# INDEX 1 ABBREVIATIONS 2 SYSTEM COMPONENTS 3 DEFNITIONS 4 MATERIAL & FINISH OPTIONS 5 GENERAL INFORMATION 6 ADAPTATION TO NEMA STANDARDS 7 CABLE TRAYS 8 CABLE LADDERS 9 ACCESSORIES 10 SUPPORTS 11 INSTALLATION INSTRUCTIONS 12 STORAGE 13 PACKAGING 14 LABELING 15 MAINTENANCE & INSPECTION 16 TESTS 17 SAFETY 18 SAFE WORKING LOADS 19 REFERENCE STANDARDS
ABBREVIATIONS mm denotes millimeter; m denotes meter; pc denotes piece; N denotes newtons; in denotes inch; ft denotes foot; lb denotes pound; kg denotes kilogram; SWL denotes safe working loads; UDL denotes uniformly distributed loads; J denotes jules; F denotes degree Fahrenheit; C denotes degree Celsius; PG denotes pregalvanized; HDG denotes Hot dip galvanized; SS denotes stainless steel grades; AL denotes aluminum; ESB denotes electro static paint coating; MS denotes mild steel; APB denotes primer coating.
SYSTEM COMPONENTS Cable tray and cable ladder systems include various types of accessories which are referred as system components. The main components are; Cable trays Cable ladders Wall brackets Cantilever brackets Hanger brackets I brackets Channels Channel connectors Splice plates Hinge plates Flat bends Tee bends Crossings Inside bends Outside bends Covers Fixing sets Braided earth links Hold down clips Fish plates End plates Dividers Concrete anchors Threaded rods And misc. accessories
DEFINITIONS Cable tray system: An assembly of cable tray straight sections, fittings and accessories that forms a rigid structural system to support cables. Cable tray term is also used for cable ladder in the meaning that cable ladder is a straight section that carries cables. Cable trays are manufactured in single flanged and return flanged options in standard. Also cable trays are available in perforated and non-perforated options. Cable ladders: A prefabricated metal structure consisting of two longitudinal side rails connected by individual C form members (rungs). C rungs are perforated for fixing additional items to the ladders. Rungs are connected to the side rails by welding method. Rung spacing can be manufactured as 200mm, 250mm, 300mm depending on the cable loads and as per customer requirements. In standard, the rung spacing is 300mm. Splice plate: A connector piece which joins cable tray and cable ladder straight sections and fittings or both. Flat bend: A cable tray fitting which changes the direction of the cable route in the same plane. Tee bend: A cable tray fitting which is suitable for joining cable trays in 3 directions at 90 intervals in the same plane. Crossing: A cable tray fitting which is suitable for joining cable trays in 4 directions at 90 intervals in the same plane. Reducer: A cable tray fitting which is suitable for joining cable trays of different widths in the same plane. Abrupt reducer: A cable tray fitting which is suitable for joining cable trays of different widths in the same plane. Abrupt fittings do not have a bottom plane or a rung to support cables but are used only to connect the cable trays of different widths just like the splice plates. Inside & outside bend: A cable tray fitting which is suitable for joining cable trays of the same widths in different vertical levels.
MATERIAL & FINISH OPTIONS We offer a variety of material and finish options for the cable tray systems which enables to choose the most suitable and economic product in every corrosive environment; PG Hot dip pregalvanized HDG Hot dip galvanized EG Electro galvanized ESB Electro static paint coated (epoxy) SS Stainless steel grades (available in AISI 304 and AISI 316 grades) AL Aluminum grades APB Prime coated PG Also known as mill galvanized or hot dip mill galvanized. Produced by coating coils of sheet steel with zinc by continuously rolling the material through molten zinc at the mills. Hot dip pregalvanized finish is made to ISO EN 10327 (former EN 10142 & BS 2989) Steel is hot dip galvanized before fabrication. Ideal for use in non acidic and non humid areas. Provides smooth and fine texture with a glossy look. Coating thickness range is between 15 to 35 µm. Used in material thicknesses up to 2mm. HDG Hot dip galvanized finish is made to ISO EN 1461 & BS 729. Enables zinc coating up to 85 µm (and over 100 µm with high carbon content steel grades). Due to high durability capacity, it is recommended for use in open areas. Used in all material thicknesses. EG Electro galvanized finish is recommended for use on the fixing components such as bolts, nuts, rods and washers. Coating thickness is between 8 to 15 µm. Used in all material thicknesses. Provides smooth and fine texture with a glossy look ESB Ideal for use in acidic environments. Can be applied as a final coating on all materials. (Preferable on PG or HDG surfaces) Highly durable in most severe corrosive conditions. Offers a variety of color options. SS Available in SS4 (AISI 304) and SS6 (AISI 316). Provides maximum anti corrosion performance in all environments. Does not require an extra coating. Idel for use in onshore & offshore environments. SS4 and SS6 are non-magnetic, and belong to the austenitic stainless steels group, based on alloy content and crystallographic structure. Exhibits increased strength when cold worked by roll-forming.
AL Highly corrosion resistant in severe conditions. Does not require an extra coating. Forms an aluminum oxide film that immediately reforms when scratched or cut. In most outdoor applications, aluminum has excellent resistance to weathering. MS Cable tray systems can be offered in mild sheet steel (to BS 1449, ST37 and a variety of different options). Mild steel made items require surface treatment after manufacture. Galvanizing, epoxy coating, primer coatings are recommended. APB Primer coating is an ideal way of protecting steel items from corrosion. Prime is generally in red color.
GENERAL INFORMATION # General Properties of Gerpaas Cable Tray & Cable Ladder Systems to IEC 61537 1. Metallic material 2 Fire resistant (non-flame propagating system component) 3. Electrical continuity 4 Electrical conductivity 5. Metallic coated 6. Ideal temperature range in stocking, shipping, and installation is between -20 C / +105 C 7. Free base area of GE-KT cable trays is C class. 8. Free base area of GE-MC cable ladders is Y class Environmental Gerpaas holds an internal environmental policy for all inhouse facilities handled. Thermal Gerpaas cable trays are designed to accommodate any thermal expansion and contraction witin certain temperature ranges. Light Such metallic articles (steel and stainless grades) do not be affected by artificial or natural light. RoHS The cable tray and ladder system components do not include any of the materials identified in the RoHS regulations. # Recommended Conditions For Stocking, And Shipping Of Cable Tray & Cable Ladder Systems 1. Avoid stocking and shipping in humid or wet conditions. Dry environment is required for all metal components. 2 Keep all components away from the risk of physical impacts. Preferably all items be kept in original packages, and it is strongly recommended to store on pallets and/or in cardboard boxes. Goods are palletized and shrink wrapped with secure PVC straps in export packaging. 3. System components must not be used as walkway or support unit for people as since such behavior may reduce the performance of the components where as it also may cause personal injury and harm the entire electrical system. 4 In case that any damage is detected in the system components, immediate precautions must be taken by repairing the components or by changing with new ones. 5. Recommended temperature ranges must be taken in consideration at all times. 6. Installation of cable tray & cable ladder systems must be performed by qualified personnel. 7. SWL diagrams must be taken in consideration in electrical projects and installations. 8. Each packaged product is labeled in accordance with ISO EN 61537:2002.
Advantages of cable tray systems: Offers a wide selection of materials and finishes to meet your demanding environmental conditions Cable tray is less expensive, and more adaptable to the changing needs Water or any other liquid cannot penetrate to the electrical current Cable tray systems bring lower engineering and maintenance costs A major advantage of cable tray system is its adaptability to new needs and technology. Maintenance costs are lower and easier Fire resistance enables maximum safety Can be observed, and tested more practically
ADAPTATION TO NEMA STANDARDS Gerpaas standard sizes and equivalents in NEMA standards: Metric units are used in calculations in standard. However, for the enquiries listed with imperial units including inches the nearest metric standard dimensions are taken into consideration as shown in the table below; Size in inches Conversion to mm Adaptation to Gerpaas standards 3 76.2 75mm 4 101.6 100mm 5 127.0 125mm 6 152.4 150mm 8 203.2 200mm 9 228.6 225mm 10 254.0 250mm 12 304.8 300mm 16 406.4 400mm 18 457.2 450mm 20 508.0 500mm 24 609.6 600mm 30 762.0 750mm 35 889.0 900mm
Cable trays: Gerpaas manufactures perforated and non-perforated type cable trays in a variety of dimensions and material & finish options. The cable tray are perforated on the base section to allow heat dissipation and also have multiple, regularly positioned fixing points for the use of cable ties to hold the cables to the tray. The cable tray and accessories provide good ease of handling during use and installation. It is simple to de-burr the cut lengths of cable tray has the appearance of robustness and functionality. Cable Tray dimensions are all external. Perforation standard is for M8 fixings (7.8 7.9mm slot holes with lengths of 20 25 35mm) Cable tray type Material & Finish Perforated(P)/ Non-perforated (NP) Series options Standard type PG, HDG, SS, AL, ESB P & NP GE-KT1 Return flanged type PG, HDG, SS, AL, ESB P & NP GE-KT 2 Wire Mesh type HDG, SS, ESB NP GE-TLK Cable trunking PG, HDG, SS, AL, ESB NP GE-TRNK Marine type HDG, SS, ESB P & NP GE-KTG Underfloor type PG, HDG, SS, ESB NP GE-DKG PG Pregalvanized HDG Hot dip galvanized SS Stainless steel grades AL Aluminum ESB Electrostatic paint coated Part No T W A L Kg GE-KT2-5-A50 1.5 50 50 3000 1,92 GE-KT2-7-A50 1.5 70 50 3000 2,16 GE-KT2-10-A50 1.5 100 50 3000 2,52 GE-KT2-12-A50 1.5 120 50 3000 2,76 GE-KT2-15-A50 1.5 150 50 3000 3,12 GE-KT2-20-A50 1.5 200 50 3000 3,72 GE-KT2-22-A50 1.5 225 50 3000 4,02 GE-KT2-25-A50 1.5 250 50 3000 4,32 GE-KT2-30-A50 1.5 300 50 3000 4,92 GE-KT2-40-A50 2.0 400 50 3000 8,16 GE-KT2-45-A50 2.0 450 50 3000 8,96 GE-KT2-50-A50 2.0 500 50 3000 9,76 GE-KT2-60-A50 2.0 600 50 3000 11,36 GE-KT2-75-A50 2.0 750 50 3000 13,76 GE-KT2-90-A50 2.0 900 50 3000 16,16 GE-KT1 series, single flanged Standard type cable trays are manufactured with single flanges on sides for load capacity optimization. Length: 3000mm GE-KT1 series are manufactured with perforation in 8mm slot holes in standard. GE-KTN part numbers are for solid bottom (non-perforated) cable trays. GE-KT2 series, return flanged Heavy duty type cable trays are manufactured with return flanges on sides for load capacity optimization. Length: 3000mm GE-KT2 series are manufactured with perforation in 8mm slot holes in standard.
r² (2r²) 1. Use (2r²) formula to find the area of each cable. 2. Find the total area of cables required for your cable tray route. 3. It is recommended to keep a +%20 reserve margin for future revisions in cable route. 4. Choose the corresponding size of cable tray using the table below. 5. It is highly recommended to choose the nearest higher value.
CABLE LADDERS Gerpaas cable ladders have a space saving design with side rail flanges turned in where the side rail flanges protect cables. All designs permit easy cable dropout with no sharp edges to damage the cables. The slots at the rungs and the side rails enable simple cable fastening via cable ties. Cable ladders consist of two longitudinal side rails with transverse rungs welded on the side members. Rung spacing is specified for each type of cable ladder. High strength splice plates allow random locations between supports. Available in HDG, SS, ESB options. Complete line of fittings and accessories offered. All cable ladders are available in 3000mm lengths. Long span cable ladders of 6000mm lengths available upon request. Cable ladder widths are available up to 900< millimeters. Part No T W A L Kg/m GE-MC2-10-A100 1.5 100 100 3000 4.00 GE-MC2-15-A100 1.5 150 100 3000 4.15 GE-MC2-20-A100 1.5 200 100 3000 4.30 GE-MC2-25-A100 1.5 250 100 3000 4.45 GE-MC2-30-A100 1.5 300 100 3000 4.60 GE-MC2-40-A100 1.5 400 100 3000 4.90 GE-MC2-45-A100 1.5 450 100 3000 5.05 GE-MC2-50-A100 1.5 500 100 3000 5.20 GE-MC2-60-A100 1.5 600 100 3000 5.50 GE-MC2-75-A100 1.5 750 100 3000 5.95 GE-MC2-90-A100 1.5 900 100 3000 6.40 A100 stands for OUTER SIDE HEIGHT: 100MM, please see product catalogues for other dimensions.
Structural properties of GERPAAS cable ladder rungs: CABLE LADDER RUNG TYPE-1: W Density Mass Volume Surface Area mm gr/mm 3 gr mm 3 mm 2 100 0,0078 56,64 7261,78 10316,18 150 86,42 10822,82 15325,11 24 200 112,19 14383,86 20334,03 250 139,97 17944,90 25342,96 12 300 400 167,75 223,30 21505,94 28628,02 30351,89 28628,02 450 251,07 32189,06 40369,74 500 278,85 35750,10 50387,60 Area of Section 78,21 mm 2 600 334,40 42872,17 60405,45 I X 1496,44 mm 4 750 417,73 53555,29 75432,23 I Y 5958,81 mm 4 900 501,06 64238,41 90459,01 CABLE LADDER RUNG TYPE-2: W Density Mass Volume Surface Area mm gr/mm 3 gr mm 3 mm 2 37 100 150 0,0078 120,09 179,41 15396,53 23001,66 16355,89 24308,86 200 238,73 30606,80 32261,82 20 250 300 298,05 357,37 38211,93 45817,06 40214,79 41867,75 400 476,01 61027,33 64073,68 450 535,33 68632,46 72026,65 500 594,65 76237,59 79979,61 Area of Section 161,42 mm 2 600 713,29 91447,86 95885,54 I X 8317,01 mm 4 750 891,25 114263,30 119744,40 I Y 32161,30 mm 4 900 1069,21 137078,65 143603,33
Side rail slot hole dimensions available in 8 and 10, also 12mm upon request. Series Structural properties Cross section GE-MC1 GE-MC2 GE-MX Flanged-in type Welded rungs Flanged-in type Welded rungs Out-flanged type Welded rungs Flat bends: Gerpaas flat bends enable fixed angular connections on horizontal cable runs. Available angles in flat bends are 30, 45, 60 and 90 degrees. Please choose the suitable radius for bends depending on the required bend positions of your cables. Description Available Angles Available Radii Cable trays 30, 45, 60, 90 300, 450, 600, 750, 900mm Cable ladders 30, 45, 60, 90 300, 450, 600, 750, 900mm Tee bends: Tee bends are available in sizes of cable tray widths. The available radius sizes are listed in the below shown table; Description Available Radii Cable trays 300, 450, 600, 750, 900mm Cable ladders 300, 450, 600, 750, 900mm Crossings: Crossings are available in sizes of cable tray widths. The available radius sizes are listed in the below shown table; Description Available Radii Cable trays 300, 450, 600, 750, 900mm Cable ladders 300, 450, 600, 750, 900mm Inside & Outside bends: Inside and outside bends are available in sizes of cable tray widths. Inside and outside bends are manufactured in flexible form; that is the required angle of bend can be achieved by manual bending to the required angle.
Reducers: Reducers are available in 2 types, 1- Reducers 2- Reducers (Abrupt) Abrupt reducers are manufactured as splice plate with angles with the required width to provide the connection of different widths of 2 cable trays. It must be noted that the standard reducers do not function as a cable support as since they have no plain bottom; Reducers for cable ladders ACCESSORIES GERPAAS cable management systems include a wide range of accessories for fixing, fastening, maintenance of the components. The below listed items are the most widely used types all manufactured to the relevant EN and DIN norms. Threaded rod GE-KAT Spring nut GE-CKSO Channel nut GE-CKSO LINE Hex nut GE-S LINE Lock nut GE-S LINE Square washer GE-PD Washer GE-PUL Hex bolt GE-HXC Round head screw GE-KC LINE Beam clamp GE-
SUPPORTS GE-KD series brackets are used to support cable tray and cable ladder systems, and additional equipment where necessary such as conduits, and HVAC systems. Material gauges of the support system must be studied when selecting the suitable bracket for your requirements. The recommended support distance is maximum 1500 millimeters. Optimum strength is achieved in spans of 1500mm maximum. Supports for cable ladder should be spaced with the recommended span in order to suit the load capacity of the cable tray system most economically. The general rule is that the load carrying capacity of a system increases as the span decreases. In circumstances where spans of 3000mm or 6000mm are required, long span type cable trays and cable ladders must be used. It is important to install the supports properly and apply the loads correctly in order to keep undue stresses minimized. The safe working loads of brackets are based on a uniform loading within the cable tray and/ or cable ladder and it is assumed that the correct length and type of bracket is used. Therefore it is highly recommended to apply symmetrical loads close to the bracket head plate where applicable. 1- Single U channel ceiling suspension system 2- Single U channel ceiling suspension system, with prop support 3- Single rod ceiling suspension system with outer clamp for cable tray 4- Two side load ceiling suspension system with U channel 5- Single rod with C clamp ceiling suspension system 6- Double U channel ceiling suspension system with no clamps for cable tray. Bottom horizontal support available in U and channel options. 7- Single rod ceiling suspension system with inside clamp for cable tray 8- Single W channel ceiling suspension system inside clamp for cable tray
Apply uniformly distributed cable loads. (UDL) Locate cable tray/ladder close to the bracket head plate. Use support prop when the load on the bracket is at extremes. Locate unsymmetrical (non-udl) cable loads close to the bracket head plate and avoid such loads on the extremes where applicable.. Wall type brackets must be fixed onto rigid walls in order to achieve a secure fixing. Gerpaas standard GE-KD wall brackets require 2 pieces of M10 concrete anchors for fixing on to wall. Safe work load capacities must be taken into consideration for wall brackets. The applied load must not exceed to allowed load capacity. Cable trays and cable ladders must be fixed on the wall brackets through the slot holes on the wall brackets. M8 fixing sets must be used for fixing the cable trays / cable ladders to the wall brackets. Position the cable tray or cable ladder close to the bracket head plate. Fix the cable tray onto the bracket through the matching slots. All slot holes are M8 sized. Avoid loose fixings. Make sure the cable tray is strongly fixed to the bracket. A minimum of 2 pairs of M8 bolts and nut must be used for each bracket.
SUPPORTS L/20 L The safe working load is limited by a maximum deflection of L/20 at the end of the bracket. A safety factor of 1.7must be included. The recommended support distance is 1500 millimeters since optimum strength is achieved in spans of 1500mm. Supports for cable ladder should be spaced with the recommended span in order to suit the load capacity of the cable tray system most economically. The general rule is that the load carrying capacity of a system increases as the span decreases. A deflection of less than the 20/1 L is measured in all GERPAAS support brackets in accordance with IEC61537. To avoid horizontal sliding support brackets must be suitable with the width of cable ladder / cable tray. For correct installation the below shown table must be followed; Width of cable tray (W) (mm) Width of cable ladder Length of wall bracket 50 50 50 70 70 70 100 100 100 150 150 150 200 200 200 260 260 260 300 300 300 400 400 400 500 500 500 600 600 600 GE-KA HANGER BRACKETS Hanger bracket system creates a suspension system where wall support system is not permissible. The support systems can either be fixed directly to the ceiling or to a channel system above. Hanger brackets must be used with perforated U channels and be mounted with pins or fixing sets. Cable trays and cable ladders must be fixed onto the hanger brackets through the M8 slot holes. The U channels must be fixed to the ceiling with the appropriate ceiling brackets and be fixed to the ceiling bracket with M8 fixing sets where a minimum of 2 pairs of fixing sets required. The ceiling bracket must be fixed on the ceiling with concrete anchors. GE-KA 5 GE-KA 7 GE-KA 10 GE-KA MATERIAL GAUGES TABLE HDG, SS, PG
GE-KA 20 GE-KA 25 GE-KA 30 GE-KA 40 GE-KA 50 GE-KA 60 GE-KA 75 GE-KA-90 HDG, SS, PG HDG, SS, PG HDG, SS, PG 1.5 / 2.0 / 2.5 / 3.0< GE-U channels form a strong and also practical channel system for use in vertical and horizontal fixings. U channels are available in a variety of dimensions and gauges for many types of applications. SLOT PATTERN OF U CHANNELS SLOT PATTERN OF C CHANNELS Item no. Gauge Finish GE-U1 2 GE-U2 2 GE-U3 2.5 GE-U4 3 PG, HDG, SS GE-U5 3 GE-U6 3
RECOMMENDED LOADS FOR STRUTS Span (mm) 41x21x2.0 41x21x2.5 41x21x2.5 41x41x2.0 41x41x2.5 41x41x2.5 41x21x2.0 41x21x2.5 41x41x2.0 41x41x2.5 Perforated Perforated nonperforated Perforated Perforated Nonperforated Back-to-back Back-to-back Back-to-back Back-to-back 500 210 250 270 640 780 825 610 750 1820 2300 750 105 120 145 430 520 555 415 500 1250 1500 1000 55 65 80 320 390 410 310 375 950 1100 1250 35 40 50 215 265 305 205 245 760 980 1500 25 30 35 150 180 210 140 170 635 750 1750 15 20 25 110 135 155 105 125 540 650 2000 15 15 20 80 100 120 80 95 475 570 2250 10 12 15 65 80 95 60 75 385 475 2500 10 10 10 55 65 75 50 60 315 385 2750 8 9 10 45 55 60 40 50 260 320 3000 7 8 8 35 45 50 35 40 215 265 CEILING BRACKETS FOR USE WITH U CHANNELS ITEM NO. AVAILABLE FINISH OPTIONS GE-AS1 PG, HDG, SS GE-AS2 PG, HDG, SS GE-TA3S HDG, SS GE-TA3D HDG, SS CEILING BRACKETS FOR USE WITH RODS LLLLLL ITEM NO. AVAILABLE FINISH OPTIONS GE-AE2 PG, HDG, SS CEILING BRACKETS FOR USE WITH W CHANNELS ITEM NO. AVAILABLE FINISH OPTIONS GE-AE7 PG, HDG, SS
INSTALLATION INSTRUCTIONS 1. System components must be installed in a way that no components damage the other parts on the system. 1.1. System components must have a smooth surface to avoid any damage to the cables during cabling. 1.2. Protective gloves and caps must be worn at all times. 1.3. All fixing bolts connecting the cable trays with the splice plates must be shank or round head type. It is recommended to use GE-KC fixing sets for installation of cable tray & cable ladder system components. The round headed part of the bolt must be facing the cables within the cable raceways for secure and space saving installation. In hot dip galvanized products M6 fixing sets are recommended for faster installation. In pregalvanized, aluminum and stainless steel applications M8 must be used. The recommended use of GE-KC fixing set is shown in the figure below; Item no D2 D1 B L Weight kg/pc GE-KC 01 6 6 9 12 0.010 GE-KC 02 8 8 12 15 0.015 GE-KC 03 8 8 16 20 0.018 d 1 d 2 maks k maks f maks b to 125 b to 200 b over 200 M5 13.55 3.3 4.1 16 - - M6 16.55 3.88 4.6 18 24 - M8 20.65 4.88 5.6 22 28 - M10 24.65 5.38 6.6 26 32 45 M12 30.65 6.95 8.75 30 36 49 M16 38.8 8.95 12.9 38 44 57 M20 46.8 11.05 15.9 - - 46
1.4 Safe working load capacities must be considered at all times. 1.5 Cable trays straight lengths must be used with the components manufactured or recommended by the manufacturer. 1.6 Support brackets must be suitable to the cable trays to avoid horizontal slide. 1.7 Coupling points of the cable trays must be suitable for the support brackets. The recommended span distance for this application is 1.5 meters. Please see the safe working loads charts for each cable tray type. The stated SWL must be followed in design making and installation. Load is a major factor which determines the efficiency and safety of cable support systems. These loads comprise of dead loads including the self-weight of the cable ladder system, the weight of the cable loads and additional equipment attached on the trays (or ladders), loads occurring during cable pulling operations, and external natural loads such as wind loads, snow loads, ice loads and similar. Splice plates are used for prevention of slip between system. components. The holes of the splice plates must match the holes of the connecting lengths of cable trays or cable ladders in order to form a strong and rigid coupling. Gerpaas coupling system has a profile that provides an exact and precise coupling performance combining the systemcomponents properly. All splice plates are delivered singly, but not in pairs. Cable tray fittings (tees, bends, and crossings) do not require splice plates for coupling; instead, each end of the cable tray fittings can be used for coupling through the slot holes designed for such purposes. (See figure below)
Cable ladder fittings require splice plate for each connection. Details available in the below shown table; Component Type Product line # of splice plates required (pcs) Straight Cable ladder Cable ladder 2 Flat bend Cable ladder 2 Tee bend Cable ladder 2 Crossing Cable ladder 2 Reducer Cable ladder 2 Inside / Outside bend Cable ladder 2 Straight cable tray Cable tray 2 Flat bend Cable tray 0 Tee bend Cable tray 0 Crossing Cable tray 0 Reducer Cable tray 0 Inside / Outside bend Cable tray 2 Position of splice plates (couplers) in the interconnection of cable trays / cable ladders must not exceed a distance of 500mm from the supports (brackets or suspension points) for high performance coupling. Each splice plate requires a minimum of 2 fixing sets; and in heavy duty systems, a minimum of 4 fixing sets required for each splice plate. Each coupling must be fixed securely for the safety and the accuracy of the cable tray system. To avoid deflection, each coupling point must be positioned to a maximum of 500mm distance from the support. SWL values of must be followed. 1.8 Splice plates (couplers) are not used when connecting horizontal and vertical bends, tees, crossings to cable trays. However, cable ladder connections require splice plates for all bends, tees, crossings. 1.9 Support brackets must be fixed on to rigid structures. Cracked or deformed areas are not recommended for anchorage. The recommended anchorage component is concrete anchor for fixing support brackets to walls and/ or constuctions.
The length of the support bracket must not be less than the width of the cable tray or cable ladder. It is recommended to apply uniformly distributed loads on support brackets. The cable tray / cable ladder component must be fixed to the support bracket by means of fixing bolts. No loose connections must remain. 1.10 Cable tray and cable ladder components must be used within the recommended temperature ranges at all times. External effects of snow loads, wind loads and else must be taken into consideration. Safe working loads and installation instructions must be taken in consideration at all times. 2. The recommended stocking and shipping temperature range for cable tray systems is between -20 C / +105 C arasıdır. Thermal contraction is an issue in high temperature changes. Thus, the span distance must be 1m in temperatures above +40 C and 0.5m in temperatures above +70 C. 3. The corrosion resistance of cable trays and cable ladders is class 5 with a mean coating of 45 µm zinc coating as per EN 1461. The zinc coating thickness is reached above 200 µm as per customer requirements. 4. General properties of cable tray & cable ladder systems 4.1. Metallic 4.2. Non-flame propagating system component 4.3. Cable tray system or cable ladder system with electrical continuity characteristics 4.4. Electrically conductive system component 4.5. System component with metallic coating 4.6. Temperature range for stocking and transportation -20 C / +105 C 4.7. Surface area opening as per class C, %15-30 4.8. Surface area opening as per class Y, %80-90 4.9. Impact resistance to 5J. 5. Electrical continuity of cable trays and cable ladders must be realized with tinned copper earth links; widths between 50mm-300mm must be linked to each other with 16mm2 earth links, and 300-600mm widths must be linked with 25mm earth links. The fixing of the earth links must be made with M8x15 fixing bolts and nuts, either galvanized, stainless steel, or brass parts. 6. Cable trays and cable ladders and their components must be kept in traffic free areas in an ideal temperature range of -20 / +105 C. Humidity, water and mud must be kept away from the system components. Original containers / packs must be used when stocking, and transporting. External loads must not be allowed on packs or on the products other than the instructions. The components must be kept with elevation off the ground. Walking or applying intolerable loads on the components must not be allowed. An defected or damaged component must be repaired and/ or changed with the brand new ones. Visual and manual inspection must be made before installation.
7. Dimensions DIMENSIONS Thickness Length Width Side height 1.5 2,0 3000 50, 70, 100, 120, 150, 200, 225, 250, 300, 400, 450, 750, 900 25, 40, 50, 60, 75, 100 8. ISO metric threaded bolts must be used for fixing components. The bolts must be of good quality to satisy the 5 tightening/untightening test. 9. The recommended support distance for cable trays and cable ladders is 1.5m. The load capacity drops as the span distance increases. Project details and load capacity diagrams must be followed at all times. The deflection on cable tray must not exceed the 1/100 of the width, and the deflection on support bracket must not exceed the 1/20 of the length of the bracket arm on horizontal section. 10. Coupling points must be close to the support point. The maximum distance between the coupling point to the support point is 0.4L. 11. The load capacity of cable tray fasteners in Y distance from support point is 12.5kg/pc in indirect-support method.
STORAGE Cable support system components must be stored with caution in order to enable durable and safe electrical and mechanical systems. Proper storage includes storage at factory, warehouse, truck, container and at work site. All equipment and materials must be stored in a proper for long time protection and to withstand all environmental conditions. Not only the end user is responsible for this process but also the manufacturer, warehouse keeper, and also all suppliers are. FRAGILE! sign is labeled on each pack or individual item which have any risk of breaking and /or deformation with regular impacts upon request. All components of metallic cable support system must be free of wet and humid areas. It must be under consideration that galvanizing or additional coatings are made for this purpose but exposing the metallic items to water or humidity will reduce the item(s) durability against corrosion. It is a general must-do to keep all items elevated off the ground in order to protect the items from water, mud, and dust. Also it is a general rule to keep these items in a closed area where at least there must be a protective roof. It is recommended to protect the components with a waterproof, chloride free over-wrapping cover or pack. It must be kept in mind that acidic and salty environment is the most destructive. An area where human or vehicle traffic is high is harmful for the cable support systems. In case that the items will be kept in such areas, the items must be kept with original packs.
PACKAGING Also proper packaging must be used for safe storage of the cable support systems. Any impact may remove and deform the items which may harm the cables, the mechanical system and also mechanical impacts may reduce the anti-corrosive characteristics of the system components. Therefore, proper packaging is extremely important. Especially the painted items must be wrapped with nylon or similar covers in order to avoid paint scraps due to small impacts during transportation and / or storage. Special considerations must be given to the packaging to insure that - breakage, damage and theft are prevented, - rust and corrosion are inhabited - water intrusion is prevented - handling is facilitated - economical costs Cable support equipment may be packed, securely anchored and skid mounted when required. Separate, loose, spare parts and also small pieces are generally packed in durable cardboard boxes. Wooden frames and / or wooden pallets are used on the bottom when storing or packing straight pieces, and also cardboard boxes. For packing and storage purposes Gerpaas uses wooden frames, wooden pallets, cardboard boxes and durable nylon bags. In most cases cardboard boxes place on to 4-way-entry wooden pallets are shrink-wrapped with durable nylon bubble-wraps for secure storage. Straight pieces like cable trays, cable ladders, and channels are placed onto wooden pallets or frames and bundled at each end with secure straps. For special components additional packing methods (crates, inner packaging, etc.) can be used.
LABELING All packs are labeled after packaging. Labeling is made with standard Gerpaas product labels which include the following data of the pack; - GERPAAS logo and contact details - Description - Quantity - Weight of pack - Pack number (on request) And all the above listed data is filled completely where necessary. These storage and packaging guidelines are the GERPAAS standard methods and additional methods may be used depending on the buyer s instructions and requests at all times. Standard cardboard box labeling
MAINTENANCE & INSPECTION Installation and maintenance of cable tray wiring systems shall be conducted only by qualified personnel. After completion of installation, including the fittings, inspect exposed finish. Remove burrs, dirt and construction debris and repair damaged finishes, including chips, scratches, and abrasions. Repair damage to galvanized finishes of tray and fittings with zinc-rich spray. It is recommended to check the cable trays and other system components on a regular basis regularly for any damages on the system and on the cables. Visual checks should be made for loose bolted connections at joints and bonding areas. Tighten all hardware in suspect areas. Inspect cable tray after any severe weather including high winds, seismic disturbances, or other abnormal occurrences. When additional cable installation is required on the system check adequacy of supports before installing additional loads. No electrical apparatus should be worked on while it is energized. When it is necessary to work in the vicinity of energized cables, all safety precautions should be followed. If cables are to be touched or moved, they should be de-energized. Neglecting installation and maintenance guidelines may lead to personal injury as well as damage to property.
TESTS We perform standard tests at our inhouse facilities to assure high production quality. These tests are ran as per EN 61537 and include load tests, EMC tests, galvanization thickness tests, mechanical load tests. Other tests which require 3 rd party testing laboratories are performed at accredited test labs, technical universities and / or international institutes.
SAFETY Cable trays, cable ladders nor any of the system components must be used as a walkway, or support for people; this may cause personal injuries, and also damage to the components, the cable support system, and as well as the cables. All system components must be controlled physically for any burrs, sharp edges and irregularities that may harm cables, other equipment or workers. Deformed system components must be repaired or must be changed with new components. Protective gloves and caps must be worn during shipping and carrying the system components. During loading and unloading of cable tray system components by hand, workers must wear safety gloves for protection. Safe working load capacities must be taken in consideration at all times. It is always recommended to set up an upgradeable support system for your requirements also in the future. External loads must be taken into account when designing a cable tray or cable ladder system (e.g. wind loads, snow loads, ice loads etc.) Cable tray and cable ladder interiors where the cables and related equipment will be installed must have smooth surface to allow for easier cable pulling and minimize the risks of damaging the cables. All cable tray and cable ladder straight pieces must be combined at the ends by splice plates. The performance of a cable tray wiring system is dependent on its proper installation, including supports and cables. Neglecting installation and maintenance guidelines may lead to personal injury as well as damage to property. All components of our cable tray and cable ladder systems are metallic type. Please note that nonmetallic supports and hardware may require special load bearing considerations due to material composition and application temperature. (Re.Gerpa-AS- EnvironmentPolicy.pdf)
SAFE WORKING LOADS Created on: 01.01.2010
GE-KT1-A25 N/m 2500 2000 1500 1000 500 1.5mm 1mm 0 1 1.5 2 SPAN (m) GE-KT2-A40 N/m 2500 2000 1500 1000 500 1.5mm 1mm 0 1 1.5 2 SPAN (m) GE-KT2-A50 N/m 2500 2000 1500 1000 500 1.5mm 1mm 0 1 1.5 2 SPAN (m) GE-KT2-A100 N/m 2500 2000 1500 1000 2mm 1.5mm 500 0 1 1.5 2 SPAN (m)
3000 GE-MC1-A50 2500 2000 1500 100 0 500 N/m 1.0 1.5 2.0 2.5 3.0 Span (m) 3000 GE-MC1-A70 2500 2000 1500 1000 500 N/m 1.0 1.5 2.0 2.5 3.0 span (m) 3000 GE-MC2-A100 2500 2000 1500 1000 500 N/m 1.0 1.5 2.0 2.5 3.0 span (m) 3500 GE-MC2-A125 3000 2500 2000 1500 1000 N/m 1.0 1.5 2.0 2.5 GE-MC1-A150 3500 3000 2500 2000 1500 1000 span (m) 1.0 1.5 2.0 2.5 3.0 span (m)
REFERENCE STANDARDS ISO EN 1461 & BS 729 ISO EN 10327 & BS 2989 ISO 9223 ISO EN 14713 structures zinc IEC 61537 NEMA VE 1-1998 NEMA VE 2-2001 Hot dip galvanization Pregalvanization Corrosion of metals & alloys corrosion of atmospheres Protection against corrosion of iron and steel in and aluminum coatings Cable tray and cable ladder systems Cable tray installation guidelines Cable tray installation guidelines