How do FRP cable trays improve safety and performance in industrial settings?
Cable management is not only about keeping wires organized or neat within today’s industrial environment (e.g., Chemical Processing plants, Power Generation facilities), but it is also about the protection of Workers, Equipment, and Operations. The design of a good quality cable tray will provide the safest, most reliable, and most efficient paths for the installation of electrical cable. There are a number of materials available to be used for the construction of cable trays, with Fibre Reinforced Polymer (FRP) cable trays being a superior form of cable tray for many industrial applications.
In this article, we will cover: What are the features of Fibre Reinforced Polymer (FRP) Cable Trays, In what ways are Fibre Reinforced Polymer (FRP) Cable Trays better than traditional materials such as Steel and Aluminium, and why the Industrial Sector is increasingly using Fibre Reinforced Polymer (FRP) as opposed to Traditional Metal Cable Trays.
What Are FRP Cable Trays?
Fiber Reinforced Polymer (FRP) – also referred to as Glass Reinforced Plastics (GRP) – is an engineered composite consisting of a resin polymer matrix which is strengthened or reinforced by glass fibres. The cable trays made from FRP are designed to allow for safe and organised routing of electrical power, communication, and control cables in an industrial setting. The properties of FRP allow for a mixture of high strength with resistance to many chemicals (as well as electrical non-conductivity) and very low maintenance; such a mixture is uncommon when using metals.
There are many different designs of FRP cable trays, including channel, ladder, perforated, and TRH cable trays; all of these designs use different types of cables and wiring styles based on the weight requirements of the cables or how they are used or routed.
1. Enhanced Safety Through Electrical Non-Conductivity
One key advantage of FRP cable trays over metal trays is their electrically non-conductive design. Because FRP does not carry electrical current like aluminum or steel, it provides additional protection against accidental electrocution to your workers through accidental contact with an energized cable.
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In industrial settings, this means:
- Less chance of electrical shock to workers due to the absence of electrical conductivity from the tray.
- Metal trays typically need to be grounded correctly in order to avoid the possibility of exposing a worker to electrical shocks. Since FRP cable trays do not conduct electricity, you do not need to ground them; therefore, the installation and materials costs associated with installation are reduced by eliminating that requirement.
FRP’s insulating capabilities also limit the chance of internal shorts and reduce the amount of current that can travel between your various types of cables, especially where there is a close proximity between power/data/control cables.
For all these reasons, FRP is considered a very suitable option to use in applications such as:
- Power Plants
- Substations
- High Voltage Applications
- Industrial Areas With Cable Types Mixed Within A Cable Tray.
2. Lightweight Design and Structural Strength
FRP’s low weight (40%–70% lighter than steel trays) provides an opportunity for faster and less expensive installation. When we install FRP trays, we do not need as many employees or use large heavy-duty cranes to lift them. As a result, this will also save you money on labor and equipment costs.
Since FRP has a high strength-to-weight ratio, it can carry very heavy cables over very long spans without the cables sagging or deforming.
In addition to the advantages of being lightweight, it is also very cost-effective to use FRP in industrial plants where there are long runs of cables that must be supported reliably.
3. Outstanding Corrosion and Chemical Resistance
In hostile environments such as Chemical Plants, Waste Water Treatment Facilities, and Offshore Oil Platforms. The potential of harm from corrosive elements, like Acids, Salts, and V.O.C.s on Electrical components (Cables, Controls, etc) is magnified without FRP Trays. When a Metal Tray, it can Rust, Pitting occurs, and it will eventually break down.
In addition to the factors above, Composite materials used for FRPs are selected based upon their:
- High Strength
- Excellent Durability
- Ability to resist degradation from moisture, solvents, oils, and other aggressive aqueous solutions.
- To maintain its structural integrity, long after installation in a harsh industrial environment.
As a result of these High Strength and Excellent Durability characteristics, FRP will enhance the electrical safety of the environment and decrease its requirement for future maintenance.
4. Fire Safety and Smoke Suppression
FRP cable trays have an additional advantage of being fire-retardant. The majority of FRP trays are made using fire-resistant resin and are manufactured to have the flame retarding properties as stated in industry standards. Because FRP trays tend to contain flame during a fire, they impede and slow down the progress of a developing flame, in addition to producing less smoke or toxic gases as a result.
Metal cable trays are better than FRP trays as they conduct heat to the surrounding cables they support more efficiently than FRP trays will; therefore, the potential for damage to insulation or an increased likelihood of fire propagation exists due to the interaction of these types of trays. Because of this, FRP has a higher ignition temperature than metal and, therefore, due to slow heat transfer, provides greater overall fire safety to high-risk industrial applications such as oil refineries, chemical storage facilities, and power generation stations than metal.
5. Resistance to UV, Weather, and Temperature Extremes
Cable trays in industrial settings can be exposed to various weather elements such as sunlight, humidity, and varying temperatures. Compared to metal and plastic cable trays, FRP cable trays have superior resistance to UV rays and temperature fluctuations.
Some plastics become brittle when exposed to the sun for long periods or degrade due to heat over time. FRP cable tray materials have been engineered to be UV-resistant and have no appreciable deterioration due to exposure to ultraviolet radiation, making them a good choice for outdoor applications, rooftop installations, and exposed cables in industrial facilities located in open areas.
FRP trays also provide mechanical and structural strength over a wide range of temperatures. For this reason, FRP trays are well-suited for both hot (i.e., furnaces) and cold (i.e., refrigerated or cryogenic) applications.
6. Low Maintenance and Lifecycle Cost Savings
The initial price for FRP (fiber-reinforced plastic) trays is generally more expensive than for metal cable tray systems, but FRP trays last longer with less maintenance, which makes them less costly compared to metal cable trays over a period of time. Unlike metal trays, FRP trays do not need repainting or treatment with anticorrosive chemicals such as galvanization. In addition, the lack of scheduled maintenance allows maintenance crews in industrial facilities more time to concentrate on other types of work instead of devoting their time and money to routine inspections of tray systems. As a result, companies will save on both maintenance and equipment replacement as well as on interruptions associated with equipment downtime.
7. Improved Cable Management and Heat Dissipation
Organizing Your Cables Helps You Stay Safe and Maintain Your System Performance. Using FRP Cable Trays with Ladder or Perforated Designs allows for Air to Move Freely Around Your Cables; therefore, The Improved Ventilation Helps Reduce the Risk of Heat Buildup, which will cause Damage to the Cables’ Insulations, Decrease Performance, and Decrease The Life of The Cables.
As Cables Carry Current Through High-Load Electrical Systems They will Generate Large Amounts of Heat. By providing a Good Airflow, You Will Reduce the Risk of overheating while Maintaining Your Cable Operating at Designed Levels, even with heavy usage and Highly Demanding Continuous Applications of Electrical Power in Industrial Environments.
8. Flexibility and Ease of Customization
There are several benefits of Fiber Reinforced Plastic (FRP) trays. One of the main benefits is the flexibility of these trays. The flexibility of FRP trays makes them ideal for accommodating custom routing requirements (e.g., routing cables around machines), which may be complex.
Unlike with metal trays, where welding tools, specialized equipment, and additional support are typically needed, FRP trays can be adjusted easily without the need for special tools or equipment; therefore, no additional support is needed to hold an FRP tray together. This means that engineers have more options for determining how to route cables through a facility, allowing them to create a more organised cabling system while also reducing the amount of stress placed on the cables.
9. Long Service Life and Durability
Because of the wide range of benefits associated with the properties of FRP (Fiber Reinforced Polymer), there is an increase in usage based on existing properties including (but not limited to), the/frp cost effectiveness to replace metal cable trays, Long-term durability with reduced life-cycle costs; increased assurance FRP Cable Management Systems will provide continued function over their entire life, and for those Industries where time lost due to product downtime is worth $$ or where threats to safety are associated (results of damaged/ defective products), PRIMARY safety reason(s) FRP Cable Management Systems are utilized.
10. Wide Range of Industrial Applications
FRP cable trays are adaptable products that can be found in many different industries, including:
Chemical and Petrochemical – Resistant to acetic, hydrochloric, fluid solvents, and many other harsh chemicals.
Electric Power Generation and Utilities – Electric safety is increased in a high-voltage environment due to the non-conductive properties of FRP cable tray products.
Wastewater Treatment Plants – Will not deteriorate under extreme moisture or chemical conditions.
Manufacturing – Lightweight and easily routed through complex infrastructures.
The ability to withstand extreme environments and provide robust performance makes FRP cable trays an ideal solution for any location where safety, reliability, and performance are of paramount importance.
Conclusion
In industrial applications, there are clearly defined requirements for cable management solutions that combine high-performance with safety, durability, and, as a result of those combined factors, cost-effectiveness. FRP has the unique properties needed for cable management solutions that traditional metal cable tray products do not possess. FRP’s non-conductive property provides greater protection against electrical hazards than metal products while also having greater chemical and corrosive resistance, allowing for a longer lifespan when utilized in environments that could be considered “hostile”. In addition to the above attributes, lightweight FRP trays make them easier and faster to install, thereby lowering installation labor costs compared to traditional cable trays. Moreover, the fire-retardant and UV-resistant grades of FRP product further enhance the overall safety and outdoor use characteristics.
While the up-front capital investment costs associated with FRP trays may be higher initially, the savings through decreased repair/maintenance costs, reduced replacement costs, and increased operational efficiency in the long-term will make FRP trays a great investment for industrial companies. Additionally, since FRP cable trays are used in all major industrial sectors, they are redefining the cable management product standard for safety and performance where they are installed.