Cable trays, ladder trays and

conduits
 Conduits (trunking)
• The term "electrical conduit" refers to durable tubing or other
types of enclosure used to protect and provide a route for
individual electrical wiring conductors. Conduit is typically
required where wiring is exposed or where it might be subject to
damage. A conduit can be made of metal or plastic and may be
rigid or flexible.
• All conduit is installed with compatible fittings (couplings, elbows,
connectors) and electrical boxes, usually made of the same or
similar material. Conduit must be installed in accordance with the
National Electrical Code (NEC) and all applicable local code rules.
• There are seven different types of conduit used commonly in
residential and light commercial wiring.
 Rigid Metal Conduit—RMC and IMC
• Rigid metal conduit, or RMC, is heavy-duty galvanized steel
tubing that is installed with threaded fittings. It is typically
used outdoors to provide protection from damage and can
also provide structural support for electrical cables,
panels, and other equipment. RMC is sold in 10- and 20-
foot lengths and has threads on both ends.
• Intermediate metal conduit, or IMC, is a thinner, lighter-
weight version of rigid metal conduit and is approved for
use in all of the same applications as RMC. Because IMC is
lighter and easier to work with than RMC, it is more
common in new construction.
 Electrical Metallic Tubing—EMT
• Another example of a rigid electrical conduit is EMT (electrical metal
tubing), which is most commonly made of galvanized steel but can
also be aluminum. EMT is also called "thin-wall" conduit because it
is thin and lightweight, especially compared to RMC. EMT is rigid but
can be bent with a simple tool called a conduit bender.
• EMT is installed with couplings and fittings that are secured with
setscrew or compression-type fasteners. The tubing itself is not
threaded like RMC and IMC. Common sizes of EMT include 1/2-inch,
3/4-inch, and 1-inch. It is commonly used for exposed
indoor wiring runs in residential and light commercial construction.
If installed outdoors in exposed locations, it must be assembled with
special watertight fittings.
 Electrical Non-Metallic Tubing—ENT
• Electrical nonmetallic tubing (ENT) is flexible corrugated
plastic tubing that is moisture-resistant and flame-retardant.
It is easy to bend and installs with snap-lock or glued plastic
fittings. Unlike EMT, non-metallic tubing cannot installed in
exposed locations, so it is commonly used inside walls.
• In addition to installation in standard wood- or metal-frame
walls, ENT can be installed inside concrete block structures
and can be covered with concrete. Due to the blue color of
one common brand of this conduit, ENT is nicknamed
"smurf tube," after the Smurfs cartoon characters.
Flexible Metal Conduit—FMC and LFMC
• Flexible metal conduit (FMC) is also called "Greenfield,"
after the name of its inventor. It has a spiral construction
that makes it flexible so it can snake through walls and
other structures. Standard FMC is used in dry indoor
locations, often for short runs between a wall box and a
motor or fixed appliance, such as a garbage disposer.
• Liquid-tight flexible metal conduit (LFMC) is a special type
of flexible metal conduit that has a plastic coating and is
used with sealed fittings to make it watertight. It is
commonly used with outdoor equipment, such as air
conditioner units.
 Rigid PVC Conduit
• Rigid polyvinyl chloride (PVC) is similar
to plastic plumbing pipe and is installed with
plastic fittings that are glued in place. It can be
bent after being heated in a portable heater
box. Because the conduit tubing and fittings
are glued together, the conduit assemblies can
be watertight, making PVC suitable for direct
burial in the ground for many applications. It is
also allowed in corrosive environments.
Conduits
 Example
• Example: Calculate Size of Conduit (Hume
Pipe) for Following Size of Cables
• 5 No’s of 3.5 Core 50 Sq.mm XLPE Cable.
Diameter of cable is 28mm
• 3 No’s of 3.5 Core 185 Sq.mm XLPE Cable.
Diameter of cable is 54mm
 Example
• Calculations:
• Area of Cable =3.14 X (Diameter/2)2
• Area of 50 Cable =3.14X (28/2)2 =615.44 Sq.mm
• Total Area of 50 Cable=No of Cable X Area of Each Cable
• Total Area of 50 Cable=5X615.44 =3077.2
• Area of 185 Cable =3.14X (54/2)2 = 2289 Sq.mm
• Total Area of 185 Cable=No of Cable X Area of Each Cable
• Total Area of 185 Cable=3X2289=6867.18
• Total Area of Conductor= Total Area of 50 Cable+ Total Area of 185
Cable
• Total Area of Conductor=3077.2+6867.18
• Total Area of Conductor=9944 Sq.mm
 Example
• Suppose We Select 150mm Diameter Hume Pipe
• Total area of 150 mm Diameter Hume Pipe =3.14 X (Diameter/2)2 =3.14X(150/2)2.
• Total area of 150 mm Diameter Hume Pipe=17662 Sq.mm.
• % Fill up Area of Conduit due to Cables as per above Table is 40%
• Actual Fill up Area of Hume Pipe =40% X Area of Conduit =40% X 17662
• Actual Fill up Area of Hume Pipe =7065 Sq.mm
• Required No of Conduit = Total Area of Cables / Actual Fill up Area of Conduit
• Required No of Conduit = 9944 / 7065
• Required No of Conduit= 2 No’s
• Suppose We Select 3000mm Diameter Hume Pipe
• Total area of 300 mm Diameter Hume Pipe =3.14 X (Diameter/2)2 =3.14X(300/2)2.
• Total area of 150 mm Diameter Hume Pipe=70650 Sq.mm.
• Actual Fill up Area of Hume Pipe =40% X Area of Conduit =40% X 70650
• Actual Fill up Area of Hume Pipe =28260 Sq.mm
• Required No of Conduit = Total Area of Cables / Actual Fill up Area of Conduit
• Required No of Conduit = 9944 / 28260
• Required No of Conduit= 1 No’s
• Results:
• Either We Select:
• 2 No’s of 150 mm Diameter Conduit /Hume Pipe or
• 1 No’s 300 mm Diameter Conduit /Hume Pipe
Conduits
 Conduit fittings
• Conduit fittings, also called electrical fittings,
are used to connect runs of conduit together
or to connect conduit to electrical devices.
• The types of fittings you use will depend on
whether you’re using metallic or non-metallic
conduit, the types of connections you need to
make, and the diameter of the conduit you’re
connecting.
Couplings: Joining Conduit with Conduit
• Couplings are used when you need to connect separate metallic conduit segments in the same circuit.
There are three main mechanisms by which couplings perform their function:
• Threaded couplings simply have internal threads, as implied by their name, and they are used to join
threaded conduit with ease (e.g. threaded RMC). Normally, this type of coupling is a single-piece
fitting.
• Set-screw couplings achieve a union with adjustable screws, to lock conduit in place once it has been
inserted. Although the main body of a set-screw coupling is a single piece, the screws are normally
removable.
• Compression couplings are normally three-piece fittings. The coupling has external threads and
locknuts, in order to insert conduit and fix it in place by compression. Note that the threads are used
by the locknuts, not the conduit.
• Since set-screw and compression couplings are both intended for unthreaded conduit, electrical
design engineers must often choose between them. Compression couplings are more expensive, but
they grip the conduit all around its diameter, not at a single spot like set-screw fittings. However, set-
screw fittings have a lower cost and easier to install, adapting to more locations because they are
adjusted with a screwdriver - compression couplings need a wrench and may be difficult to install
when space is reduced. Keep in mind that couplings must be rated for the type of conduit; for
example, EMT couplings are for EMT conduit only, even if other types of conduit fit.
• FMC and LFMC use a special type of screw-in coupling, similar to the central portion of a compression
fitting, but without the locknuts. Note that there are also combination couplings, where each end is
intended for a different type of raceway. For example, you can find couplings that join RMC and LFMC.
Couplings: Joining Conduit with Conduit
 Connectors: Joining Conduit with Electrical
Boxes
• Connectors are used to join metallic conduit with pull boxes, junction boxes and
other electrical enclosures. Metallic boxes typically come with knockout holes,
which are designed to insert connectors. The connector attaches to the electrical
box with a thread and lock-nut, while conduit is attached with similar methods as
those used for connectors:
1. For conduit types EMT, IMC and RMC, there are both set-screw and
compression connectors.
2. Conduit types FMC and LFMC use a special type of screw-in connector that has
a compression locknut.
3. All-purpose connectors use a pair of screws to adjust a metallic grip, and they
can be used with flexible conduit of smaller diameters, as well as armored and
sheathed cable.
4. f you must change the position of a connector in an electrical box and have
already opened a knock-out hole, there are seals available. Like in the case of
couplings, compression connectors offer have a higher cost but offer a more
rigid connection, while set-screw connectors have a lower cost and are easier to
install in reduced spaces.
Connectors: Joining Conduit with Electrical
Boxes
 Straps and Strut Clamps: Attaching Conduit
to Fixed Surfaces
• Straps are used to fix conduit to surfaces. They have a U-shaped body
that allows them to clip around the conduit, and have one or two
extensions with holes for screws. Since conduit comes in a wide range
of diameters, normally ranging from ½” to 6”, straps are also available
in the corresponding sizes.
• Strut clamps achieve a similar purpose, fixing conduit to surfaces, but
the design differs. A c-shaped strut is connected to a surface with
screws, and the clamps are then inserted into the strut, held in place
by hook-shaped legs. Each clamp is made of two identical halves that
are joined with a screw at their intersection, holding conduit in place.
• When dealing with a single conduit run, straps are the most practical
solution. However, strut clamps are very useful when there are parallel
conduit runs, since the same strut segment can hold several clamps.
Straps and Strut Clamps: Attaching Conduit
to Fixed Surfaces
 Elbows: Conduit Direction Change
• Elbows are short conduit segments that are manufactured with a
specified turn angle, typically 90° or 45°. Being conduit
themselves, they are normally connected to straight conduit runs
by using couplings - threaded, set-screw or compression. Just
keep in mind that threaded elbows required threaded couplings,
otherwise there is choice between set-screw and compression.
• Metallic conduit can be bent, so elbows may be avoided in many
cases. EMT of smaller diameters tends to be easy to bend, so
elbows are rarely needed. The difficulty of bending increases as
conduit diameter becomes larger, or if you are dealing with the
more rigid types: IMC and RMC. A hand bender is generally useful
for EMT of small diameter.
Elbows: Conduit Direction Change
• Standard size of conduits
• ½ ´´ → 16 mm
• ¾´´ → 20 mm
• 1´´ → 25mm
• 1¼´´→ 32 mm
• 2´´ → 50 mm
• 3´´ → 75 mm
• 4´´ → 100 mm
• Note
• ½ ´´ conduits are not recommended
• ¾´´ (20 mm) 0r 1´´ (25 mm) conduit can be use for wiring lighting
• 1´´ (25 mm) or (32mm) conduit can be used for wiring of s/o , w/h , w/m , c/r ,
pumps and low current system like fire alarm wires , CCTV telephone and TV wires.
 Cable trays
• In the electrical wiring of buildings, a cable tray system is used to support
insulated electrical cables used for power distribution, control, and
communication. Cable trays are used as an alternative to open wiring
or electrical conduit systems, and are commonly used for cable management in
commercial and industrial construction. They are especially useful in situations
where changes to a wiring system are anticipated, since new cables can be
installed by laying them in the tray, instead of pulling them through a pipe.
• According to the National Electrical Code standard of the United States, a cable
tray is a unit or assembly of units or sections and associated fittings forming a
rigid structural system used to securely fasten or support cables and raceways.
able trays are capable of supporting all types of wiring, such as:
1. High voltage power lines
2. Power Distribution lines
3. Optical lines
4. Telecom and control lines
 Cable tray materials used
• The material selection for the cable tray is based on the
purpose and coatings are provided on purpose.
• Aluminum: Aluminum trays are lightweight and used
because of high strength-to-weight ratio. The advantage
of using aluminum is that it is maintenance free.
• Steel: Steel trays gives mechanical strength and low cost
but has a high weight.
• Stainless steel: It has the high mechanical strength and
high ambient temperature. Stainless steel cable tray is
roll-formed from AISI Type 316 stainless steel.
 Types of cable trays
• Ladder tray:
• Generally used in applications with intermediate to long support spans 12 to 30 feet.
• Ladder cable tray is used for about 75 percent of the cable tray wiring system installations.
It is the predominate cable tray type due to its many desirable features:
• A ladder cable tray without covers permits the maximum free flow of air across the cables.
This allows the heat produced in the cable’s conductors to effectively dissipate. Under
such conditions, the conductor insulation in the cables of a properly designed cable tray
wiring system will not exceed its maximum operating temperature. The cables will not
prematurely age due to excessive operating temperatures.
• The rungs of the ladder cable trays provide convenient anchors for tying down the cables
in the non-horizontal cable tray runs or where the positions of the cables must be
maintained in the horizontal cable tray runs. This capability is a must for single conductor
cable installations. Under fault conditions (short circuit), the magnetic forces produced by
the fault current will force the single conductor cables from the cable tray if they are not
securely anchored to the cable tray.
• Cables may exit or enter the ladder cable trays through the top or the bottom of the cable
tray. Where the cables enter or exit conduit, the conduit to cable tray clamps may be
installed upright or inverted to terminate conduits on the top or bottom of the cable tray
side rail.
• Moisture can’t accumulate in ladder cable trays.
 Characteristics
• Solid side rail protection and system strength
with smooth radius fittings.
• Maximum strength for long span applications
• Standard widths of 6, 12, 18, 24, 30 & 36
inches
• Standard depths of 3, 4, 5 & 6 inches
• Standard lengths of 10, 12, 20 & 24 feet
• Rung spacing of 6, 9, 12 & 18 inches.
 Solid Bottom Cable Tray
• Generally used for minimal heat generating electrical or telecommunication
applications with short to intermediate support spans 5 to 12 feet.
• The main reason for selecting solid bottom cable tray (with covers) is the
concern of EMI/ RFI shielding protection for very sensitive circuits. A solid
bottom steel cable tray with steel covers provides a good degree of shielding
if there are no breaks or holes in the completed installation.
• The solid bottom cable tray system has a disadvantage in that moisture can
build up in the cable trays. This can be controlled by drilling 1/4 inch drain
holes in the bottom of the cable tray at three foot intervals (at the middle
and very near the sides) if the cable tray is not being used for EMI/RFI
shielding.
• Some engineers and designers specify solid bottom cable trays (often with
covers) in the belief that all electrical circuits have to be totally enclosed by
metal. The cable trays are just supporting cables that are designed for such
installations. Cable failures in cable tray runs rarely happen. Cable failures
due to cable support problems in cable trays are nonexistent.
 Characteristics
• Non-ventilated continuous support for delicate
cables with added cable protection available in
metallic and fiberglass
• Solid bottom metallic with solid metal covers for
non-plenum rated cable in environmental areas
• Standard widths of 6, 12, 18, 24, 30 & 36 inches
• Standard depths of 3, 4, 5 & 6 inches
• Standard lengths of 10, 12, 20 & 24 feet.
 Trough Cable Tray
• Generally used for moderate heat generating applications with
short to intermediate support spans—5 to 12 feet
Characteristics:
• Moderate ventilation with added cable support frequency—
with the bottom configuration providing cable support every
four inches.
• Available in metal and nonmetallic materials
• Standard widths of 6, 12, 18, 24, 30 & 36 inches
• Standard depths of 3, 4, 5 & 6 inches
• Standard lengths of 10, 12, 20 & 24 feet
• Fixed rung spacing of 4 inches on center.
 Channel Cable Tray
• Used for installations with limited numbers of tray cable when
conduit is undesirable. Support frequency with short to
medium support spans 5 to 10 feet.
Characteristics
• Economical support for cable drops and branch cable runs
from the backbone cable tray system
• Standard widths of 3, 4, & 6 inches in metal systems and up to
8 inches in nonmetallic systems
• Standard depths of 1 1/4 to 1 3/4 inches in metal systems and
1, 1 1/8, 1 5/8 in nonmetallic systems
• Standard length of 10, 12, 20 & 24 feet.
 Wire mesh cable tray
• Generally used for telecommunication and fiber optic
applications, installed on short support spans—4 to 8
feet.
Characteristics:
• A job site, field adaptable support system primarily for
low voltage, telecommunication and fiber optic cables.
• These systems are typically steel wire mesh, zinc plated
• Standard widths of 2, 4, 6, 8, 12, 16, 18, 20 & 24 inches
• Standard depths of 1, 2 & 4 inches
• Standard length of about 10 feet.
 Single Rail Cable Tray
• Generally used for low voltage and power cable installations
where maximum cable freedom, side fill and speed to install are
factors.
Characteristics
• These aluminum systems are the fastest systems to install and
provide the maximum freedom for cable to enter and exit the
system
• Single hung or wall mounted systems in single or multiple tiers
• Standard widths are 6, 9, 12, 18 & 24 inches
• Standard depths are 3, 4 & 6 inches
• Standard lengths are 10 & 12 feet.
Types of cable trays
 Video representations
• Conduit wiring:
• https://www.youtube.com/watch?v=gbJJOMdcGkA&t=70s
• https://www.youtube.com/watch?v=cExvnYuVWGM
• https://www.youtube.com/watch?v=rRrJkZmbp9U
• https://www.youtube.com/watch?v=xLDszOdYVgM
• https://www.youtube.com/watch?v=bgHFkI2qU6E
• Cable trays:
• https://www.youtube.com/watch?v=IaU27HLsNcU
• https://www.youtube.com/watch?v=uLbJ0U1m63M
• https://www.youtube.com/watch?v=pAsmOgzf2Lk
• Ladder trays:
• https://www.youtube.com/watch?v=gWolrtYSaP0
• https://www.youtube.com/watch?v=SfnYIXeqcSk