facility equipped with the latest technology machines supported with highly trained staff to further improve the products, add new ones with much more capacity. Our list of products is no longer limited to Cable management system/ Pipe supports and metal framing systems/ but extends to a lot of requir- ements needed for power generation and telecom structures and transmission (Fencing, Structures, Towers, Poles ..... etc,) and almost any steel structure. No doubt, project designers, consultants and managers will find that the fully integrated and simple to install systems offered by AL-ASHOURY mean major savings in time, effort and money at all stages of the project. Cz ang SGS_ [ruin ‘005 os!Gentlemen, | have a great pleasure in introducing AL Ashoury Industries, one of the leading & foremost steel structural fabricators & manufacturers of Cable manage- ment system in Kingdom of Saudi Arabia. With two decades of proven track record. Al Ashoury products are well suited for use in power & telecom networks, power generating stations, large industrial & administration buildings, chemical plants., oil refineries, airport terminals, hospitals, Residential Apartments, hotels, etc. The Material used for our products is selected to meet all weather conditions. Our full integrated facility , our commitment to Quality have enabled us to provide a new industry definition which gives each system outstanding flexibility thus enabling it to be used in projects large & small and offers integrated solutions. Quality & customers service are the two most important aspects of our corporate policy. With ceaseless effort directed at continued innovation & product quality enhancement. Our technical Sales team will also provide you with rapid solution to your toughest application question with a strive to answer your entire request whether it be for a quote in reference to Catalogue or for special product. Your trust is an honour for us. We sincerely look forward to cooperate with you & having a mutual benefit. In view of the above we extend an invitation to visit our factories at your convenience to see our infrastructure and products. We are confident that your requirements will be fulfilled to your complete satisfaction Thanking You, For ALASHOURY GROUP OF COMPANIES AWORLD OF QUALITY & SUPPORT. ASHCO ASHPOWERS FABRICATION & GALVANIZING Cable Management Systems Power ,Telecom & Steel Industry TECHNOLOGIES LTD. & Building AccessoriesContents D Chapter One - General Information D Chapter Two - Cable Ladder D Chapter Three - Cable Tray D Chapter Four - Cable Trunking D Chapter Five - Channels The Factory started production since 1990 Catalogue fifth Edition - 2011 55-79 81-98 101-135Chapter One General InformationChapter One Contents D Reference Standards D Raw Materials specifications & properties D Stainless Steel D Aluminium D Mild Carbon Steel D Material Finish D Site Environment & Material Finish DAlAshoury Cable Support Systems D Hot Dip Galvanized DASTM A123 & ISO 1461 (BS729) D Hot Dip Galvanized - Item Service Life D Electrical Grounding D Cable Tray Dimensions design D Loading Consideration D Tolerance D Storage & Installation D Thermal Expansion D Support InstallationGeneral Info References: Al Ashoury Industry Cable Support System are manufactured to Comply with the Following Stan- dards: National Electrical Manufacturers Association (NEMA) » NEMA VE1: this standards publication provides technical requirements concerning the construction, testing, and performance of metal cable tray systems. The development of this publication is the result of many years of research, investigation, and experience by the members of the metal cable tray section of NEMA It has been developed through consultation among manufacturers, with users and engineering societies, to result in improved serviceability and safety of metal cable tray systems. » NEMA VE2: this standards publication is intended as a practical guide for the proper installation of cable tray system. Cable tray system design shall comply with NEC Article 392, NEMA VE1, and follow safe work practices as described . It is recommended that the work described be performed by qualified persons familiar with standard electrical construction practices, electrical equipment, and safety of electrical wiring systems. The publication addresses shipping, handling, storage, and installing cable tray systems. Information on maintenance and system modification is also provided. » The National Electrical Code (NEC). Publishes the standards for all types of electrical applications. Articles 392,250,800 etc which covers various aspects of cable tray systems. ‘The National Electrical Code, Article 392-7 allows for Cable Tray to be used as an equipment grounding conductor in commercial and industrial establishments. The tables in page 15 under Grounding section lists specific ampere ratings and the minimum cross sectional area requirements for each rating. » ASTM A123 and BS EN ISO 1461 : Standard Specification for Zinc (Hot-Dip Galvanized) Coatings covers the requirements for galvanizing by the hot-dip process on iron and steel products made from rolled, pressed, and forged shapes, castings, plates, bars, and strips.( see pages 17 )Cable Tray / Cable Ladder Selection: ‘Anumber of factors must be considered when selecting the proper cable tray system and planning the installation: » Material and Finish » Electrical Grounding » Electrical Continuity » Cable tray Dimensions » Loading consideration » Manufacturing Tolerances » Installation & Storage » Thermal Expansion and Contraction » Support & Installation Raw Materials i ) » Stainless Steel. » Aluminum. » Mild Steel — Black. » Mild Steel Galvanized. Stainless Steel Stainless steel is the name given to a group of corrosion resistant and high temperature steels. Their remarkable resistance to corrosion is due to a chromium-rich oxide film which forms on the surface. So stainless steel is defined as a steel alloy with a minimum of (11% ) Chromium content by mass. Stainless steel does not stain, corrode, or rust as easily as ordinary steel , It is also called corrosion-resistant steel or CRES . There are different grades and surface finishes of stainless steel to suit the environment the alloy must endure. Stainless steel is used where both the properties of steel and resistance to corrosion are required. ‘There are many grades of stainless steels. By varying the chemical composition, heat treating, and cold-working, a wide range of properties is achieved. Wrought stainless steels are designated by a three digit number. The numbering system is applied by the American Iron and Steel Institute (AISI). The symbols designating cast stainless steels are defined by the alloy casting institute (ACI). Corrosion resistant grades have designations with the prefix C; heat resistant grades have designa- tions with the prefix H. 200 Series The family series started from designated Number 200 to 300 they are non magnetic and have an austenitic structure. The basic alloy contains 17% chromium, 4% nickel and 7% manganese. Although these alloys are somewhat more resistant to the corrosion attack than the more common 300 series stainless steels.300 Series This group of alloys are non-magnetic and have an austenitic structure. The basic alloy contains 18% chromium and 8% nickel. These alloys are subject to crevice corrosion and pitting. They have ‘a range of incubation times in seawater ranging from essentially zero in the case of the free machin- ing grades, such as Type 303, to 6 months to 1 year for the best alloys, such as Type 316. They have been widely used in facilities with mixed results. If used in an application where chloride levels are low or where concentration cell corrosion has been prevented through design, they are likely to perform well. When chloride levels are high and where concentration cells can occur, the perfor- mance of these alloys is often poor. They must always be selected with care for a specific applica- tion and the effect of potential non-uniform attack, like pitting and crevice corrosion or stress corro- sion cracking, on system performance must be addressed. 400 Series Stainless Steels. This group of alloys are magnetic and have a martensitic structure. The basic alloy contains 11% chromium and 1% manganese. These alloys can be hardened by heat treatment but have poor resistance to corrosion. They are subject to both uniform and non-uniform attack in seawater. The incubation time for non-uniform corrosion attack in chloride containing environments is very short, often only hours or a few days. Unless protected, using these alloys in seawater or other environ- ments where they are susceptible to corrosion is not recommended. 600 Series Stainless Steels. This series of stainless steels is commonly referred to as “Precipitation Hardening’ stainless steels. These steels can be heat treated to high strength levels. They are subject to crevice corro- sion and pitting in chloride containing environments and are also subject to stress corrosion crack- ing and hydrogen embrittlement. The incubation time for crevice corrosion and pitting corrosion of stainless steel in seawater is relatively short, often only a few days. The incubation time for stress corrosion cracking can be very short, sometimes measured in hours. The use of these alloys in chloride containing environments is not normally recommended unless they are carefully selected, their heat treatment is carefully specified and controlled, and the effect of pitting and crevice corrosion is properly addressed. Grade EURONORM Content of Content of Max Content Min Yield Min Tensile Min. USA Chromium Nickel ofCarbon Strength Strength Elongation ASTM (Mpa) (Mpa) % 304 XSCrNi18-10 18 9 0.08 205 515 40 304L 18 9 0.03 170 485 40 316 EN10088 7 "1 0.08 205 515 40 316L — XSCrNi18-10 7 "1 0.03 170 485 40 Physical Properties : Density (8 kg /dm3) , Modulus of Elasticity (200KN/mm2) , Thermal conductivity (15 Wi(m*K) , Electrical Resistivity (0.75 Ohm*mm2/m). 304L & 316 L are the same of 304,316 respectively but modified for Welding.Aluminum ‘Aluminum is a soft, durable, lightweight, ductile and malleable metal with appearance ranging from silvery to dull gray, depending on the surface roughness. Aluminum is nonmagnetic and nonsparking Itis also insoluble in alcohol, though it can be soluble in water in certain forms. The yield strength of pure aluminum is 7-11 MPa, while aluminum alloys have yield strengths ranging from 200 MPa to 600 MPa. Aluminum density (2.7g/cm3) about one-third the density and stiffness of steel. It is easily machined, cast, drawn and extruded. Wrought alloys The International Alloy Designation System is the most widely accepted naming scheme for wrought alloys. Each alloy is given a four-digit number, where the first digit indicates the major alloying elements. Series (1000) for pure Aluminium (99%) , Series (2000) are alloyed with Copper , 3000 series are alloyed with manganese, 4000 series are alloyed with silicon. 5000 series are alloyed with magnesium. 6000 series are alloyed with magnesium and silicon, are easy to machine. 7000 series are alloyed with zinc, and can be precipitation hardened to the highest strengths of any aluminium alloy. 7000 series are alloyed with zinc, and can be precipitation hardened to the highest strengths of any aluminium alloy. ALUMINIUM 6063 T6 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. The standard control- ling its composition is maintained by The Aluminum Association. It has generally good mechanical properties and is heat treatable and weldable. It is similar to the British aluminium alloy HES. 6063 is mostly used in extruded shapes for architecture, particularly window frames, door frames, and roofs. It is typically produced with very smooth surfaces fit for anodizing T6 temper 6063 has an ultimate tensile strength of at least 30,000 psi (207 MPa) and yield strength of at least 25,000 psi (172 MPa). In thicknesses of 0.124-inch (3.1 mm) or less, it has elongation of 8% or more; in thicker sections, it has elongation of 10%. The four most common aluminium grades available as sheet metal are 1100-H14, 3003-H14, 5052- H32, and 6061-T6. Grade 1100-H14 is commercially pure aluminium, so it is highly chemical and weather resistant. It is ductile enough for deep drawing and weldable, but low strength. It is commonly used in chemical processing equipment, light reflectors, and jewelry. Grade 3003-H14 is stronger than 1100, while maintaining the same formability and low cost. It is corrosion resistant and weld able, Its often used in stampings, spun and drawn parts, mail boxes, cabinets, tanks, and fan blades Grade 5052-H32 is much stronger than 3003 while still maintaining good formability. It maintains high corrosion resistance and weld ability. Common applications include electronic chassis, tanks, and pressure vessels. Grade 6061-T6 is a common heat treatable structural aluminium alloy. It is weldable, corrosion resist- ant, and stronger than 5052, but not as formable. Note that it foses some of its strength when weldedMild Carbon Steel- Black Steel is an alloy of iron and carbon. It is produced in a two-stage process. First: ron ore is reduced or ‘smelted with coke and limestone in a blast furnace, producing molten iron which is either cast into pig iron or carried to the next stage as molten iron. In the second stage, known as steelmaking, impurities ‘such as sulfur, phosphorus, and excess carbon are removed and alloying elements such as manga- nese, nickel, chromium and vanadium are added to produce the exact steel required. Steel mills turn molten steel into blooms, ingots, slabs and sheet through casting, hot rolling and cold rolling Mild carbon steel. ASTM A386 steel is a mild-carbon steel with a very simple chemical ara structure. It is consists of 98 percent iron, 1.03 percent manga- ? a. nese, 0.25 to 0.29 percent carbon, 0.28 percent silicon, 0.20 percent copper and less than 0.10 percent phosphorous and sulfur. Its tensile strength is 58,000 to 79,800 psi, while its yield strength is 36,300 psi and its elongation at break of 20 percent and at 50mm. of 23 percent. The modulus of elasticity is at 29,000 ksi and a bulk modulus at 20,300 ksi. ASTM A36 is the most common type of steel alloy. Produced in a variety of forms, including bars, pipes, plates, sheets and various other structural shapes It is used for most building components, including columns, beams, decking and for other structural purposes. It can be riveted, bolted or welded through normal processes, such as, Arc, MIG and oxyacetylene welding Equivalent International norms: ASTM A 36 (USA) ; JIS G 3101 (Japan) ; EN 10025-2 (Euro Norm); DIN 17100 (Germany) ; BS 4360 (UK). ASTM A572 Grade 50, used in large-scale construction, is an extremely strong alloy with a yield strength of 65,000 psi, an allowable bending stress of 39,000 psi Equivalent International norms: ASTM A572 (USA) ; JIS G 3101 (Japan) ; EN 10025-2 (Euro Norm); DIN 17100 (Germany) ; BS 4360 (UK).Mild Steel - Pre-Galvanized Hot Dip Mill-Galvanized steel (ASTM-A-653-G90 CQ) is zinc coated by a hot dip process. Steel strip from a coil is fed through a continu- ous zinc coater which cleans, fluxes and coats the steel with molten zinc. After cooling, the steel is recoiled. The minimum coating of 27 microns Zinc thickness per sides,on both sides. Mill galvanized ladder is generally used indoors or in locations not exposed to the elements or corrosives. Standard Sheet Metal Gauge The sheet metal gauge (sometimes spelled gage) indicates the standard thickness of sheet metal for a specific material. For most materials, as the gauge number increases, the material thickness decreases. Rate of change in thickness Vs gauge number Standard sheet metal gauges Gauge Steel Galvanized steel Stainless steel Aluminum in (mm) in (mm) in (mm) in (mm) 10 0.1345 (3.42) 0.1382 (3.51) 0.1406 (3.57) 0.1019 (2.59) " 0.1196 (3.04) 0.1233 (3.13) 0.1250 (3.18) 0.0907 (2.30) 12 0.1046 (2.68) 0.1084 (2.75) 0.1094 (2.78) 0.0808 (2.05) 13 0.0897 (2.28) 0.0934 (2.37) 0.094 (2.4) 0.072 (1.8) 14 0.0747 (1.90) 0.0785 (1.99) 0.0781 (1.98) 0.0844 (1.63) 15 0.0673 (1.71) 0.0710 (1.80) 0.07 (1.8) 0.057 (1.4) 16 0.0598 (1.52) 0.0635 (1.61) 0.0625 (1.59) 0.0508 (1.29) 17 0.0538 (1.37) 0.0575 (1.46) 0.056 (1.4) 0.045 (1.1) 18 0.0478 (1.21) 0.0516 (1.31) 0.0500 (1.27) 0.0403 (1.02) 19 0.0418 (1.06) 0.0456 (1.16) 0.044 (1.1) 0.036 (0.91) 20 0.0359 (0.91) 0.0396 (1.01) 0.0375 (0.95) 0.0320 (0.81) 21 0.0329 (0.84) 0.0366 (0.93) 0.034 (0.86) 0.028 (0.71) 22 0.0299 (0.76) 0.0336 (0.85) 0.031 (0.79) 0.025 (0.64) 23 0.0269 (0.68) 0.0306 (0.78) 0.028 (0.71) 0.023 (0.58)Finish i). PVC Coating: Cable tray and supporting members can be furnished with PVC coating for special corrosive location. The PVC coating is a very effective corrosion barriers to the damaging effects of weather, salt spray, water, solvents, gasses, acids, and alkaline at moderate temperatures. ii), Powder Coating: Powder coating is the technique of applying as a free flowing, dry powder, the coating is typically applied electro statically and is then cured under heat to allow it to flow and form a continuous film. Powder coating produces a high specification coating which is relatively hard, abrasion resistant (depending on specification) and tough ili), Electro Galvanizing : ASTM B633 and BS 1706 Electro galvanized finish is mostly used in fixing parts like bolts, nuts, washers, and threaded rods. Electro-galvanized items are not ideal for use in open areas, but require dry areas. The texture of electro galvanized finish is smooth, bright, and highly metallic. Electrolytic technique is used for the coating process. iv). Hot Dip Galvanized After Fabrication (HDGAF) ASTM A123 and BS EN ISO 1461 » ASTM A123 and/ BS EN ISO 1461 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on lron and Steel Products : covers the requirements for galvanizing by the hot-dip process on iron and steel products made from rolled, pressed, and forged shapes, castings, plates, bars, and strips. It covers both un-fabricated products and fabricated products, for example, assembled steel products, structural steel fabrications, large tubes already bent or welded before galvanizing, and wire work fabricated from uncoated steel wire. This specification also covers steel forgings and iron castings incor- porated into pieces fabricated before galvanizing or which are too large to be centrifuged (or otherwise handled to remove excess galvanizing bath metal). (our galvanizing plant (Galvatec) is one of the largest plants in middle east see page 16). These specifications also includes the minimum coating thicknesses according to material category as well as finish and adherence requirements Fabricated products which are hot dip galvanized after fabrication (HDGAF), are thoroughly cleaned, fluxed and immersed in to a bath of molten zinc . Where a metallurgical process during which external surface composition of steel changes, there's a zinc diffusion into iron making an alloy, this type of coating is suitable for applications where protection from severe corrosion is required. This method results in complete zinc coverage and a thicker coating than pre-galvanized or electro-plated steelCorrosion Classification & Req juired Material Finish Protection The choice of surface treatment are made according to factors effecting the product in the surround- ing environment, as specified in the SFS-EN ISO 12944-2 standard. Corrosivity category C1 very low C2 low C3 medium 4 high Ch Very high (industrial) C5-M Very high (marine) Notes: Examples of typical environments in a temperate climate (informative only) Exterior Atmospheres with low Level of pollution. Mostly rural areas. Interior Heated building with clean atmospheres.e.g, office shops.schools, hotels. Unheated buildings where conden- sation may occur,e.g. warehouses, sport halls. Urban and industrial atmospheres, Production rooms with high humid. moderate Sulfur dioxide pollution ty and some air pollution, e.g, food Coastal areas with low salinity. Industrial areas and coastal areas with moderate salinity Industrial areas with high humidity and harsh atmosphere Coastal and offshore area with high salinity. ~ processing plants, laundries, breweries, dairies. Chemical plants, swimming pools, coastal ship — and boatyards. Building or areas with almost permanent condensation and with high pollution, Building or areas with almost permanent condensation and with high pollution, Surface Treatment required Hot galvanized sheet metal, or plastic coated sheet metal Hot galvanized sheet metal, or plastic coated sheet metal Hot galvanized after assembly. Hot galvanized after assembly, Hot galvanization and epoxy painting after assembly. Acid - proof steel. Surface treatment chosen case-by-case. Hot galvanization and epoxy painting after assembly. Acid - proof steel. Surface treatment chosen case-by-case, 1. The loss values used for the corrosivity categories are identical to those given in ISO 9223.In coastal areas in hot, humid zones, the mass or thickness losses can exceed the limits of category C5UM.Special precaution must therefore be taken when selecting protective paint systems for structures in such areas.1. Cable ladder and cable trays are intended only for supporting cables. 2. When cable ladders and other conduit products are installed, the load carrying capacity of brackets has to be observed. and care should be taken in order to see that there is sufficient strength in the fixtures and surface material. 3. Cable trays must not be used as ladders or walkiways. The manufacturer is not responsible for direct or indirect damages caused by inappropriate use of any of our products.0 Mis .GALVATEC - FABRICATION & GALVANIZING TECHNOLOGIES LTD. GALVATEC is our new, huge capacity galvanization Plant, was established in the Second Industrial City of Riyadh, created on a total area of 17,000sq m-and installed with the most modernized furnace of galvanizing bath of capacity 14.5 meter long x 1.6 meter width x 2.8 meter The Fundamental steps in galvanizing process are: 1-Surface Preparation Degreasing /Cleaning :A cleaning solution removes dirt, oil, grease, shop oil, and soluble markings. Pickling : Dilute solutions of hydrochloric acid removes surface rust and mill scale to provide a chemi- cally clean metallic surface. Fluxing : Steel is immersed in liquid flux (usually a zinc ammonium chloride solution) to remove oxides and to prevent oxidation prior to dipping into the bath of molten zinc. 2-Galvanizing The article is immersed in a bath of molten zinc between (435-455 C). During galvanizing, the zinc metallurgical bonds to the steel, creating a series of highly abrasion-resistant zinc-iron alloy layers, commonly topped by a layer of impact-resistant pure zinc. GALVATEC observes conformance to ASTMA123 class B2 BS EN ISO 1461 Equivalent to any other required International Standard As per customers specification.The hot dip galvanizing process are ruled by the following international standards: ASTM A 123 Table 1: Minimum Average Coating Thickness Grade by material Category All Specimens Tested Steel Thickness Range (Measured) in (mm) Material category 3/16to< 1/4 9 2 1/4 (<16) (4.6t0<3.2) (B2to4.810<6.4) (26.4) Structural Shapes and Plates 45, 65 vt) 85 100 Strips and Bars 45 65 75 85 100 Pipe and Tubing 45 45 ra 75 75 Wire 35 50 60 65 80 BS EN ISO 1461 — (formerly BS 729) Table 1: Coating minimum masses (related to Thicknesses) on samples that are not centrifuged. Local Coating (minimum) Mean Coating (minimum) Article & its thickness ae im ai um Steel 26 mm 505 70 610 85 Steel 2 3 mm to <6 mm 395 55. 505 70 Steel 2 1.5 mm to < 3mm 325 45, 395 55 Steel < 1.5mm. 250 35, 325 45 Castings = 6 mm 505 70 575 80 Castings < 6 mm 430 60 505 70 BS EN ISO 1461 - (formerly BS 729) For THREADS & HARDWARES Table 2: Coating minimum masses (related to Thicknesses) on samples that are centrifuged. | oo Local Coating (minimum) Mean Coating (minimum) Article & its thickness ae i oi 7 Articles with threads: 2 20 mm diameter 325 45 395 55 26mm to < 20 mm diameter 250 35, 325 45 <6 mm diameter 145 20 180 25 Other Articles ( including Castings): 23mm 325 45 395 55 <3mm 250 35, 325 45,Hot-dip galvanizing (HDG) is used to protect steel from corrosion in a variety of environments, including air, water, chemicals, and soil applications. Galvanized steel's performance in each of these applications is dependent upon a unique set of corrosion variables. The information in the below table what variables impact the coating’s performance and how long it will last in the given environment. Service Life Chart for Hot-dip Galvanized Coatings 2% 0 75 100125180175 200 200 Rural 250 2 urban : 2 150 Temperate Marine | 3 _ 7 losartely usta g 7 J Tropical Marine — 0 ° 0 1 2 3 4 3 6 7 8 Average Coating Thickness (microns top. mils bottom) “Service life is defined as the time to 5% rusting of the steel surface (Note: 1 mil - 1.8 oz / ft?) . Most commonly, hot-dip galvanized steel applications are in the atmosphere or open air. In atmospheric applications, hot-dip galvanized steel naturally exposed to wet and dry cycles which are crucial to the development of a series of films on the zinc surface known as the patina. The patina is stable and non-reactive unless exposed to aggressive chlorides or sulfides, and is a key component to galvanizing’s long life.Electrical Grounding As Per National Electrical code (NEC) Article 392-7 A. Metallic Cable Tray : Metallic Cable tray that support electrical conductors shall be grounded as required for conductor enclosures in Article 250. B. Steel or Aluminum Cable Trays Systems : Steel or Aluminum cable tray system shall be permitted to be used as equipment grounding conductors The following table shows the minimum cross sectional area of the metallic cable tray with respect to the max. Ampere rating , we can see the following » The steel cable tray (perforated , solid and ladders) shall not be used as equipment grounding conductor for circuits ground-fault protection above 600 Amperes. Aluminum cable trays shall not be used as equipment grounding conductors for circuits with ground fault protection above 2000 amperes. » The cross sectional area in the below table is the total cross sectional area of both side rails for ladder or trough cable trays , or the minimum cross sectional area of metal in channel cable trays or cable trays of one piece construction Table 392.7(B) . Metal Area requirements for Cable Trays used as equipment Grounding conductor. Maximum Fuse Ampere rating circuit breaker ampere trip setting, or circuit breaker protective relay, ampere trip Stee! Cable Trays Aluminum Cable Trays setting for Ground-Faultprotec- tion of any cable circuit in the Minimum Cross sectional Area of Metal Cable Tray system med ee me a 60 129 0.20 129 0.20 100 258 0.40 129 0.20 200 4515 0.70 129 0.20 400 645 4.00 258 0.40 600 967.5 4.500 258 0.40 1000 - - 387 0.60 1200 - - 647 4.00 1600 - - 967.5 1.50 2000 - - 1290 2.00b(7) = Bonding jumpers/Straps The net Electrical Resistance round the connections of the cable tray should not exceed 330 Q (micro-ohms). Electrical bonding straps are required where cable trays are joined by connec- tors which allow for movement, such as; vertical adjustable connectors, horizontal adjustable connectors, and expansion connectors. Proper grounding is also necessary where cable trays run parallel to each other, are stacked upon one another, and in other instances, where tray runs are discontinuous. Al Ashoury cable tray were subjected for electrical continuity test in King Saud University (KSU) the test results are as shown below. Test Results KING SAUD UNIVERSITY TESTScarom ca | Cable Tray Dimensions: To answer the question of what is the cable tray width and height to be used in my project application: As per NEC 392-9 The cable tray dimensions are controlled mainly by the following;- Cable Tray Capacity (Width): ‘Type of cables are: > Multi Conductor cables normally rated 2000 volts or less installed according to requirements of section 392-10 shall be distributed as fig (A). » Single Conductor cables normally rated 2000 volts or less installed according to require- ments of section 392-10 shall be distributed as fig (B). Control Multi-Conductor Cable —_600V Single Conductor Cable Applications for multi-conductor cables include computers, communications, instrumentation, sound, control, audio and data transmission. Each of these cables is designed to protect signal integrity under critical conditions by reducing hum, noise and crosstalk. a a A ain EH min fer eave lanpacty be Seman tom Boe BSTO3" Sonex. ro) EE roo)@ Cable Tray Cross Sectional Area & Height: Any mixture of cables in a cable ladder or ventilated through cable tray contains multiconductor, power, lightning, control and signal cables shall conform to as follows: i). Where all of the cables are smaller than no 4/0. » The sum of the cross sectional areas of all cables shall not exceed the maximum allowable cable fill area in column 1 of table 392-9 for appropriate cable tray width. ii), Where all cables are no 4/0 or larger. » The sum of diameters of all cables shall not exceed the cable tray width » The cables shall be installed in a single layer. iii). Where the cables are no 4/0 AWG or larger cables are installed in the same cable tray with cables smaller than 4/0 AWG, » The sum of the cross-sectional areas of all cables are smaller than no 4/0 shall not exceed the maxi- mum allowable fill area resulting from the computation in column 2 of table 392-9. » The cables shall be installed in a single layer and other cables shall be placed on them. » The sum of cross sectional areas of all cables at any cross section shall not exceed 50 percent of the interior cross-sectional area of the cable tray. Allowable cable fill area for multiconductor cables in ladder, ventilated Table 392-9 through or solid bottom cable trays for cables rated 2000 volts or less Maximum allowable fill area in square inches for multiconductor cables Ladder or ventilated through Solid bottom cable trays, cable trays, section 392-9(a) section 392-9(c) Inside width of cable Column tapplicable Column 2° Column 3 applicable Column 4* tray (inches) for section 392-9(a) applicable for sor section 392-9(c) applicable foe (2) only (square section 392-9(a) (3) (2) only (square section 392-9(c) (3) inches) only (square inches) inches) only (square inches) 6 7 7-(1.28d)* 55 5.5- Sd" 12 14 14-(1.2Sd) 11.0 11.0-Sd 18 2 21 -(1.2Sd) 16.5 16.5-Sd 24 28 28 - (1.2Sd) 22.0 22.0-Sd 30 35 35-(1.2Sd) 275 27.5-Sd 36 42 42 -(1.2Sd) 33.0 33.0-Sd For SI units: one square inches = 645 square mm.*The maximum allowable fill areas in column 2 and 4 shall be computed. For example: The maximum allowable fill, in square inches, for a 6-inches (152mm) wide cable tray in column 2 shall be 7 minus (1.2 multiplied by Sd) **The term Sd in columns 2 and 4 is equal to the sum of diameters in inches of all nos 4/0 and larger multi conductor cables in the same cable tray with smaller cables. Ina ventilated channel cable tray containing multiconductor cables of any type, the combined cross sectional area of all cables shall not exceed 1.3 square inches (839sq mm) in 3 inches (76mm) wide channel tray 2.5 square inches (1613sq mm) in 4 inches (102mm) wide channel tray 3.8 square inches (2452sq mm) in 6 inches (152m) wide channel tray Allowable cable fill area for single conductor cables in ladder ventilated Table 392-10 through cable trays for cables rated 2000 volts or less Maximum allowable fil area in square inches for single conductor cables in ladder or ventilated through cable trays Inside width of cable tray (Inches) Column 4 applicable for section Column 2* applicable for section 392-10(a) (2) only 392-10(a) (3) only (square inches) (square inches) 6 6.50 6.50- (1.18d)"* 12 13.0 13 -(1.18d) 18 195 19.50 -(1.18d) 24 26.0 26.00 - (1.18d) 30 325 32.50 -(1.18d) 36 39.0 39.0-(1.18d) For SI units: one square inches = 645 square mm. *The maximum allowable fill areas in column 2 and 4 shall be computed. For example: The maximum allowable fil, in square inches, for a 6-inches (152mm) wide cable tray shall be 6.5 minus (1.1 multiplied by Sd) ** The term Sd in column 2 is equal to the sum of diameters in inches of all 1000Kemil and larger single conductor cables in the same ladder or ventilated through cable tray with smaller cables.=a Loading Consideration Itis important to note that when specifying loading requirements, there are other loading factors that may need to be considered over and above the actual cable loads. Destruction Load Capacity The total weight in the tray which causes the tray to collapse is called the "destruc- tion load capacity’. When trays do collapse, they generally do so by premature lateral buckling (compression) of the top flange. Concentrated Loads A concentrated load is a static weight applied between the side rails at mid span. When specified, these concentrated static loads may be converted to an equivalent uniform load (We), in pounds per linear foot, using the folowing formula: = 2Concentrated Load We= Support Span Length This load (We) is then added to the static weight ofthe cable before selecting the appropriate NEMA load span designation. DIMENSIONS Cable trays, cable ladders and support systems have various options in dimensions. Our standard production enables straight lengths of trays and ladders . Our stock items are 2.4m in standard, mainly for use in our domes- tic market. Our flexible production systems enable us to offer custom production when required by our clients. This is a distinguishing feature from most of other manufacturers in the global market.) Dimensions Tolerances for cable tray & cable ladders or the cable trays support system as per NEMA. VE1-1998 (Reference extract from NEMA VE1~1998 — page 7 8 &9) Lengths of straight sections: (not including connectors) Lengths of straight sections: (not including connectors) Length mm (ft) Tolerance mm (in) 2440 mm (8 ft) 5mm (3/16 in) 3000 mm (10 fi) +5mm (+ 3/16 in) 3660 mm (12) £5mm (43/16 in) 6000 mm (20 ft) £9mm (45/16 in) 7320 mm (24 fi) +£9mm (45/16 in) Widths for typical width sections other than channel trays are Widths mm (in) Tolerance mm (in) a). 75mm (3 in) b). 100mm (4 in) c). 150mm (6 in) d), 225mm (9in) e). 300 mm (12 in) Depths for typical depth for sections other than channel or single-rail trays are #). 450mm (18 in) 4g). 600mm (24 in) £6 mm (£ 1/4 in) fh). 750mm (30 in) i). 800mm (36 in) Widths mm (in) Tolerance mm (in) ‘The measurement shall be at Fea £10. mm (+ 3/8 in) from the top of the cable ¢). 125 mm (5 in) eT the top d). 150mm (6 in)(7) == STORAGE & INSTALLATION Guide Lines STORAGE: Hot dipped galvanized after fabrication (H.D.G.A.F) Steel, Aluminum, Stainless Steel Cable tray and its accessories can be stored outside without cover, but should be loosely stacked ,elevated off the ground ,and ventilated to prevent stain. If appearance is important, cable tray should be stored indoors to prevent water or other foreign materials from staining or adhering to cable tray. Mill galvanized or electro galvanized cable tray must be protected or stored in a well ventilated , dry location. ‘SUPPORT INSTALLATION: In order to install the cable tray supports, first find the required elevation from the floor to the bottom of the cable tray and establish a level line with a laser or nylon string. Astring works well because it can be used to align the threaded rods on one side of a trapeze and find the top of the support. CABLE TRAY SUPPORTS: ‘Supports for cable trays should provide strength and working load capabilities sufficient to meet the load requirement of the cable tray wiring system. Consideration should be given to the loads associated with future cable additions or any other additional loads applied on the cable tray or support systems. Ashco Strut Support Exploded View Wall Mount B250 Gusset Cantilever Wall SupportC-Channel Support Double Cable Ladder Hanger Vertical Threaded Rod Support Cable Ladder to Floor Connector qSite Storage Galvanizing Thickness Inspection »] Cable Tray & Support System Installation at siteSTORAGE & INSTALLATION Guide Lines INSTALL STRAIGHT SECTION: After the supports are in place , the installation of cable tray can begin at any place that i convenient . Its ideal to lay out the system so that the splice joints fall between the support and the quarter point , this maximize the rigidity of the cable tray. CAUTION: The support span should not be greater than the straight section length , to ensure no more than one splice plate is located between supports. Avoid placing splice plates over supports or at mid-span . EXPANSION SPLICE PLATES It is important that the thermal contraction and expansion be considered when installing cable tray systems, the length of the straight cable tray run and the temperature differential govern the number of expansion splice plates required. Maximum spacing between expansion joints that provide for one inch movement DIFFERENTIAL eoeeed ALUMINUM °F °C Feet Meter Feet Meter 25 14 512 156 260 79 50 28 256 78 130 40 75 42 171 52 87 27 100 56 128 39 65 20 125 70 102 3t 52 16 150 83 85 26 43 13 175 7 73 22 37 11 The temperature differential is the difference in the hottest and coolest days of the year. p : Standard Connector Expansion Joint ConnectorHold Down and Guide Clamp location: Accurate gap setting at the time of installation is necessary for the proper perforation of the expansion splice plates the following procedure should assist the installer in determining the correct gap: 1. Plot the highest expected temperature on the maximum temperature line. Example value =38°C. 2. Plot the lowest expected temperature on the minimum temperature line. Example = -33°C. 3. Draw a line between the maximum and minimum points. 4. Plot the temperature at the time of installation to determine the gap setting. Example value =10°C. Metal Cable Tray expansion joints require bonding for electrical continuity. Supports should located within 2 ft (600mm) of each splice plate. ac Toe Toe oC CABLE TRAY TEMPERATURE AT TIME o - OF INSTALLATION (F° OR C°) a A A 0 cs » » ° ° ~ ® » » . » : » o}»t»1> ® ® ° ws Y 7 ° a 10 y 10 a » ey 10, vi 10 » “30 vi 30 “0 Y “0 . gs GAP SETTING, Inches (mm) Figure 4.13B GAP SETTING OF EXPANSION SPLICE PLATE 1 in. (25.4 mm) Gap MaximumSUPPORT INSTALLATION LOCATIONS FOR FITTINGS (As recommended by NEMA VE 2 ) NS poses” B= 3045 90 HORIZONTAL ELBOWS. |L.2.0" Max ‘= {sion = \ \ sx iT Re Lear HORIZONTAL WHY 20° Ma, 220" Max, (tse) (ison SC Bet STRAIGHT REDUCER 20" Max, i istbont }iBet OFFSET REDUCER t wat b LD a0. 90 VERTICAL ELBOWS, hi sf 2.0" Max, '=[cionmt = + a VERTICAL TEE q