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GRP/FRP Cable Management Systems

+ Cable trays+ Cable ladders+ Trunking & accessories

www.arcinsulations.com

Works:Village: Ramdevpur, P.O.: BawaliP.S.: Bishnupur, Dist.: 24 Pgs(S)West Bengal, IndiaTel: +91 33 2495 4231Fax: +91 33 2495 4233E-mail: [email protected]

Correspondence:Flat 25B, Tower - A

South City375, Prince Anwar Shah Road

Kolkata - 700 064West Bengal, India

Mobile: +91 9830433678, 9748708809

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GRP/FRPCable ManagementSystems

UncompromisedInsulat ion Qual i ty

The growing use of composites as an alternative to traditional materials such as steel, aluminium, etc, is basically due to the specific characteristics of the composite, such as:

• The unique resistance to corrosion contributes to reduce the life cycle costs of the composite installation.

• A specific mechanical strength is higher at lower weight, in comparison to conventional materials of construction.

• Easy & quick installation.

• High electrical Insulation properties.

Above all durability & resistance to corrosion lead to lower costs during the life of installation.

The ARCFRP Cable trays are designed & manufactured to provide a stable & dependable cable support in highly corrosive applications. From power plants to fertilizer industries, paper mills to refineries & laboratories, sound electrical design requires an adaptable cable support system that is reliable. The ARCFRP Cable trays provide a solution for cabling networks that must be upgraded, reconfigured or relocated, The variety and sophistication of overhead distribution systems offer greater choice in selecting the right cable tray for new construction and retrofit applications. Whether concealed in suspended ceilings or installed in open overhead spaces, cable trays offer a high degree of flexibility, both in terms of locating the components and accessing the cabling contained within them. The ARCCable Support Systems possess unique properties which enable them to resist many corrosive environments, particularly where conditions indicate that conventional materials will not provide art economic service life.

Constructed from glass reinforced thermoset Isopthalic resins, ARCCable Support Systems are designed and manufactured with a structural integrity normally only associated with steel and aluminum, but without their corrosion, weight and electrical conductivity problems.

The ARC profiles art designed and manufactured as structural components. Hence, it is essential to control the position and orientation of the glassfibre reinforcement in longitudinal and transverse direction to maintain their structural integrity. Additionally the presence of surface veil causes a resin (Isopthalic) rich barrier layer which enhances the degree of corrosion resistance. UV stabilizers & Fire retardants are added to enhance the properties.

All cable support system components are manufactured using Isophthalic polyester fire retardant resin systems that enable compliance to a flame spread rating of less than 25 for ASTM E-84 and a self extinguishing rating under ASTM D 635. Cable trays are constructed from high strength pultruded channel profile. Tray can be provided plain or perforated to provide cable fastening and/or ventilation. All fitting, horizontal bends, risers, reducers, tees. etc. used to enable cable routings to deviate from a straight line onto another plane, are constructed from the same profiles as the straight ladder sections. Standard joining of cable ladder or tray sections and fittings, is accomplished via FRP splice plates and stainless steel fasteners. Fibreglass joining accessories are also available for systems requiring total insulating properties. Straight sections and fittings can be pre-drilled to accept joining accessories, if desired. Cut edges and drilled holes are all sealed at manufacture.

The Pultrusion process used to manufacture the profiles achieves the optimum combination of these parameters.

All ARC Cable Tray Systems (CTS) are designed using high strength to weight ratio pultruded structural composite profiles. The ARC CTS are manufactured as per:

• NEMA FG 1: 1993 Rev. 1 (1994)

• IS 6746: 1994

• ONGC 4000 S

• EIL-50 OEDS - 422 Rev. 4

Manufactur ing

Process

Rovings GuidePlate Resin

ImpregnatorSurfacing

VeilForming &Curing Die

ContinuousStrand Mat

Preformer

*Caterpiller Pullers (shown) orReciprocating Pullers

Pulling System*

Cut-Off Saw

AdvantagesARC

GRP/FRPCable

ManagementSystem

• Full Ventilation - Power cables need not be derated in a ventilated cable tray system. Explosive gases cannot be trapped or transmitted as in totally enclosed wiring systems.

• Long Support Spans- ARC Cable Tray Systems are designed for up to 3mtr support spans, longer than most other wiring methods. Fewer supports reduce both installation time and cost.

• Corrosion Resistance - The inherent chemical resistance makes it desirable for severely corrosive environments. Life cycle costs of ARC cable tray installations can be dramatically reduced by the extended life expectancy of this product.

• Transparent to RF transmission - Fibreglass composites do not cause electromagnetic interference and are transparent to radio frequency transmissions. ARC Cable Support Systems provide a solution in applications where clarity of communication transmissions is paramount.

• Non Conductive and Non Magnetic - As ARC cable ladder and tray is non conductive, there is no concern of transmitting electricity into the support system from damaged cables. Additionally, there is no requirement for special support conditions to prevent electrolytic corrosion. Non conductive and non magnetic features mean a safer support system.

• Lightweight and Manageable - Pultruded fibreglass profiles used in ARC Cable Support Systems have a specific gravity of one-fourth that of steel and two-thirds that of aluminum, allowing for considerably simplified erection and handling. Unlike stainless steel, ARC Cable Support Systems can be easily cut and drilled on site using only hand tools.

• High Strength to Weight Ratio - ARC Cable Support Systems have a superior strength to weight ratio compared to steel or aluminum whilst maintaining a similar structural integrity. The Pultrusion process utilised in manufacture, results in high glass content and consistent reinforcement location. These are critical for consistent performance and achievement of the necessary physical properties.


• Cable Loads - The cable load is simply the total weight of all the cables to be placed in the tray. This load should be expressed in Kg / mtr.

• Concentrated Loads - A concentrated static load represents a static weight applied between the side rails. Tap boxes, conduit attachments and long cable drops are just some of the many types of concentrated loads. When so specified, these concentrated static loads may be converted to an equivalent, uniform load (We) in kilograms per linear meter by using the following formula:

We= 2 x concentrated static load

Span length (mtrs)

• Wind Loads - Wind loads need to be determined for all outdoor cable tray installations.

• Ice Loads - Glaze ice is the most commonly seen form of ice build-up. It is the result of rain or drizzle freezing on impact with an exposed object.

• Snow Loads - Snow is measured by density and thickness. The density of snow varies almost as much as its thickness.

• Seismic Loads - The cable tray/strut support system exhibit more seismic capacity than originally expected.

• Splices - A lot of attention has been given to the strength of the side rails. These load bearing side rails must be spliced to form a continuous system, therefore the design of the splice plate is very important.

• Simple Beam - A good example of simple beam is a single straight section of cable tray supported but not fastened at either end. When the tray is loaded the cable tray is allowed to deflect.

• Continuous Beam - Continuous beam is the beam configuration most commonly used in cable tray installations. An example of this configuration is where cable trays are installed across several supports to form a number of spans. The continuous beam possesses traits of both the simple and fixed beams.

• Cantilever Beam - A cantilever beam configuration occurs when one end of the beam is rigidly attached to the support and the other end is unsupported. This type of configuration is typically used when wall mounting a bracket to support cable tray. Since one end is unsupported.

• Fixed Beam - A fixed beam configuration has both ends of the beam rigidly attached to the supports. A good example of a fixed beam is the rung of a cable tray. By attaching the ends of the rung to the side rails, the ends are not free to move, bend or twist.

Structural Character ist ics of

Cable Tray and SupportsASTM standards define physical properties tests for the materials used to pultrude the cable tray. The specific ASTM test methods for mechanical, thermal and flammability properties are identified below. ASTM standard material properties for fiberglass channel and strut are identical to those of the cable tray because they are pultruded from the same materials.

Properties Test Method Unit / Value Longitudinal Transverse

Tensile Strength ASTM D638 MPa 207.0 48.0

Tensile Modulus ASTM D638 MPa x 104 1.724 0.552

Flexural Strength ASTM D790 MPa 207 69

Flexural Modulus ASTM D790 MPa x 104 1.10 0.552

Izod Impact ASTM D256 kJ/m 1.495 214.0

Compressive Strength ASTM D695 MPa 207.0 103.4

Compressive Modulus ASTM D695 MPa x 104 1.724 0.690

BARCol Hardness ASTM D2583 -- 45.0 45.0

Shear Strength ASTM D732 MPa 38 38.0

Density ASTM D1505 Kg/m3 1605 - 1716.0 -

Coefficient of Thermal Expansion ASTM D696 cm/cm/°F 5 x 10-6 -

Water Absorption ASTM D570 Max % 0.5 -

Dielectric Strength ASTM D149 kV/mm 8.0 -

Flammability Classification UL94 VO - -

Flame Spread ASTM E-84 25 max - -

Tests and Standards for the

Pu l t ruded Prof i les


Section 4 of NEMA FG 1 provides the performance standards and class designations, for fiberglass cable tray systems. Based on a twenty foot support span, three working load classifications are recognized:

Load Class Allowable Working Load (Kg / mtr)

A 74.4

B 111.6

C 148.8

The following Load / Span Class designations are applicable

Working Load Support Span NEMA Class Kg / mtr. mtr Designation

74.4 2.44 8A

111.6 2.44 8B

148.8 2.44 8C

74.4 3.66 12A

111.6 3.66 12B

148.8 3.66 12C

Load Data - 'C' Type Channel

Channel Specification Load (Kg/mtr) Width (mm) Max. allowable deflection (mm)

100 mm 80.9 149.9 7.620

C-Channel 162.0 299.7 12.700

with 4 mm 202.4 449.6 15.240

Thickness 242.9 599.4 17.780

100 mm

80.9 149.9 7.620

C-Channel

162.0 299.7 10.160

with 6 mm

202.4 449.6 15.240

Thickness

242.9 599.4 17.780

324.0 749.3 17.780

150 mm

405.0 749.3 12.700

C-Channel

485.8 1000.8 15.240

593.9 1198.9 17.780

26.9 50.8 2.540

Ladder Type

40.4 99.1 5.080

Span - 2 mtr.

54.0 149.9 5.080

67.5 200.7 5.080

80.9 299.7 5.080

Note: 1) In all ladder type trays 90 kg concentric load will be kept after putting above written UDL, without breaking or developing cracks. 2) In perforated type trays no concentric load will be allowed.

It is important that thermal contraction and expansion be considered when installing cable tray systems. The length of the straight cable tray runs and the temperature differential govern the number of expansion splice plates required. The cable tray should be anchored at the support nearest to its midpoint between the expansion splice plates and secured by expansion guides at all other support locations. The cable tray should be permitted longitudinal movement in both directions from that fixed point.

Accurate gap settings at the time of installation are necessary for the proper operation of the expansion splice plates. The following procedure should assist the installer in determining the correct gap:

• Plot the highest expected tray temperature on the maximum temperature line.

• Plot the lowest expected tray temperature on the minimum temperature line.

• Draw a line between the maximum and minimum points.

• Plot the tray temperature at the time of installation to determine the gap setting.

ThermalContract ion and Expansion

Load Standards

X

X

X

X

X

X

Expansion Splice Plates

Typical Cable Tray Installation

Tray

Tem

perature

At Time

of Ins

tallatio

n

MaximumTemperature

MinimumTemperature

(3.2) (6.3) (9.5) (12.7)

(15.9)(0.0)

1/8 1/4 3/8 1/2

5/8

50

40

30

20

10

0

-10

-20

-30

-40

50

40

30

20

10

0

-10

-20

-30

-40

130

110

90

70

50

30

10

-10

-30

130

110

90

70

50

30

10

-10

-30

FºFº CºCº

1

3

2

4

0

GAP SETTING

Inches (mm)

100 mm C-Channelwith 4 mm thickness

100 mm C-Channelwith 6 mm thickness


• The installation of ARCCable Tray should be made in compliance with the standards set forth by the NEMA Publications FG-1 (current issue).

• Always observe common safety practices when assembling tray and fittings in the field. Assemble in well-ventilated areas as dust from field cuts can accumulate. This presents no serious health hazard but can cause skin irritation and, if allowed to accumulate with grease and other machining lubricants, can become abrasive. Personnel should wear safety goggles, dust mask, coveralls or a shop coat when sawing, machining and/or sanding.

• Avoid generating excessive heat in any machining operation, as heat softens the bonding resin in the fiberglass, resulting in a ragged rather than a clean-cut edge.

• Avoid excessive pressure when sawing, drilling, and routing, etc. Use carbide-tipped drill bits and saw blades for extended tool life.

• The use of lubricant during machining is not recommended.• To avoid chipping of material at cut edges, secure cable tray and fittings properly during field cutting operations.• We recommend the use of compatible sealant for sealing surfaces and cut edges after field cuts are made.

Supports must be located so that connectors (splice joints) between horizontal runs fail between the support point and the quarter point of the span. Standard engineering practice requires that the splice joints be located where they will resist little or no bending moment. This allows the cable tray system to act as a continuous member with spans working in conjunction with one another to resist loading. When a cable tray system is installed with the splice joints located directly over the support, the previous continuous span condition is changed to one of a number of simple spans. These spans act independently of each other and excessive stress will occur at substantially less loading. Vertical straight lengths should be supported at intervals dictated by the building structure not exceeding 7.4 mtrs. on centers.A support should be located 600 mm on each side of an expansion connection.

There are two types of FRP cable trays:

• The cable ladders comprises two channel side rails connected by transverse rungs. All rungs to side channel connections have both a mechanical and adhesive lock. They are used for any mixture of power or lighting cables with any mixture of control or signal cables. For electrical service of 2000 volts or less and 2001 volts or more.

• The perforated type, solid bottom, pre- drilled cable tray are designed for light loads namely instrumentation and control cables and for transition from cable trays to individuals control points. Perforations are on standard 300 mm centres and provide both ventilation and sites for cable tie down.

Horizontal Fitting Supports Vertical Fitting Supports

Supports should be placed within 610 mm of each fitting extremity, and as follows: 90° supports at the 45° point of the ARC, 45° supports at the 22.5° point of the ARC (except for the 12” Ø), 30° supports at the 15° point of the ARC (except for the 305 mm Ø).

Vertical fittings at the top runs should be supported at each end. Fittings at the bottom of runs should be supported at the top of the fitting, and within 610 mm) of the lower extremity of the fitting.

Insta l la t ion Guide

Support Support

Straight Sections

splice atL/4

splice at

length of span = Lin multiple span condition

L/4

30 , 45, 90

2’-0’’ M

AX

2’-0’’ MAX

(.61m

)

(.61m)

1/2Ø Ø

2’-0’’ MAX

(.61m)Ø

Ø

Ø 30 45 60 90

Horizontal Tee Supports Horizontal Cross Supports

Supports should be placed within 610 mm of each of the three openings connected to other cable tray items for 305mm Ø. On all other radii, at least one support should also be placed under each side rail of the tee.

Supports should be placed within 610 mm of the four openings connected to other cable tray items for the 305mm Ø. On all other radii, at least one support should also be placed under each side rail of the cross.

2’-0’’ MAX

(.61m)

1/2

2/3 R

L

L

2’-0’’ MAX

TYP

TYP

TYP

2’-0’’ MAX

(.61m)

TYP

TYP

2’-0’’ MAX

(.61m)TYP

Reducer Fitting Supports Vertical Tee Supports

Straight reducer and right/left hand reducer fittings should be supported within 610 mm of each fitting extremity.

Vertical tee fittings should be supported within 610 mm of each fitting extremity

2’-0’’ MAX

(.61m)TYP

2’-0’’ MAX

(.61m)TYP

2’-0’’ MAX

(.61m)

2’-0’’ MAX

(.61m)TYP TYP

2’-0’’ MAX

(.61m)TYP

2’-0’’ MAX

(.61m)TYP

2’-0’’ MAX

(.61m

)TY

P

laddertypesystem

perforatedtype

system


• These are manufactured by assembling various cross sections like side runners / 'C' channels and rungs. According to the loading condition, a suitable 'C' channel is selected.

• The working (allowable) load capacity represents the ability of fibreglass cable ladder to support the static weight of the cables. It is equivalent to the destruction load capacity, with a minimum safety factor of 1.5.

• The longitudinal members or side runners are the pultruded 'C' sections, which provide excellent strength.

• The Cable Ladder width is the distance between two channels which is fitted by rungs / unistruts. It is the length of the rung / unistruts, between the two channels. The rungs / unistruts are inverted channels of 40 mm width x 20 mm depth and 4 mm thickness. The rungs are secured to the side runners / longitudinal members by SS 304 / SS 316 fasteners. The rungs are designed to eliminate rolling over. Our rung / unistruts length range is 150 mm, 200 mm, 300 mm, 400, 450 mm, 500 mm, 600 mm, 750 mm, 900 mm, 1000 mm and 1200 mm.

• The Cable Ladder length is the length of the side runner / 'C' channels. Our range is 3000 mm length.

• The Cable Ladder rang spacing is the distance between two rungs / unistruts. Our rung spacing is 300 mm.

• The Cable Ladder height is the height of the side runner / 'C' channel. Our range is 100 mm and 150 mm.

• The Cable Ladder tray thickness is the thickness of the side runner / 'C' channel. Depending upon the load condition the thickness is selected. Our range is 4 mm, 5mm and 6 mm.

• The fittings are used whenever cable needs to be bent at variable angles (90°, 60°) by using variety of fittings. The fittings are mitered at 305 mm radius. Whenever the width of the cable ladder needs to be changed, reducers are used. To run the cable three ways, 'T' fittings are used and likewise to run a cable four ways 'Cross' fittings are used.

H - Height T - Thickness W - Width (mm) (mm) (mm) 100 4 30 100 6 30 150 4 40 150 6 40

Model Nos. Width - W (mm) Height (mm) ARC-LT6 150 100/150 ARC-LT8 200 100/ 150 ARC-LT12 300 100/150 ARC-LT16 400 100/150 ARC-LT18 450 100/150 ARC-LT20 500 100/150 ARC-LT24 600 100/150 ARC-LT30 750 100/150 ARC-LT36 900 100/150 ARC-LT40 1000 100/150 ARC-LT48 1200 100/150

Specif icat ionsCable Ladders

HT

W

3000

(STANDARD LENGTH)

RUNG

SIDEMEMBER

300(TYP)

150

COUPLER PLATE

100

/ 15

0

W

4 / 6

SIDE MEMBER RUNG


W (mm) L (mm) A (mm) 152 1207 854 229 1314 930 305 1422 1006 457 1638 1159 610 1854 1311 762 2070 1464 914 2286 1616

Mitered Fi t t ings for the Cable Ladders

W

L

A

RR

90° Horizontal Radius Bend

W (mm) A (mm) 152 330 229 406 305 483 457 635 610 787 762 940 914 1092

90° Horizontal Direct Bend

A

A

W

WA

R

L

RA

WL

W (mm) A (mm) L (mm) 100 530 749 150 530 749 200 530 749

W (mm) A (mm) L (mm) 100 505 714 150 555 786 200 606 857

90° Inside Vertical Radius Bend

90° Outside Vertical Radius Bend

Straight Reducer

W (mm) A (mm) L (mm) 152 780 1410 229 850 1410 305 930 1410 457 1080 1640 610 1240 1880 762 1390 1880 914 1540 2110

Horizontal Radius Tee

W (mm) A (mm) L (mm) 152 780 1410 229 850 1410 305 930 1410 457 1080 1640 610 1240 1880 762 1390 1880 914 1540 2110

Horizontal Radius Cross

W1

W2

L

W1

W2

L

W1 (mm) 914 762 610 457 305 229 152 1105 1029 953 876 679 670 229 1067 991 914 838 670 - 305 1029 953 914 679 - - 457 953 908 679 - - - 610 908 679 - - - 762 679 - - - - - L (mm)

W2

(mm

)

Right or Left Hand Reducer W1 (mm) 914 762 610 457 305 229 152 1410 1175 1175 940 940 705 229 1175 1175 940 940 705 - 305 1175 940 940 705 - - 457 940 940 705 - - - 610 940 705 - - - 762 705 - - - - - L (mm)

W2

(mm

)


W1

W2

L

A

R

R

AW1W2

(A)L

RR

The perforated type, solid bottom, pre-drilled cable tray are designed for light loads i.e. instrumentation and control cables and for die transition from cable trays to individual control points.

• Load design is for a support span of 2.5 mtrs. Standard tray length is 3.0 mtrs.

• Maximum deflection range 12.7 - 25.4 mm.

• Load bearing UDL for other models are available on request.

Specif icat ionsPerforated Type Cable Trays

FRP Cable Tray covers

• Most economical installation with Thermo- plastic Drive Rivets

• Cover Hold Down Clamps allow cover to be removed for easy access to cables

• Available in ventilated & non-ventilated type.

Two nos. of Coupler / Splice Plates are required for each 3 mfrs. length of Cable Tray to be clamped with nuts & bolts on two ends for connecting it to another length of cable tray.

• Eliminates the Need to Drill or Punch Holes While Allowing for Normal Expansion

• This Guide becomes a clamp with use of a 316 SS set screw on top.

• Set SCREW is included with part.

• Guide is also easily adaptable for right or left sided installations.

Peaked CaverFlat Cover

FRP Splice / Connector Plate

Cable Tray Hold Down Clamp

Perforated Load Cable Tray bearing Model No. UDL(Kg/mtr) ARC -PT2A 11 ARC -PT2B 15 ARC -PT2C 18 ARC -PT2D 25 ARC -PT2E 30

Perforated Tray Runner Thickness Cable Tray height - H width - W - T Model No. (mm) (mm) (mm) ARC -PT2A 50 50 3.0 ARC -PT2B 50 100 3.0 ARC -PT2C 50 150 3.0 ARC -PT2D 50 200 3.0 ARC -PT2E 50 300 3.0 ARC -PT3A 80 100 3.0 ARC -PT3B 80 150 3.0 ARC -PT3C 80 200 3.0 ARC -PT3D 80 250 3.0 ARC -PT3E 80 300 3.0 ARC -PT3F 80 400 4.0 ARC -PT3G 80 500 4.0 ARC -PT3H 80 600 4.0 ARC -PT4A 110 100 4.0 ARC -PT4B 110 200 4.0 ARC -PT4C 110 300 4.0 ARC -PT4D 110 400 4.0 ARC -PT4E 110 500 4.0 ARC -PT4A 110 600 4.0

H

T

W


W (mm) A (mm) 50 565 75 565 100 565 150 565 200 565 250 568

90° Vertical Inside Bend W (mm) A (mm) 50 559 75 559 100 559 150 559 200 559 250 559

90° Vertical Outside Bend

W1 (mm) W2 (mm) 51 51 76 76 102 102 152 152 203 203 255 255

Horizontal Cross

Cable TrayHold Down Clamp

Cable Tray FRP CoverHold Down Clip

W (mm) A (mm) 50 610 75 635 100 660 150 711 200 762 250 813

90° Horizontal Bend W1 (mm) W2 (mm) 51 51 76 76 102 102 152 152 203 203 255 255

Horizontal Tee

A

W

R

22°-30°

22°-30°

45º

10’’

Mitered F i t t ings for the Perforated Cable Tray

22°-30°

22°-30°

10”

AR

W

45°

10’’

A

R

W

22º-30º

22º-30º

45º

W1

18’’ (+57)

18’’ (

+57)

W2

18’’ (+57)

18’’ (+57

)

W1

W2

(8)

(13)

A

(38)

1/2’’

11/2’’

5/16’’

2’’ (51)1/4’’ Bolt

3/16’’ (5)

This catalogue is issued to provide outline information only and is not deemed to form part of an offer or contract. With the policy of continuous development, ARC reserves the right to change details without prior notice.


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