NO: AC.2006.CT.01 خاص) شرکت کامپوزیت آسیاآسیا(سهامی تولیدکننده انواع قطعات کامپوزیتی گریتینگ و سینی کابل) (پروفیل FRP SPECIFICATIONS OF PULTRUDED LADDER-TYPE CABLE TRAYS E- mail:info@asiacomposite.comww w.asiacomposite.com
THE PULTRUSION PROCESS Pultrusion is a manufacturing process for producing continuous lengths of reinforced polymer structural shapes with constant cross-sections. Raw materials are a liquid resin mixture (containing resin, fillers and specialized additives) and flexible textile reinforcing fibers. The process involves pulling these raw materials (rather than pushing, as is the case in extrusion) through a heated steel forming die using a continuous pulling device. The reinforcement materials are in continuous forms such as rolls of mat and doffs of roving. As the reinforcements are saturated with the resin mixture ("wet-out") in the resin bath and pulled through the die, the gelatin or hardening, of the resin is initiated by the heat from the die and a rigid, cured profile is formed that corresponds to the shape of the die. While pultrusion machine design varies with part geometry, the basic pultrusion process concept is described in the following schematic. The creels position the reinforcements for subsequent feeding into the guides. The reinforcement must be located properly within the composite and this is the function of the reinforcement guides. The resin bath saturates (wets out) the reinforcement with a solution containing the resin, fillers, pigment, and catalyst plus any other additives required. The interior of the resin bath is carefully designed to optimize the wet-out of the reinforcement. 1
On exiting the resin bath, the composite is in a flat sheet form. The performer is an array of tooling which squeezes away excess resin as the product is moving forward and gently shapes the materials prior to entering the forming and curing die. In the forming and curing die, the thermosetting reaction is heat activated (energy is primarily supplied electrically) and the composite is cured (hardened). On exiting the die, it is necessary to cool the hot part before it is gripped by the pull blocks (made of durable urethane foam) to prevent cracking and/or deformation by the pull blocks. Strong well uses two distinct pulling systems, one that is a caterpillar counter-rotating type and the other a hand-overhand reciprocating type to pull the cured profile to the saw for cutting to length. CABLE TRAY Per the National Electrical Code, a cable tray system 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 race ways". Composite cable trays are fabricated from components derived from a process called PULTRUSION. This process enables a high percentage of reinforcement to be incorporated into the components giving it very superior strength. The strength of it in relation to its weight therefore exceeds the performance of those of steel or aluminum. Composite cable trays are made from a selection of premium resin reinforced with reinforcements to form a strong composite which is resistance to must chemicals and ultra violet. Composite cable tray resists acids, salts, alkalis and a wide range of aggressive chemicals and solvents. They are also available in fire retardant grade. DIFFERENT TYPES OF CABLE TRAYS ARE: 1) Ladder type FRP cable trays: 2) Box type FRP cable trays: 2
APPLICATIONS OF CABLE TRAYS Applications: Chemical and purification plants Refineries Tunnels Effluent treatment plants Marine industry Metallurgical plants Fertilizer plants Oil & Gas sector Food & Drag industry etc. Users: Railway cable laying Telephone cable laying Electrical cable laying Protection of medium and low tension cable on walls or poles 3
Benefits and Characteristics of FRP Cable Trays Corrosion Resistance Mechanical Strength Fire Resistance High Performance Non-Magnetic Easily Worked Impact Resistance Cut and drilled on site Non-sparking Easy to install Maintenance Free Long Life Light Weight Non rust Cost Saving Nor do they ever require painting Non-Conductive Resistance to most chemicals Low Installation Costs Gives added fire protection to the cables in Superior Strength case of external fire DESCRIBTION CORROSION RESISTANCE The ability of Composite Cable tray is to guard against deterioration from industrial chemicals and environmental factors makes it a logical and cost-effective alternative to carbon steel, aluminium or other conventional materials also it is resistance to weather and UV. Whether Cable tray is exposed to continuous submersion, splash, spills, fumes or gases, you can be assured that Composite Cable tray will outperform other mediums. FIRE RESISTANCE Composite Cable tray is available in various resin systems, two of which meet the Class 1 flame spread rating of 25 or less, in accordance with ASTM E-84 Tunnel Test Method. If a flame spread of 10 or less is required, it will be available in request. 4
NON-MAGNETIC The non-magnetic properties allow the Composite Cable tray to be used in sensitive installations where the inherent magnetic properties of metallic Cable tray would prove unsuitable. IMPACT RESISTANCE The impact resistance of Composite Cable tray allows repeated deflection without permanent deformation. A certain amount of deflection can occur with loading. However, once the load is removed, the grating will return to its original shape, unlike metallic Cable tray, which will remain deformed and require costly repairs or replacement. NON-SPARKING The non sparking qualities of Composite Cable tray systems are ideally suited for those installations where hydrogen or other combustible gases may be found and which may explode or cause a fire from sparks produced. MAINTENANCE FREE The use of Composite Cable tray virtually eliminates maintenance costs since painting is not required and UV inhibitors protect against degradation from the sun. LIGHTWEIGHT Composite Cable tray weighs about one-quarter as much as steel Cable tray. So it needs few men for handling. The lightweight design of the Cable tray reduces installation and fabrication costs. COST SAVINGS In a review of costs, Composite Cable tray showed significant savings over the use of stainless steel Cable tray, and when consideration is given to life cycle costs, the saving over the use of metal Cable tray alternatives is quite considerable. 5
NON-CONDUCTIVE Composite Cable trays don't conduct heat or electricity and also protects the cables. LOW INSTALLATION COSTS Composite Cable tray weighs considerably less than conventional metal Cable trays and is easier and less expensive to transport, install and remove. SUPERIOR STRENGTH The high glass-to-resin ratio of Composite Cable tray provides superior strength and load-bearing characteristics. With structural integrity protected by its unique corrosion resistance capabilities, Composite Cable tray lasts longer than traditional materials. MECHANICAL STRENGTH Breaking strength under a lateral force is exceptional. The uni-directional continuous Composite reinforcement offers numerous advantages, including rigidity, shock-resistance and no permanent deformation after overloading. These factors provide excellent mechanical strength and a generous factor of safety. Composite Cable tray is designed for maximum safety in intensive industrial use. HIGH PERFORMANCE Composite structural Composite Cable tray materials have demonstrated a proven ability to withstand the harsh side effects of corrosive conditions better than galvanized steel. For many years, composites have been reliably used in traditionally corrosive industries while the cost of material is an important criteria in the design of a project, it does not reflect the total cost of the project. Beyond material purchase price, the engineer also should consider the related costs of installation, maintenance over time and replacement of debilitated materials. 6
FIBERGLASS CABLE TRAY SELECTION Straight Section Horizontal Bend 90º, 45º (HB) Horizontal Bend 90º Horizontal Bend 45º Horizontal Tee (HT) Horizontal Tee 7
Horizontal Cross (HX) Horizontal Cross Reducer (LR) Left Reducer Reducer (SR) Straight Reducer Reducer (RR) Right Reducer 8
Horizontal Reducing Tee (HT) Horizontal Reducing Tee Horizontal Expanding Tee (HT) Horizontal Expanding Tee Horizontal Expanding / Reducing Cross (HX) Horizontal Expanding / Reducing Cross 9
Vertical Tee Down (VTD) Vertical Tee Up (VTU) Vertical Tee Down Vertical Tee Up Outside Vertical Bend (VO) Outside Vertical Bend 90º Outside Vertical Bend 45º Inside Vertical Bend 45º Intside Vertical Bend 90º Inside Vertical Bend (VI) 10
90º Direct Horizontal Bend 90º Horizontal Bend 12" Radius 45º Direct Horizontal Bend 45º Horizontal Bend 12" Radius 90º Direct Vertical Inside Bend 90º Vertical Inside Bend 12" Radius 45º Direct Vertical Inside Bend 45º Vertical Inside Bend 12" Radius 11
90º Direct Vertical Outside Bend 90º Vertical Outside Bend 12" Radius 45º Direct Vertical Outside Bend 45º Vertical Outside Bend 12" Radius Horizontal Tee Direct Horizontal Tee 12" Radius Horizontal Cross Direct Horizontal Cross 12" Radius 12
CABLE TRAY CHEMICAL RESISTANCE GUIDE CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Oper. Temp F Acetic Acid 10 190 10 210 Acetic Acid 50 125 50 180 Acetone N/R N/R 100 75 Aluminum Chloride SAT 170 SAT 200 Aluminum Hydroxide SAT 160 SAT 170 Aluminum Nitrate SAT 150 SAT 170 Aluminum Sulfate SAT 180 SAT 200 Ammonium Chloride SAT 170 SAT 190 Ammonium Hydroxide 1 100 10 150 Ammonium Hydroxide 28 N/R 28 100 Ammonium Carbonate N/R N/R SAT 150 Ammonium Bicarbonate 15 125 SAT 130 Ammonium Nitrate SAT 160 SAT 190 Ammonium Persulfate SAT N/R SAT 150 Ammonium Sulfate SAT 170 SAT 200 Amyl Alcohol ALL N/R ALL 90 Amyl Alcohol Vapor - 140-120 Benzene N/R N/R 100 140 Benzene Sulfonic Acid 25 110 SAT 200 Benzoic Acid SAT 150 SAT 200 Benzoyl Alcohol 100 N/R 100 N/R Borax SAT 170 SAT 200 Calcium Carbonate SAT 170 SAT 200 Calcium Chloride SAT 170 SAT 200 Calcium Hydroxide 25 70 25 165 Calcium Nitrate SAT 180 SAT 200 Calcium Sulfate SAT 180 SAT 200 Carbon Disulfide N/R N/R N/R N/R Carbonic Acid SAT 130 SAT 180 Carbon Dioxide Gas - 200-200 Carbon Monoxide Gas - 200-200 Carbon Tetrachloride N/R N/R 100 75 Chlorine, Dry Gas - 140-170 Chlorine, Wet Gas - N/R - 180 Chlorine Water SAT 80 SAT 180 Hydrogen Bromide, Wet 100 75 100 130 Hydrogen Chloride - 120-200 CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Oper. Temp F Chromic Acid 5 70 10 120 Citric Acid SAT 170 SAT 200 Copper Chloride SAT 170 SAT 200 Copper Cyanide SAT 170 SAT 200 Copper Nitrate SAT 170 SAT 200 Crude Oil, Sour 100 170 100 200 Cyclohexane N/R N/R N/R N/R Cyclohexane, Vapor ALL 100 ALL 130 Diesel Fuel 100 160 100 180 Diethy Ether N/R N/R N/R N/R Dimethyl Phthalate N/R N/R N/R N/R Ethanol 50 75 50 90 Ethyl Acetate N/R N/R N/R N/R Ethylene Chloride N/R N/R N/R N/R Ethylene Glycol 100 90 100 200 Fatty Acids SAT 180 SAT 200 Ferric Chloride SAT 170 SAT 200 Ferric Nitrate SAT 170 SAT 200 Ferric Sulfate SAT 170 SAT 200 Ferrous Chloride SAT 170 SAT 200 Fluoboric Acid N/R N/R SAT 165 Fluosilicic Acid SAT N/R SAT 70 Formaldehyde 50 75 50 100 Formic Acid SAT N/R 50 100 Gasoline 100 80 100 150 Glucose 100 170 100 200 Glycerine 100 150 100 200 Heptane 100 110 100 120 Hexane 100 90 100 130 Hydrobromic Acid 50 120 50 120 Hydrochloric Acid 10 150 10 200 Hydrochloric Acid 20 140 20 190 Hydrochloric Acid 37 75 37 95 Hydrofluoric Acid N/R N/R 15 80 Hydrogen Bromide, Dry 100 190 100 200 Potassium Hydroxide N/R N/R 25 150 Potassium Nitrate SAT 170 SAT 200 13
CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Oper. Temp F CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Hydrogen Peroxide 5 100 30 100 Potassium Permanganate 100 80 100 210 Hydrogen Sulfide, Dry 100 170 100 210 Potassium Sulfate SAT 170 SAT 200 Hydrogen Sulfide, Wet 100 170 100 210 Propylene Glycol ALL 170 ALL 200 Hypocholorous Acid 20 80 20 150 Phthalic Acid - - SAT 200 Isopropyl Alcohol N/R N/R 15 80 Sodium Acetate SAT 160 SAT 200 Kerosene 100 140 100 180 Sodium Benzoate SAT 170 SAT 200 Lactic Acid SAT 170 SAT 200 Sodium Bicarbonate SAT 160 SAT 175 Lead Acetate SAT 170 SAT 200 Sodium Bisulfate ALL 170 ALL 200 Lead Chloride SAT 140 SAT 200 Sodium Bromide ALL 170 ALL 200 Lead Nitrate SAT - SAT 200 Sodium Carbonate 10 80 35 160 Linseed Oil 100 150 100 190 Sodium Chloride SAT 170 SAT 200 LithiumChloride SAT 150 SAT 190 Sodium Cyanide SAT 170 SAT 200 Magnesium Carbonate SAT 140 SAT 170 Sodium Hydroxide N/R N/R 50 150 Magnesium Chloride SAT 170 SAT 200 Sodium Hydroxide N/R N/R 250 80 Magnesium Hydroxide SAT 150 SAT 190 Sodium Hypochloride N/R N/R 10 150 Magnesium Nitrate SAT 140 SAT 180 Sodium Monophosphate SAT 170 SAT 200 Magnesium Sulfate SAT 170 SAT 190 Sodium Nitrate SAT 170 SAT 200 Mercuric Chloride SAT 150 SAT 190 Sodium Sulfate SAT 170 SAT 200 Mercurous Chloride SAT 140 SAT 180 Sodium Thiosulfat ALL 100 ALL 120 Methyl Ethyl Ketone N/R N/R N/R N/R Stannic Chloridee SAT 160 ALL 190 Mineral Oils 100 170 100 200 Styrene N/R N/R N/R N/R Monochlobenzene N/R N/R N/R N/R Sulfated Detergent 0/50 170 0/50 200 Naphtha 100 140 100 170 Sulfur Dioxide 100 80 100 200 Nickel Chloride SAT 170 SAT 200 Sulfur Trioxide 100 80 100 200 Nickel Nitrate SAT 170 SAT 200 Sulfuric Acid 93 N/R 93 N/R Nickel Sulfate SAT 170 SAT 200 Sulfuric Acid 50 N/R 50 180 Nitric Acid 5 140 5 150 Sulfuric Acid 25 75 25 190 Nitric Acid 20 70 20 100 Sulfurous Acid SAT 80 N/R N/R Oleic Acid 100 170 100 190 Tartaric Acid SAT 170 SAT 200 Oxalic Acid ALL 75 ALL 120 Tetrachloroethylene N/R N/R FUM 75 Paper Mill Liquors - 100-120 Toluene N/R N/R N/R N/R Perchlorethylene 100 N/R 100 N/R Trisodium Phosphate N/R N/R SAT 175 Perchloric Acid N/R N/R 10 150 Urea SAT 130 SAT 140 Perchloric Acid N/R N/R 30 80 Vinegar 100 170 100 200 Phosphoric Acid 10 160 10 200 Water, Distilled 100 170 100 190 Phosphoric Acid 100 120 100 200 Water, Tap 100 170 100 190 Potassium Aluminum Sulfate SAT 170 SAT 200 Water, Sea SAT 170 SAT 190 Potassium Bicarbonate 50 80 50 140 Xylene N/R N/R N/R N/R Potassium Carbonate 10 N/R 10 120 Zinc Chloride SAT 170 SAT 200 Potassium Chloride SAT 170 SAT 200 Zinc Nitrate SAT 170 SAT 200 Potassium Dichromate SAT 170 SAT 200 Zinc Sulfate SAT 170 SAT 200 Oper. Temp F 14
PHYSICAL PROPERTIES OF LADDER - TYPE CABLE TRAY Properties Test Method Unit Value Ultimate Tensile Strength ASTM D638 PSI 30,000 Ultimate Compressive Strength ASTM D695 PSI 30,000 Ultimate Flexural Strength ASTM D790 PSI 30,000 Tensile Modulus PSI 10 6 2.5 Compressive Modulus PSI 10 6 2.5 Flexural Modulus PSI 10 6 1.6 Ultimate Shear Strength PSI 5,500 Ultimate Bearing Stress PSI 30,000 Izod Impact Strength (sample thickness 1/8") ASTM D256 Ft.-LBS. Per Inch of notch Barcol Hardness ASTM D2583-75 50 Electric Strength, Short Term in Oil 1/8" ASTM D149 VPM 200 Electric Strength, Short Term in Oil KV Per Inch 35 Dielectric Constant ASTM D150 60HZ 5.6 Dissipation Factor ASTM D150 60HZ 0.03 Arc Resistance ASTM D495 Second 120 Surface Burning characteristics ASTM E84 15 Thermal Coefficient of Expansion ASTM D696 Inches / Inch / F 5 10-6 Thermal Conductivity ASTM C-177-76 BTUPer Sq. Ft./Hr./ F/In Specific Heat BTU / Lb. / F 0.28 Density ASTM D792 Lbs. / In 3 0.065 Specific Gravity ASTM D792 1.8 Water Absorption (24 hour Immersion) ASTM D570 % by weight 0.5 25 4 15
PHYSICAL PROPERTIES OF BOX - TYPE CABLE TRAY Properties Test Method Unit Value Ultimate Tensile Strength ASTM D638 PSI 30,000 Ultimate Compressive Strength ASTM D695 PSI 30,000 Ultimate Flexural Strength ASTM D790 PSI 30,000 Electric Strength, Short Term in Oil 1/8" ASTM D149 VPM 200 Electric Strength, Short Term in Oil KVPer Inch 35 Thermal Coefficient of Expansion ASTM D696 Inches / Inch / F 5 10-6 Density - Solid Shape ASTM D792 Lbs. / In 3 0.065 Water Absorption (24 hour Immersion) ASTM D570 % by weight 0.5 Surface Burning Characteristic ASTM E84 25 16
LOAD DESCRIPTION Fiberglass Box-Type Cable Tray System Catalog Number imum Span (Ft) imum Loading (Lb / Ft) CCT1 10 10 CCT2 10 12 CCT3 10 20 CCT4 10 25 Dimension mm Catalog No. A B C CCT1 102 121 129.75 C B CCT2 102 324 333.75 CCT3 152 171 180.75 CCT4 152 324 333.75 A Fiberglass Ladder-Type Cable Tray Systems - Working (Allowable) Load Lbs./Ft. (Kg/m) Support Span Ft. (m) ELL3 Class A ELL4 Class A EHL4 Class A Kind of Resins ELL6 EIL6 EMZ6 Class B Class A D-EHL6 EHL6 Class C D-EHL8 EHL8 Class C D-EHL10 Class C 30 (9.1) - - - - - - - 100 (148) 20 (6.0) - - 50 (74) 50 (74) 75 (111) 100 (148) 100 (148) 225 (335) 18 (5.5) - - 76 (113) 61 (90) 92 (137) 123 (183) 123 (183) 277 (412) 16 (4.8) - - 103 (153) 78 (116) 117 (174) 156 (232) 156 (232) - 14 (4.3) - - 134 (199) 100 (149) 150 (232) 200 (298) - - 12 (3.6) - 50 (74) 176 (262) 139 (207) 208 (310) - - - 10 (3) - 72 (107) 224 (333) 200 (298) - - - - 8 (2.4) 50 (74) 112 (167) - - - - - - 17
SPLICE PLATES, CONNECTORS & ACCESSORIES FIBERGLASS CABLE TRAY SYSTEMS StandardSplice Plate Expansion Splice Plate Horizontal Splice Plate (30º, 45º, 90º) Vertical Splice Plate (30º, 45º, 90º) 18
90Degree Angle Connector Horizontal Adjustable Connector Vertical Adjustable Connector Tray To Box Splice Plates 19
Step Down Plates Blind End Plate Ladder Drop-out Standard Cover Clamp Heavy Duty Cover Clamp 20
STANDARDS OF FRP COMPOSITES The Following Standards are used in composite productions: ASTM C-177-85 ASTM D-149-87 ASTM D-229-86 ASTM D-256-87 ASTM D-495-84 ASTM D-570-81 ASTM D-635-81 ASTM D-638-87b ASTM D-695-85 ASTM D-696-79 ASTM D-709-87 ASTM D-732-85 ASTM D-790-86 ASTM D-792-86 ASTM D-953-87 ASTM D-1499-84 ASTM D-1505-85 ASTM D-2344-89 ASTM D-2583-87 ASTM D-2584-85 ASTM D-3647-84 ASTM D-3846-85 ASTM D-3914-84 ASTM D-3916-84 ASTM D-3917-88 ASTM D-3918-80 ASTM D-4385-88 ASTM D-4475-85 ASTM D-4476-90 ASTM E-84-87 ASTM E-662-83 ASTM E-831-86 ASTM F-1092-94 ASTM G-23-81 ASTM G-53-84 Heat Flux Dielectric Strength Testing Rigid Sheet for Electrical Insulation (Ladder) Impact Resistance Electrical Resistance Water Absorption Flammability Tensile Strength Compressive Strength Thermal Expansion Specifications for Laminated Thermosetting Materials Shear Strength by Punch Flexural Strength Specific Gravity Bearing Strength Weathering Density Interlaminar Short Beam Shear Strength Hardness Ignition Loss Classifying Pultruded Shapes In-plane Shear Strength In Plane Shear Tensile Dimensional Tolerances Pultrusion Terms Visual Defects Short Beam Shear Strength Flexural Properties Tunnel Beam Test Smoke Chamber Linear Thermal Expansion (CTE) Handrails Weathering Weathering 21