Section 8
CABLE TRAY
GENERAL
Cable tray is a unit or an assembly of units or
sections and associated fittings made of metal or
other noncombustable materials forming a
continuous rigid structure used to support laid in
cables. The support system includes ladders,
troughs, channels, and similar support systems.
Cable tray is not a wiring method and may be used
only as the mechanical support for approved
raceways or multiconductor cable wiring methods or
specially approved multiconductor cables designed
for use in cable trays; or 1/0 or larger single
conductors in industrial establishments where
conditions of maintenance and supervision assure
that only qualified persons will service the cable-tray
system. First, the cable tray is installed, and then the
cables or raceways are installed and secured to the
cable tray. This system has particular merit in
industrial applications or similar uses for which
many power, control, or signal cables are required
and flexibility is a consideration.
Cable trays are a mechanical support system and not
a raceway system. The National Electrical Code
defines a raceway as “An enclosed channel of metal
or nonmetallic materials designed expressly for
holding wires, cables, or busbars”.
Cable Tray separation groups are based on voltage
and instrumentation requirements as defined by the
Electrical Design Engineering discipline. In
addition, these requirements are defined in the
SETROUTE database.
GLOSSARY OF TERMS
Accessories. Devices which are used to supplement
the function of straight sections and fittings, and
include such items as dropouts, covers, conduit
adapters, hold-down devices and dividers.
Cable Tray Connector. A device which joins cable
tray straight sections or fittings, or both. The basic
types of connectors are:
• Rigid
• Expansion
• Adjustable
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
• Reducer
Cable Tray Fitting. A device which is used to
change the direction or size of a cable tray system.
Cable Tray Support. A device which provides
adequate means for supporting cable tray sections or
fittings, or both. The basic types of cable tray
supports are:
• Cantilever bracket
• Trapeze
• Individual and suspension
Channel Cable Tray. A prefabricated metal
structure consisting of a one-piece ventilated bottom
or solid bottom channel section, or both, not
exceeding six (6) inches in width.
Ladder Cable Tray. A prefabricated metal
structure consisting of two longitudinal side rails
connected by individual transverse members.
Solid Bottom Cable Tray. A prefabricated metal
structure consisting of a bottom with no openings
within integral or separate longitudinal side rails.
Trough Cable Tray. A prefabricated metal
structure greater than four (4) inches in width
consisting of a ventilated bottom within integral or
separate longitudinal side rails.
Horizontal Cross. A cable tray fitting which is
suitable for joining cable trays in four directions at
90-degree intervals in the same plane.
Horizontal Bend. A cable tray fitting which
changes the direction in the same plane.
Horizontal Tee. A cable tray fitting which is
suitable for joining cable trays in three (3) directions
at 90-degree intervals in the same plane.
Cable Tray System. An assembly of cable tray
straight sections, fittings, and accessories that forms
a rigid structural system to support cables.
Reducer. A cable tray fitting which is suitable for
joining cable trays of different widths in the same
plane. The basic types of reducers are:
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CABLE TRAY
• Straight - A reducer with two symmetrical offset
sides.
• Right-hand - A reducer, when viewed from the
large end, has a straight side on the right.
• Left-hand - A reducer, when viewed from the
large end, has a straight side on the left.
Straight Section. A length of cable tray which has
no change in direction or size.
Ventilated Bottom. A cable tray bottom having
openings sufficient for the passage of air and
utilizing 60 percent or less of the plan area of the
surface to support cables.
Vertical Bend. A cable tray fitting which changes
direction to a different plane. The basic types of
vertical bends are:
• Inside vertical - Elbow changes direction
upward from the horizontal plane.
• Outside vertical - Elbow changes direction
downward from the horizontal plane.
Reference sample tray layout at the end of this
section.
CABLE TRAY INSTALLATION
The following apply to the installation of cable tray
system and contained cables or raceways.
1.) The system shall not present sharp edges, burrs,
or projections injurious to the insulation or
jackets of the wiring.
2.) Cable trays shall be installed as a complete
system. Field bends or modifications shall be
so made that the electrical continuity of the
cable-tray system and support for the cables
shall be maintained.
3.) Each run of cable tray shall be completed
before the installation of cables.
4.) Supports shall be provided to prevent stress on
cables where they enter another raceway or
enclosure from cable-tray systems.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
5.) In portions of runs where additional protection
is required, covers or enclosures providing the
required protection shall be of a material
compatible with the cable tray.
6.) Multiconductor cables rated 600 volt or less
shall be permitted to be installed in the same
cable tray. The exception is where cable signal
separation has to be maintained or where site
specifics, client preferences differ.
7.) Cables rated over 600 volts shall not be
installed in the same cable tray with cables
rated 600 volt or less except where separated by
solid fixed barriers or where cables over 600
volt are metal clad.
8.) Cable trays shall be permitted to extend
transversely through partitions and walls or
vertically through platforms and floors in wet
or dry locations where the installations,
complete with installed cables are made in
accordance with applicable codes and contract
requirements.
9.) Sufficient space shall be provided and
maintained around cable trays to permit
adequate access for installing and maintaining
cables.
10.) When steel or aluminum cable-tray systems are
used as equipment-grounding conductors, the
following provisions shall be complied with.
• The cable-tray sections and fittings shall
be identified for grounding purposes.
• The minimum cross-sectional area of cable
trays shall conform to the requirements of
the applicable codes.
• All cable tray sections and fittings shall be
legibly and durably marked to show the
cross-sectional area of metal in channel-
type cable trays or cable trays of one-piece
construction and the total cross-sectional
area of both side rails for ladder or trough-
type cable trays.
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CABLE TRAY

• Cable-tray sections, fittings, and connected
raceways shall be bonded in accordance
with the applicable codes, using bolted
mechanical connectors or bonding
jumpers.
Costs vary between different load classes. Since
labor costs for cable tray installation are mostly
effected by the installation of cable tray supports, use
of the higher load classes will usually be cost
effective.

11.) Cable splices made and insulated by

approved methods shall be permitted to
be located within a cable tray provided
they are accessible and do not project
above the side rails. This typically is only
authorized by the Electrical Design
Group and/or by client preference.

12.) In other than horizontal runs, the cables

shall be fastened securely to transverse
members of the cable trays. Commonly
the Cable Installation General Notes,
Symbols, and Details will provide the
parameters for cable support means and
locations.

13.) Where single-conductor cables

MATERIALS
comprising each phase or neutral of a
circuit are connected in parallel, the
Most cable tray systems are fabricated from a
conductors shall be installed in groups
corrosion-resistant metal (low-carbon steel, stainless
consisting of not more than one
steel or an aluminum alloy) or from a metal with a
conductor per phase or neutral in order to
corrosion-resistant finish (zinc, PVC or epoxy), or
prevent current unbalance in the
nonmetallic material (fiberglass). The choice of
paralleled conductors due to inductive
material for any particular installation depends on
reactance. Single conductors shall be
the installation environment (corrosion and electrical
securely bound in circuit groups to
considerations), cost, and client preferences.
prevent excessive movement due to fault-
current magnetic forces.
Aluminum

Advantages associated with the design and

TRAY CLASSES
NEMA standard VE-1 defines 12 load classes for
cable tray. The classes are defined by a number (8,
12, 16, and 20), specifying maximum span in feet
and a letter (A, B, and C), specifying the maximum
load (A = 50 lbs./ft., B = 75 lbs./ft., and C = 100
lbs./ft.). The load rating must include the weight of
the cables plus any applicable wind or snow loads.
The load capacity available for cable is therefore
reduced for outdoor applications.
installation of Aluminum Cable Tray systems are:
• High Strength to Weight Ratio.
• Superior Resistance to certain corrosive
environments.
• Relative ease of installation.
• Lightweight (50% less than Steel Tray).
• Maintenance Free.
• Non-Magnetic Electrical Losses Reduced.
Disadvantages associated with Aluminum Cable
Tray include:

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Section 8
CABLE TRAY
• Reduced Span to Load.
• Increased Thermal Expansion.
• Increased use of Bonding Jumpers.
Expansion plates must be used on Aluminum Trays
when normal Outdoor Ambient Temperatures
exceed:
• 50°F - Expansion normally every 130’ (feet).
• 75°F - Expansion normally every 80’ (feet).
Cable Tray Drawings or General Notes, Symbols,
and Details typically provide the location and detail
for the installation of these expansion plates.
Use of bonding jumpers must also be installed with
these expansion plates.
Galvanized Steel
Advantages associated with Galvanized Steel Cable
Tray are:
• Electric Shielding.
• Finish Options.
• Low Thermal Expansion.
• High Span to Load.
Disadvantages closely associated with Galvanized
Steel Tray include:
• Low Electrical Conductivity.
• Higher Installation Costs.
• Poor Corrosion Resistance.
• High Weight.
Finishes or coatings offered to improve the corrosion
resistance are:
• Pre-galvanized Zinc.
• Hot Dip Galvanized Zinc (after fabrication).
• PVC (polyvinyl chloride).
• Epoxy or Special Paints.
Stainless Steel
Advantages associated with the use of Stainless Steel
Cable Tray include:
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
• Superior Corrosion Resistance.
• Withstands High Heat Temperatures.
• High Strength and Stable Structural Properties.
• High Span to Load.
Disadvantages to use of Stainless Steel Cable Tray
are:
• High Material Costs.
• Very High Installation Costs.
• Specialized Equipment and Tools Required.
Fiberglass
Fiberglass Cable Trays are a lightweight, pre-drilled
cable tray system utilizing fiberglass hardware or
channels or PVC coated metal hardware.
Advantages associated with the use of a Fiberglass
Tray system include:
• Superior Corrosion Resistance.
• Easy Installation.
• Self Extinguishing Flame Retardant Material.
• Affords Longer Support Spans.
• Greater Allowable Safe Working Loads.
• Inhibits Ultraviolet Degradation.
• Non-Magnetic Electrical Losses Reduced.
Disadvantages associated with a Fiberglass Tray
system are:
• Elevated Temperatures Reduce Strength.
• Specialized Material.
• High Material Cost.
• No Electrical Conductivity.
CABLE TRAY FINISHES
Zinc Coatings
The most widely used coating for cable tray is zinc
galvanizing. It is cost-effective, protects against a
wide variety of environmental chemicals and is self-
healing if an area becomes unprotected through cuts
or scratches. Degree of resistance to corrosion is
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CABLE TRAY
directly related to the thickness of the coating and
the harshness of the environment.
Pre-Galvanized Tray.
Pre-Galvanized, also known as hot dip or mill-
galvanized, is produced in a rolling mill by passing
steel coils through molten zinc. The coils are then
slit to size and fabricated. Areas not normally coated
during fabrication (cuts and welds) are protected by
neighboring zinc, acting as a sacrificial anode.
Note: Pre-Galvanized steel is not recommended for
outdoor or industrial environments. Normally used
in an indoor relatively dry or mildly corrosive
environment.
Normal life of Pre-Galvanized Tray in a Highly
Industrial environment is 3 years.
Pre-Galvanized tray is the least expensive or
designed (steel) tray.
Hot-Dip Galvanized Tray
Hot-Dip Galvanized Tray is immersed in a bath of
molten zinc, after manufacturing and assembly.
This ensures all surfaces are coated.
Hot-Dip Galvanized Tray is recommended for most
outdoor environments and many harsh industrial
environment applications. Use is also indoors.
Hot-Dip Galvanized Tray is the most commonly
designed (steel) tray.
Normal life of Hot-Dip Galvanized Tray in a Highly
Industrial environment is 11 years.
PVC Coated Tray
Steel and aluminum cable trays are available with a
PVC (polyvinyl chloride) coating especially designed
for special corrosive environments. The PVC
coating provides suitable corrosive protection for
most acids up to 150° F, but is not effective against
most solvents.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
Unlike zinc coatings, the thickness of the PVC
coating does not determine how long it will last.
A disadvantage of PVC coating is that a lack of
integrity of any size can severely reduce its corrosion
resistance. Scanning with a high-frequency volt
spark is recommended (commonly performed at the
factory) and all cuts, pinholes, or any other forms of
discontinuity must be repaired with a liquid PVC
patch (performed commonly by the field after
installation).
Additional Coatings
Enamel and epoxy coatings are also available from
various tray manufacturers upon specific request.
CORROSION EFFECTS ON TRAY
Corrosion is a natural effect on all metal surfaces
when exposed to the environment, chemicals, or
direct electrochemical attack. Dependent on the
physical properties of the metal, proximity to
dissimiliar metals, or exposure(s) to chemicals.
In general, corrosive attack on metals can be
classified into two forms - direct chemical attack, or
electrochemical attack. Listed below are common
types of corrosion which significantly influence
which tray is applicable for installation based on site,
environment, or area specifics.
• Chemical Corrosion
Occurs through dissolution of the metal by reaction
with a corrosive medium.
• Electrochemical Corrosion
Caused by an electrical current flow between two
dissimiliar metals, or if a difference in potential
exists, between two areas of the same metal.
Electrochemical corrosion is the kind of corrosion
most common to electrical. Common types of this
form of corrosion are:
• Galvanic Corrosion.
• Pitting Corrosion.
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CABLE TRAY
• Crevice Corrosion.
• Erosion Corrosion.
• Intergranular Corrosion.
Supplemental Cable Tray Fittings
Complementing the cable tray installation sometimes
requires the installation of cable tray barrier sections
or cable tray covers. Barrier and cover fittings
should always be ordered to the same degree and
radius as the cable tray fitting it is complementing.
Barrier locations are typically used to separate
different cable voltage and service levels. The
SETROUTE database for cable tray installation, in
conjunction with the cable tray installation drawing,
will locate where the barrier is to be installed and for
what trays.
Cable tray covers can be identified via the
SETROUTE database, located on the design
drawings, or more commonly by the Cable Tray
General Notes, Symbols, and Details.
Tray covers are either raised, louvered, solid cover,
or flanged and their installation details are usually a
General Design installation detail.
Covers are commonly required to aid in the
protection of the cables from potential damage (trays
installed below open grating, vertical risers through
floors).
Covers and barriers are available in 6’ or 12’
lengths. Barrier height should be sized to the height
of the tray depth.
Cable Tray Hardware
Common usage hardware fittings utilized to
complete the cable tray installation include:
• Hold down clips or clamps.
• Expansion guide clamps.
• Nuts, bolts, and washers (projected outward).
• Grounding clamps and conduit adapters.
• Bonding jumpers.
• Barrier strip clips and splice joiners.
• Edge Guard.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
• Cover clamps (raised or hold down).
• Cover Joiners.
Cable Tray Supports
Location and types of supports, unless designed on
raceway layout drawings or structural steel
drawings,(structural steel fabrication drawings too)
are installed in accordance with the NEMA standard
VE-1 which requires factoring in of tray class and
load. In addition, considerations must be made to
snow, ice, and wind. Too, significant support
placements must be installed at tray fittings.
Standard construction installations usually are an
open channel type framing member. Other forms of
structural type steel (e.g. C-channel, I-beam, or
angle iron), use is not infrequent. Support
configurations generally are “trapeze” style,
cantilever, suspension, individual, or floor mounted.
Cable Tray supports installation details, locations, or
types are sometimes identified on the cable tray
installation layout drawing or via drawing symbols
which refers to a general installation detail.
Attachments to overhead framing steel; general
building steel, wall embeds, masonry block or brick,
concrete slabs, walls, columns, and pedestals, are the
most common attachment point locations.
Cable Tray Support Hardware
Mounting hardware material commonly used to
attach tray supports include:
• Beam clamps or welded plates, fittings.
• Bolt Rod and rod couplings.
• Nuts, bolts, studs, and washers.
• Wall inserts, channel, brackets, and bracing.
General Cable Tray Fabrication
Cable Tray is generically either in 12’ (foot) or 24’
(foot) straight lengths.
Tray width dimensions are “out to out” not
including the width of the flange(s).
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CABLE TRAY
Note: Constructability Review of a Tray design
must factor the flange(s) width as part of the “overall
tray envelop” inclusive of supports. Flange width
varies with each manufacturer, and with some
manufacturers, their is no outside tray flange.
Typically all trays are secured with “hold down
clips” or guides in the cases of expansion.
All trays are manufactured with pre-drilled holes for
installation of “splice plates. Cutting the tray, to suit
tray design configuration, requires drilling out for
these holes and plate installation.
Each offset fitting (horizontal or vertical) primarily
has a 3” straight tangent for the installation of the
“splice plate” fittings.
Cable Tray, cover, barrier, offsets, or miscellaneous
fittings, must be considered a “long lead time item”
when ordering or purchasing. Typical length of
delivery time is dependent on tray material
purchasing specifics but, an electrical field
engineering rule of thumb to follow on tray material
delivery is to allow the tray supplier 4--8 weeks.
Cable Tray Constructability.
The success of any electrical project is the
effectiveness of the cable tray system. Conversely;
the design and installation of trays that are under
utilized, poorly laid out, inaccessable, complex,
provide no considerations to raceways exiting them,
support or steel locations, scaffolds, cable pulling
techniques or activities, equipment locations, other
commodities, will be the “down fall” of electricals
budget, schedule, and success. Downstream effects
from a poor tray system become apparent too late to
remedy all the consequences.
Avoiding Tray Installation Pitfalls
As the tray is being installed, or as part of the
constructability review, ensuring the following will
significantly decrease rework, design changes,
material purchases, or installation problems.
• Review Material Takeoffs and order tray early.
Rev. 0 Electrical Handbook
 Bechtel Corporation 1997.
• Presume a 10% loss due to cutting, waste,
mistakes, or damage on straight tray lengths.
• Use “adjustable offset plates” in lieu of degreed
fittings for minor direction changes (horizontal
or vertical).
• Review tray sizes with respect to location use
larger sizes for the more central locations (e.g.
36” for cable spread rooms, DCS cabinets,
MCC/equipment rooms) where the greatest
concentration of cables will be the “from or to”
end destination (alleviates overfill concerns or
design addition problems later).
• Review tray (cable) service level compatibility
and consider consolidating trays with barriers to
reduce quantity of trays to install.
• Review tray design and locations for:
1. Scaffolds, Manlifts, “scissor lifts”, accessability.
2. Cable Pulling techniques or equipment needs.
3. Support Steel, framing members, attachment
points, removable grating, steel, rigging beams.
4. Free from Load or equipment paths and
openings, monorails.
5. Wall embeds, sleeves, floor or wall openings,
blockwalls, false floors, ceilings, chases.
6. Type of cable, cable radius’, tray fill, spare
capacity, cable route effectiveness, ease.
7. Raceway exiting, grounding, duct banks.
8. Fitting size, application (12” radius vs. 24”).
9. Fitting installation capability. Example: 12”
radius Tee 24” wide is 4’-6” (54”) long.
10. Location or proximity to equipment, devices,
service or voltage levels considerations.
11. Expansion joints for trays through walls.
12. Cover use for cable protection under gratings,
outdoors, risers, wall openings, cable exits.
13. Barrier use and barrier fittings for offsets.
14. How to exit trays when tray is solid bottom.
15. How the cable enters the equipment. Is
equipment top entry or bottom entry?
16. Tray Seal requirements. Fire, environment,
water, flood. Fire Stops Material Needs.
17. Tray separation or cable spacing requirements.
18. Physical proximity to Heat producing
components, pipes, insulation, steam.
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CABLE TRAY

Rev. 0 Electrical Handbook 8-8

 Bechtel Corporation 1997. 11/26/97