What safety standards should you consider when installing FRP cable trays in factories?
Industrial facilities depend on electrical systems to power machinery, automation equipment, and monitoring devices, and proper cable management for safe, efficient, and long-term use. In modern factories (especially those located in corrosive or wet environments), one of the most common products used for cable management is FRP cable tray systems.
Cable trays made of FRP (Fiber Reinforced Plastics) are extremely durable, resistant to corrosion, lightweight, and non-conductive. They’ve been installed in chemical plants, power plants, manufacturing facilities, and wastewater treatment facilities. As with other components of the industrial infrastructure, FRP cable trays must be installed according to safety and engineering standards.
By knowing these safety standards when installing an FRP cable tray, manufacturing plants will be able to minimize the risk of electrical hazards, structural failures, fire hazards, and expensive downtime. This article provides an overview of the major safety standards to remember when installing an FRP cable tray in a manufacturing plant.
Understanding FRP Cable Trays
Cable trays made of fiberglass reinforced plastics or plastics are structural systems designed to support insulated electrical cables used for power distribution and communication systems. The construction of the cable tray combines glass fibers (reinforcement) and polymer resins to create a composite material strong enough to support the weight of insulated electrical cables while remaining light enough for easy handling.
Because WHR® cable trays are made from fiberglass/epoxy resins, they will not rust or corrode like conventional steel trays. They also have electrical insulation properties and require less maintenance than metal trays. Therefore, they can provide an economical solution when used in industrial environments with metal-based cable trays that would be subject to corrosion or exposure to harsh chemicals.
Although there are many advantages to using fiberglass/epoxy cable trays, the safe and effective installation of these cable trays is critical to maintaining a reliable and productive work environment.
Safety Standards for Installing Cable Trays
Cable trays, when correctly installed and properly designed in accordance with safety standards, will perform reliably under typical industrial operating conditions. A cable tray system could tend to experience cable damage, overheating, or electrical faults, or possibly a complete failure of the supporting structure due to improper installation or design.
Compliance with safety standards will enable manufacturers to achieve the following objectives:
- Prevent electrical hazards to personnel
- Prevent overheating and fire of cables
- Provide a structural component that retains structural integrity
- Have structural stability to meet codes/regulations
- Increase the service life of a cable tray system
There are other reasons to support compliance with safety standards beyond just providing an appropriately safe work environment. Safety standards will also support preventive maintenance and provide long-term operational efficiency.
Electrical Safety Considerations
When it comes to cable tray installations, safety associated with electricity is a top priority. Although an FRP cable tray may not carry current, the cables housed within it are conductive.
The manufacturer should ensure the following:
- A sufficient amount of insulation & securing devices for the cables.
- No overloading of the tray systems
- Adequately maintaining the distance between lines of cable
- Correct or adequate grounding
- Correct wiring of cables to prevent overheating as well as decrease the potential for electrical malfunction.
Structural Design and Load Capacity
Cable trays constructed with FRP need to be designed for supporting both the weight of cables and loads resulting from the environment. Engineers should calculate load capacities before any cable installations.
When designing for structural integrity and the safety of a cable tray, consideration must be given to:
- The weight of cables housed within the system
- Any future anticipated cable installation
- Spacing of support structures
- Sources of vibration (including, but not limited to, operating machinery
- The effects of wind or other environmental conditions
When installed incorrectly or with an overload of weight, cable trays may warp or collapse under load conditions. Most manufacturers will provide load tables and span assistance that are required to be included in the installation process.
FRP Cable Trays: Compliance and Main Considerations
Factory environments require continuous operation of electrical systems, and therefore require constant attention to Fire Safety. The FRP (Fibreglass Reinforced Plastic) used in cable management must be built from fire retarding resin systems. These materials will assist in controlling the extent to which the flame will spread and the amount of smoke that can be produced.
The use of FRP and other fire-resistant materials will significantly reduce the chance of the development of an electrical fire within any given factory. The proper amount and spacing of cables will also assist in dissipating heat.
Factories should ensure that their cable trays are, where possible, installed at a distance from high temperature type of equipment.
Chemical and Environmental Resistance
FRP cable trays are frequently used in environments that have the potential to be exposed to chemicals, moisture, or extreme weather conditions. However, the type of resin used for the construction of the cable tray will determine its overall usability in relation to the environmental conditions it will be exposed to.
Warehouse facilities should consider the following:
- Chemical Compatibility
- UV Resistance
- Temperature
- Humidity
- Industry Fumes
Selecting the correct FRP materials will ensure that the cable trays will maintain their structural integrity and will not be subjected to premature failure.
Grounding & Bonding Practices
Grounding is still an essential safety feature for electrical systems. Even though FRP cable tray systems are manufactured from non-conductive materials, grounding is still a required safety feature.
Grounding is required for the following properties:
- Cable Shielding
- Metallic Support
- Electrical Equipment
- Junction Boxes
Proper grounding will help to prevent an electrical shock and will protect the equipment from fault current.
Installation Best Practices
Following the proper installation method is very important for the safety and longevity of the FRP cable trays. An inappropriate way of installing the FRP cable trays will negatively affect the strength of the FRP cable trays.
Best Practices include:
- Using Compatible Fasteners & Supports
- Proper alignment
- Do not over-tighten bolts.
- Existing Structure to provide Stable Mounting.
- Manufacturer’s Installation Guidelines.
Using a professional installer will reduce long-term maintenance issues.
Worker Safety When Installing
Ensuring a safe working environment for workers is always a top priority when performing installation work. There are many possible hazards for electrical workers in factories that require implementing measures to prevent accidents from occurring.
Here are some important safety measures to implement when working with electricity:
- Personal Protective Equipment (PPE).
- Lockout/Tag-out.
- Insulated Tools.
- Proper Supervision.
- Safe Work Environment.
Training workers in safe installation practices will dramatically reduce the likelihood of accidents occurring.
Inspection and Maintenance of FRP Cable Trays
Regularly inspecting FRP cable trays will help ensure they continue to function safely and effectively through time. In general, maintenance personnel should assess the following:
- Structural condition of trays.
- Stability of support.
- Loading of cables.
- Chemical damage.
- Anything that may lead to improper alignment.
By performing preventive inspections of FRP cable trays, maintenance personnel will be able to identify potential problems before they become critical.
Overall System Documentation and Compliance
All factories are required to provide adequate documentation for cable tray installations and safety compliance. Examples of records might include:
- Installation drawings
- Load calculations
- Inspection reports
- The manufacturer’s specifications
- Safety certifications
Documentation supports an audit or verifies regulatory compliance.
Common Mistakes to Avoid
Common installation mistakes can compromise safety and performance, including:
- Exceeding the rated load of cable trays
- Disregarding manufacturer recommendations for span limitations
- Utilizing materials that are not compatible
- Failure to properly attach or secure cable trays
- Neglecting to perform routine inspections
Avoiding these errors provides reliability and durability for the cable tray system.
Thermal Expansion and Temperature Tolerance
FRP materials have the ability to expand and contract depending on temperature changes. When installing the FRP tray system, it is important to provide expansion gaps and flexible support to avoid cracking and stress. If the factory is located in a high-temperature environment or outdoors, it is important to ensure that the FRP tray system can withstand the temperatures.
Seismic and Vibration Safety Considerations
In factories where heavy machinery is used or in areas prone to seismic activity, cable tray stability may be affected by vibration and motion. Cable trays in such factories should be properly braced and anchored to prevent shifting or damage. Vibration-resistant designs will ensure greater stability.
Proper Cable Segregation and Routing
It is necessary to have proper cable segregation while installing FRP cable trays in factories to avoid electrical disturbances and overheating. It is necessary to route the power cables, control cables, and communication cables separately or segregate them using barriers in the tray system. This will help to avoid disturbances in the signals and will also increase the efficiency of the system. Proper cable segregation also helps in easy maintenance and upgrading.
Conclusion
FRP Cable Trays Are A Good Option For Industrial Cable Management Because They Are Durable And Resistant To Corrosion. The Success Of FRP Cable Tray Solutions Relies On Proper Installation As Well As Compliance With Local, State, And National Safety Codes And Standards.
Industrial Facilities Need To Consider Electrical Safety, Structural Design, Fire Ratings, Chemical Resistance, Grounding Practices, And Inspection Procedures To Achieve The Highest Level Of Safety And Performance From Their FRP Cable Tray Systems.
The Proper Use Of Proper Installation And Safety Compliance Will Protect Employees And Equipment While Maintaining Continuous Operations In The Facility.