Feature Cable Ladders and Trays

Design and specification of a cable support system

The specification of cable support systems generally falls under the jurisdiction of the electrical or instrumentation engineer, due to the fact that he controls the cabling. As a well designed cable support system requires expertise in structural and corrosion engineering, it is necessary for the specialist supplier of cable support systems to offer technical support in these areas to ensure that their products are correctly specified for each particular application. Suppliers of cable support systems offer the market a wide range of products with varying cable carrying capabilities, manufactured in many materials and finishes (e.g. graded stainless steels, 3CR12, aluminium, fibre reinforced plastic, hot dip galvanized mild steel, duplex coated hot dip galvanized mild steel and industrial paint systems on mild steel), to cater for every type of corrosive environment imaginable. We believe that, as there are , similarly this range of products enables the designer to select the best option that will satisfy a specific set of structural and environmental design requirements for the life of the plant.
horses for courses

by laying them on a horizontal cable ladder/tray (bed), or tie them to an edge mounted cable ladder/tray (wall). Because South African engineers generally prefer the latter method of supporting cables, a cable ladder was locally developed some eighteen years ago, which is structurally superior when carrying design cable loads over long spans when mounted on its edge. This product has all but replaced the use of angle and flat bar cable ladders in mining and heavy industrial applications. The outstanding features of this product are full welding at the junction of each cross rung with the side rail and extended bottom flange, thus creating a rigid fixed joint. In addition, the end of each cross rung is cut back at an angle in order to allow a generous opening for zinc flow during hot dip galvanizing. In other parts of the world, engineers favour laying their cables on a cable ladder or tray, which is mounted in the

The cable tray on the right (hot dip galvanized to SANS 121) will out last the tray on the left (continuously hot dip galvanized material) by upwards of 4 times!

horizontal plane. When mounted in this position over long spans, the cable ladder or tray requires a deeper side rail profile in order to satisfy the design load requirements. The fact that very few locally marketed cable ladders or trays have side rails or turn ups greater than 76mm seems to prove my belief that South African specifiers support

Structural design considerations for a cable support system

Reputable suppliers of cable support systems should be able to predict the load carrying capability/performance of each of their products at different support spans in order to recommend the most suitable product for a particular use. In order to do this, all cable carrying products should be designed and categorised in accordance with local and international standards. The real challenge in the design of a cable support system lies in the industrial market, where cables often have to span long distances without intermediate supports. The design also depends on the preference of the electrical engineer to support the cables

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PO Box 53483 Troyeville 2139 Tel: [011] 894 3937 Fax: [011] 894 3954 www.hi-techelements.co.za Email: andre@hi-techelements.co.za

Volume 3 Issue 3 2006 Hot Dip Galvanizing Today 37

Feature Cable Ladders and Trays

cables in the edge mounting position in industrial application. Contact with overseas engineers/ specifiers who require horizontal mounted cable support systems in long spanning applications, will certainly influence the availability of suitable new products in order to satisfy this demand.

Corrosion protection system

When selecting the most suitable products for a cable support system, it is essential to select the correct material and/or coating system, which is capable of lasting for the life of the building or plant in which it is to operate. Should the cable support system fail prematurely, the exorbitant costs of shutting down the plant to install a new support system far exceeds the additional cost of choosing the correct corrosion protection system rather than the wrong one. We focus hereafter on corrosion protection systems involving hot dip galvanizing.

and ISO 1461, or not. It has been my experience that whereas some plants are unsuited to galvanize our products, others are unwilling to go the extra mile, regardless of price. To those galvanizers who are willing to work together with manufacturers and suppliers like ourselves in order to produce a quality product, which meets all of the design requirements of our industry, your positive attitude will serve to retain hot dip galvanizing as the preferred coating of cable support systems into the future.

Edgemounted cable ladder.

Duplex coating system (hot dip galvanizing plus powder coating)

Where cable support systems are installed for maintenance free extended life span the above duplex coating system has proved to be highly effective. For a number of decades, till the end of the 1980s, ninety five per cent of all steel cable management products were either hot dip galvanized (cable ladders, cable trays and metal framing systems) or powder coated (power skirting, some ladders, trays and metal framing for aesthetic purposes). It is thus understandable why the industry developed its interest in duplex systems almost exclusively on the use of hot dip galvanizing and powder coating. In early use, the final powder coating was applied to the hot dip galvanized coating, only after application of a strontium chromate primer. As the strontium chromate coating was proving extremely costly, attempts were made to eliminate the primer by mechanical and/or chemical transformation of the hot dip galvanized substrate. Resulting from these efforts a number of powder coaters today are able to achieve the necessary adhesion between the hot dip galvanized substrate and the powder without the strontium chromate wet spray. Resulting from a number of duplex failures, notably at Zimbali (continuously galvanized wire coated with epoxy powder) and on the West Coast of Namibia (hot dip galvanized

commercial grade mild steel and polyester powder), sound reasoning would suggest exercising extreme caution in offering duplex coating systems for severe corrosive environments, unless fully supported by the powder (or paint) manufacturer concerned as well as the specifier. It is encouraging to notice that at least one powder manufacturer has entered the precarious area of specifying a duplex solution with hot dip galvanizing for severe corrosive environments. It is my view that duplex coating systems of hot dip galvanizing and powder/paint will only come into their own when both the specifier and the manufacturers of paint and powder systems take full responsibility for their products for all corrosive environments, as well as the correct application thereof through the appointment of approved applicators, particularly where coating on hot dip galvanized steel is concerned. Rather than to continue marketing the obvious merits of duplex coating, I would much rather see the HDGASA embarking on a joint venture with a number of recognised industrial paint manufacturers and powder manufacturers to test duplex coatings in severe corrosive environments where failures are known to have taken place. This will give those of us who believe that hot dip galvanizing is a wonderful corrosion protection system for steel, another product that we can market with total confidence.
The Association would like to thank Pieter Uys of Strutfast, an affiliate member, for this article.

Hot dip galvanized coating

The coating of choice for ninety per cent of our stock of cable support system product is hot dip galvanized to ISO 1461 in the case of our mild steel manufactured items and continuously hot dip galvanized sheetings Z275 for some of our commercial cable trays and wiring ducting where no welding is required during fabrication. Even considering the massive increases in the cost of zinc in recent times, I cannot envisage a more ideal coating for our products than hot dip galvanizing to an agreed standard of quality required by the electrical specifier. Any hot dip galvanizer wishing to coat cable support products has to realise that his coating is part and parcel of the product. This, of necessity, means that surface roughness and spiking on the cable bearing surfaces and at splice mating surfaces are unacceptable, whether otherwise acceptable to SABS

38 Hot Dip Galvanizing Today Volume 3 Issue 3 2006