Of course. This is a great topic.

A cable tray system is the backbone for routing and supporting

cables in most industrial and commercial buildings.

Here is a comprehensive guide to cable trays, broken down into key sections for easy
understanding.

1. What is a Cable Tray?

A cable tray is a support system used to securely fasten and support electrical cables and wires.
It is an engineered alternative to running cables in conduit or open wiring. Think of it as a bridge
or a highway system for cables, providing a clear and protected path from one point to another.

2. Key Advantages of Using Cable Trays

 Cost Savings: For routes with a high density of cables, a cable tray system is significantly
cheaper in both materials and labor compared to installing multiple conduits.

 Flexibility & Accessibility: This is a major advantage. It is very easy to add, remove, or
change cables in a tray system at any point in the future. This is known as "future-
proofing."

 Reliability & Safety: Cables are laid out in the open, making them easy to inspect for
damage. Trays also prevent moisture buildup that can occur in conduits.

 Improved Cable Ampacity: Because trays are open to the air, they allow heat to
dissipate more effectively than enclosed conduits. This better cooling allows cables to
carry more current (higher ampacity), sometimes allowing for a smaller, less expensive
cable size to be used.

3. Types of Cable Trays

Choosing the right type depends on the application, the types of cables, and the environment.

Tray Type Image (Description) Primary Use & Key Features

Best for Power Cables. The open design provides

Looks like a ladder
maximum ventilation to dissipate heat from large
Ladder Tray with two side rails
power cables. Rungs are convenient for tying down
connected by rungs.
cables.

Perforated Tray A solid bottom tray Best for Mixed or Smaller Cables. Provides good
(Ventilated support for a higher quantity of smaller cables
 (instrumentation, data) while still offering good
Trough) with ventilation holes.
ventilation.

Best for Sensitive Cables. Offers the most protection

Solid Bottom Tray
A tray with a solid, for sensitive data or fiber optic cables from dust,
(Non-Ventilated
continuous bottom. moisture, and falling debris. Drawback: Poor heat
Trough)
dissipation.

Best for Data Centers & Low-Voltage. Extremely

Wire Mesh Tray A grid or "basket" flexible. Can be easily cut and bent on-site to form
(Basket Tray) made of steel wires. fittings, making it ideal for complex routes like those
under raised floors or above ceilings.

A simple, solid-bottom For a small number of cables. Economical choice for

Channel Tray
channel. protecting a few cables along a simple, short route.

4. Common Materials and Finishes

The material is chosen based on the potential for corrosion in the installation environment.

Material / Finish Environment / Use Case

Standard indoor use. Most common and cost-effective. A layer of zinc is

Pre-Galvanized Steel
applied before the tray is manufactured.

Outdoor and industrial environments. The entire tray is dipped in molten

Hot-Dip Galvanized
zinc after fabrication, providing superior corrosion protection, even on cut
(HDG) Steel
edges.

Corrosive or outdoor environments. Lighter than steel (easier

Aluminum
installation) and has excellent natural corrosion resistance.

Food processing, chemical plants, marine environments. Offers the

Stainless Steel highest resistance to corrosion and chemical attack but is also the most
expensive.

Fiberglass
Highly corrosive chemical environments. Non-conductive (an electrical
Reinforced Plastic
insulator) and completely resistant to most chemicals and saltwater.
(FRP)

5. Essential Components and Fittings

A complete cable tray system is more than just straight sections.

 Straight Sections: The main "roadways." Typically come in 10-foot or 20-foot (3m or 6m)
lengths.

 Fittings: Used to change direction or size.

o Horizontal Bend/Elbow: A flat turn (e.g., 90°, 45°, 30°).

o Vertical Bend (Riser): To go up ("Inside Bend") or down ("Outside Bend").

o Tee/Cross: To branch off the main run in one or two directions.

o Reducer: To connect trays of different widths.

 Accessories:

o Splice Plates: Used to connect straight sections and fittings together.

o Covers: Placed on top of the tray to protect cables from debris, dust, or sunlight
(UV). Can be solid or ventilated.

o Dividers/Barriers: A strip of metal placed inside the tray to separate different

types of cables (e.g., separating high-voltage power from low-voltage data cables
to prevent interference).

o Supports: The structures that hold the tray up (e.g., trapeze hangers made from
strut, cantilever brackets mounted to a wall).

6. Key Selection and Installation Criteria (Based on NEC Article 392)

The National Electrical Code (NEC) Article 392 in the US governs the installation of cable trays.
Here are the most critical rules simplified:

Selection Criteria (What to Order):

1. Cable Load: Calculate the total weight and cross-sectional area of all the cables you plan
to install. This determines the required width and load class of the tray. Always add 25-
50% spare capacity for future needs.

2. Support Span: Decide how far apart your supports will be (e.g., 8 feet, 10 feet). You
must choose a tray strong enough (load class) to handle the cable weight over that span
without sagging.

3. Environment: Determine the right material (steel, aluminum, FRP) based on whether the
area is indoors, outdoors, or corrosive.
Installation Best Practices (How to Install):

 Support: Trays must be rigidly supported. Follow the manufacturer's recommendations

for support spacing. The supports themselves must be strong enough to carry the weight
of the tray plus all cables.

 Bonding and Grounding: This is a critical safety step. All metal tray sections must be
electrically connected to each other (using splice plates and bonding jumpers) and
connected to the building's grounding system. This ensures the tray cannot become
accidentally energized.

 Cable Fill: Do not overfill the tray.

o For large power cables (4/0 AWG and larger): The sum of the cable diameters
cannot exceed the tray width, and they must be installed in a single layer.

o For smaller cables (less than 4/0 AWG): The total cross-sectional area of all
cables cannot exceed 50% of the tray's interior cross-sectional area (for ladder or
ventilated trays).

 Securing Cables: In vertical runs, cables must be securely fastened to the tray to support
their own weight. In horizontal runs, cables are often tied down to prevent movement,
especially for single-conductor cables.

 Cable Separation: Use dividers to separate different systems (e.g., power, control, data)
to prevent electromagnetic interference (EMI).