Guidelines for the Installation of Cable in Cable Trays

Authors:

Bob Finke, Member Sid Ticker, Member

The Okonite Company Southwire Company
1600 Parkwood Circle, Suite 603 One Southwire Drive
Atlanta, Georgia 30339 Carrollton, Georgia 301 19

Abstract

The use of ladder type trays as raceways for insulated cables is A For pulling eyes and bolts the maximum tension is
becoming more prevalent These raceways are being more heavily expressed as
loaded with increasing number and size of cables being installed Tmax = 008'N'A E.q. (1)
With this growth in the use of tray, it is increasingly important that (For copper conductors and full hard drawn
the tray and cable be installed within ipdustry recognized practices aluminum )
Discussed are the installation in tray of single and multi-conductoi
insulated cables with design limitations, example calculations, Tmax= .006 * N * A (For soft aluminum) Eq. (2)
equipment and equipment usage snd its limitations
Where Tmax = Maximum allowable pulling tension
Introduction in Ibs/(kg)
N = Number of conductors
For over thim years the use of ladder-type tray as a rigid A = Conductor area in circular Mils
structural systern for support of cables has grown dramatically (mm2)
Accompanying this increase, is the need for larger and longer ,006 or ,008 = Allowable stress per circular Mil
cables to be installed Designers and installers are continually (mm') area for referenced metals.
faced with difficult challenges in the layout and installation of cable
in tray It is incumbent that pre-planning of an orderly sequence of For pulling eyes and bolts, the tension ganerated
events takes place to ensure that a successful installation occurs in a straight section of cable tray is expressed as:
within recognized limits
T= Lxwxf Eq. (3)
Cable installed in tray is subject to many of the same
considerations as cable being installed in conduit systems Where L = The length of the cable trav section
Correctly calculated data and adherence to the design limits of the in feet (m)
cables being installed with respect to tensions, sidewall pressures, w = The total weight of the cable being
and minimum bending radii increases the probability for a pulled in pounds (kg).
successfJl installation Damage occurs more frequently as a result f = The coefficient of friction
of improper handling during installation, or inadequate protection
after installation, Cable tray layout must take rnt 3 consideration the A range of 15 to 25 is recommended f i r the
design Iimqts of the cable coefficient of friction This coefficient is a fun( tion of
the condition and alignment of sheaves

Installation Design Considerations and Formulas
-.Tensions
The maximum allowable pulling tension that can be applied
safely to a cable varies with the size and material of the conductor,
the number of cables, and the method of attachment between the
pulling line and cable
B For basket grips the limit is 1000 Ibs (45 i 6 kglm)
per grip or the value calculated in equatiJn (1)
whichever is smaller This limit applies tcr a single
conductor cable, a multi-conductor cable with a
common overall Jacket,two or three twisted
cables, or paralleled caoles using one giip It IS
desirable to pull the cable by the conduc tors if this
cho ce can be made rather than other @Degrips
C For conductor wedge type corripressior grips, the
grip manufacturer should be consulted for design
limits of these devices The same limits apply to
the>,e devices as pblling eyes and bolts

67 0-7803-2418-8-6/95 $4.00 0 1995 IEEE

Sidewall Pressures
Sidewall pressure is defined as the pressure or force per unit
length that is exerted on a cable when it is pulled around a sheave
in a cabte tray.
Darnage to cable while being installed in tray may occur if the
maximum pressures are exceeded Where change in the direction
of the cable pull is made, conveyor sheaves are employed
Conveyor sheaves are multi-sheave devices bound together by a
rigid meValframe to form an arc of various degrees Rue to the
small diameter of individual sheaves, it is recommended that each
conveyo’. sheave have a minimum of one sheave for every 20
degrees of bend (See Fig 1) The conveyor sheaves must be
properly sized with radii sufficiently large to satisfy the maximum
allowable sidewall Pressure limits and minimum bending radii
requirevents
Typically, the tension out of the sheave is
considered to be the same as the tension into the
sheave. Many believe this to be true because the
sheaves are considered to be frictionless. However, a
moment of force is generated by the cable in its effort
to conform to the shape of the sheaves. From practical
experience, this force or tension is found to be 100 to
150 pounds (45.3-68.0kg)for larger cables This
should be added to the total tension calculations.
Calculation of the sidewall pressure out of the sheave
can be obtained by using the following formula.
For single conductor cables or multi-conductor
cable urider a common jacket the formula:
SWP = To/R Eq. (4)
Where SWP = Sidewall Pressure in IbRt (kg/m)
To = Tension out of sheave in pounds (kg)
R = Radius of sheave in feet (m)

When installing new cable in existing trays with

existing cable, these existing cables need to be
protected By placing a sheet of plywood or other rigid
flat surfaced material over the tray in a bend, the
sheave can be placed on top of the plywood and over
.-
Cable Cable the existing cable This surface not only protects the
existing :able but provides support to the sheave

Proper Improper Reel Back Tension

Reel back tension ISgenerated when removing

Fig. 1 -SHEAVE CONFIGURATION the cable from the cable reel To further assure proper
pulling of the cable, a reel drive mechanism or
adequate manpower should be provided as the cable is
Alignment of the conveyor sheaves to accept the cable being renoved from the cable reel An effort should be
should be made prior to the actual pull by applying tension to the made to prevent free-wheeling of the reel during the
pulling rope and aligning the rope in the center of the sheaves pull Thc. drive mechanism (equipped with braking
Slight adjustments during the pull may be required The sheaves ability) works best in controlling cable payoff Some
and the individual sheaves of conveyor sheaves should be free installers choose to use a fulcrum and wedge device to
turning and well lubricated prevent free- wheeling This works well as lorig as the
reel is nct elevated to a height where employment of
such a rig is impossible This tension must be
The following table is recommended when considering considered when calculating the total tensior
maximuqt sidewall pressures developed during the installation The recormended
tension io calculated by the equation
TABLE I
Maximum Sidewall Pressure PMAX - Tr = 25 * W Eel (5)
(Lbslft or kglm)
Power Cables Conductor Size Where T r = Tension in pounds (kg) at the reel
<8AWG > 8AWG W = Weight per foot of cable in pounds (kg/m).
Lbslft kglm Lbslft kglm
One Single Cable 300 136 500 2268
Two or More (parallel or plex) 500 226 E 1000 453 6

Multi Conductor Power & Control Cable All Sizes

Lhslft kglm
One Cable 500 226 8
Two or Msre Cables 1000 4 5 3 6

Instrument Cable
Single Par
Multipair

68
Pulling Device
The common method of pulling cable into tray is with the use
of an electric winch or tugger, or a truck-mounted winch. Pullers
are generally rated between 4000 and 6500 pounds and provide a
direct tension readout as the pull progresses. A truck- mounted
winch has a very high tension limit, and the pulling tension is
generally read by a inline dynamometer or a tensiometer. Some
tuggers are equipped with control devices to allow for a preset
tension to be programmed. If this preset tension is exceeded, the
tugger will stop the pull. The route should be inspected foot by
foot for faulty equipment, alignment of equipment, or other
obstructions, since pre-installation calculations did not predict this
situation The tension must be read constantly during the pull
On extremely long pulls, the maximum pulling tension or
sidewall pressure limits can often limit the distance a cable can be
pulled. When using conventional pulling techniquets (i.e. one cable
puller), the installation of splices should be consil3ered. Though
not considered reliable by some, splices done ccvectly provide
long reliable service.
If an nstaller IS faced with a design calling tor a long length of
cable to be installed without splices, and back feeding ISnot a
consideration, a second, or assist puller can be used The risk of
damage to the cable is increased when back feeding a significant
portion of the cable and should be the last alternative employed
The assist puller method is accornplished by strategically
placing an additional puller and pulling line in d straight section of
the pull T'iis puller is used to pull slack to the point of the assist
puller By Dulling slack, the pulling tension and sidewall pressure
from that point are reduced The lead or main puller will have a
lesser load to pull, thereby reducincj philling tensiorls and sidewall
pressures (See Fig 2)
Good communication between the main puller and the assist
puller must be established The pi.rlling line of the assist puller is
attached to the cable by using a "mare's tail " A swivel joint must
be placed between the mare's tail or grip The mare's tail, or grip
is made of high-strength fibers and IS woven around the cable to
form a "Chinese finger" type grip that spreads the pulling tension
over several feet of the cable surface The mare's tail must be
sized prcperly to evenly distribute the pulling force over a sufficient
amount of cable length The maximum allowable tension of the
"mare's tail" is 3000 pounds (1360 8kg) for armored cable and
1000 pourids (453 6kg) for non-armored cable
Field experience has shown that several layers of friction
tape over the surface of the cable armor or jacket and beneath the
"mare's tail" provide a better gripping surface The friction tape
also serves as a bedding layer -- important when installing
thermoplastic jacketed cable in Wdrm temperatures
I' "
69
In Fig 2, the assist puller (P2) is installed in a
straight section of cable tray. The cable is pulled to the
assist puller, but not around Bend No. 2. The assist
puller rope is attached to the cable with a "mare's tail"
at point P2'. When the pull is restarted, the main puller
(PI) is now pulling only that cable from the "mare's tail"
to point B. The assist puller (P2) is pulling the cable
from the reel located at point A to the "mares tail", P2'.
As the mare's tail approaches the assist puller, the
sidewall pressure in Bend No. 2 is reduced as less
cable is pulled from P2' to the bend by puller P I . The
tension at puller P I remains fairly constant during the
pull, but increases each time the "mare's tail" is
reconnected to complete the pull. The tension at P2'
increases as more cable is pulled from the reel
Roller Mounting and SDacing
Spacing of the rollers must be adequate to
prevent the movfng cable from touching or rubbing the
tray The iollers must be placed to keep the cdble in a
fairly level position As the cable approaches t?e end
of the pull the tension is significantly greater 3t this
point, allowing for rnore distance between rollers Field
experience shows that 15' (4 57m) apart is gcod but
10' (3 04) spacing is better The Objective is tn reduce
drag and tension The following equation can be used
to calculate spacing
s=,,6HT/ W
Where S = Distance between rollers in feet (neters)
H = Height of top of rollers above tray
surface in feet (meters)
T = Tension in pounds (kg)
W = Weight per foot of cable in Ibslft, (kglm)
Use of this equation requires an estimate of
tensions along the tray route Field experienc ?
demonstrates it is not practical to establish varying
numbers of different roller spacings The inst,iller
should have excess rollers in place to prevenl excess
sag and drag
Armor LockinqlPinning
Field experience has shown that the melallrc
sheath of an interlocked or continuous corrugated
armored cable will most likely sleeve if the armor is not
adequately secured to the cable core conductors This
can be accomplished by one of three methods 1 Drill
two holes 90 degrees apart, within two feet from the
pulling eye or bolt and inserting flat head bolts or solid
wire rht?diameter of the bolts should be no smaller
than 1/4' in diameter 2 Nail the armor by inserting
nails through the armor 90 degrees apart to E depth
into the cable core sufficient to allow them to not be
easily removed 5 Use a compression grip ir
conjunct on with the pulling eye or bolt
 Pulling LinelRope
The pulling rope should be a high-strength, low- stretch,
abrasion resistant rope. Its strength should exceed the maximum
tension to be encountered during the cable pull. A safety factor of
We is recommended. Double-braided ropes made of aramid and
some polyester fibers are good. Manila hem&ine is also
acceptable. Unstressed nylon or polyethylene is not
recommended due to their high stretch characteristics.
Lubrication
Though not normally considered when installing cable in tray,
field experience has shown that friction can be reduced if the cable
is lubricated during the pulling process. This can be done by
simply swabbing the cable as it pays off the reel. A lubricant
compatible with cable outer covering should be considered. Roller
and sheave bearings should be lubricated prior to the pull as well.
Any rollers and sheaves with sharp protrusions and not free
spinning should be repaired or replaced.
Pulling Eves. Bolts and Swivels
Pulting eyes or b o b can be factory or field installed. Factory-
installed eyes or bolts are done under "ideal" conditions using
presses adequate for crimping. Eyes and bob are madefor single
and multi-conductor cable configurations. Some installers rig a
pulling eye by using the bare conductor formed into an eye shape.
If this method is chosen, the client or cable manufacturer should
be contac:tedto ensure that the pulling tensions are not exceeded,
and the strand cross-section is not reduced for convenience on
large conductors. (See Fig. 3)
COMPRESSION AR E A
- C0MPRBSSIO)V BrWCOMUPRBSSJON BOLT
Flr. J
A m v e l device should be used at the point where the pulling
eye or bolt is attached to the pulling line. This serves to reduce the
twist that normally occurs when pulling caMb during installation.
PUUlUGBiWBOLTGRIP SR'lVIL ROPE TO
TO CABLE / m m
I-
7 1 1 Y Us = Longitudinally applied mrrugatcdshield
Fig. I SIIYEI. INSTALLATION
70
Cable Trav Lavout
Whether installing cable in existing trays or newly
installed trays, it is incumbent that the tray layout be
considered when designing a cable pull. Cable tray
bends must accommodate the minimum bending
radius required during pulling so that the maximum
sidewall pressure is not violated. (Tables 11,111 give
minimum training radius for various cable construction.)
The location of the tray determines if the proper pulling
equipment can be used to complete the pull in one
section. Location of the reel with respect to the tray
entry point is critical as a large tension can be created
at this point if the reel is a substantial distance from or
below the tray entry point. These and other
considerations must be addressed in the early stages
of planning the installation. Design, planning, and
coordination between the designer, installer, and end
user is imperative.
l55 and Lm
-
170 310
3ZSandOvcr
TABLEID
Cables With Metallic Shieldine or Armor
Pmcrcontd
Muu"Bending h & u s as a Multipk dCabkDb t c r
Anoored,Oattapcorwirctype ............. U .... 12
Armored,sal& aluminum rhea* up to
0-75 hrher cabk diamettr .................... 10' .... 10'
... U
0.76 to I 5 inches cable diameter .............. 12
Ovcr 15 inches cablc diamctcr ................ 15 .... ti
Armored, Comgated sheath or intcrlockcd lypc .. 7 ..-.. 7
WithrhicMedsingleconductor................ U .... U
Withchieldcdmulti-awductor................. 7 ..... 7
Nooanmorcd, Oat or mrmgated
Tapc shielded single conductor ................ U .... l2
Tapc s h i e d multicoodudor ................. 7 ..... 7
Uswith W C jackct .................... 15 .... 15
Nooarmortd, k t shapshieldcd ............... 8 .......
Non-od, wirc shicldcd ................... I2 .......
With shiddcd conductorsl2
Other Considerations Number of Bends

TemDerature Considerations Every bend whether vertical or horizontal

increases the tensions and complicates the cable pull.
Prior to making the pull, the cable temperature should be Where design allows, these bends need to be
warm enough to prevent cracking of all the various non metallic minimized. The layout should not be looked at as
components. The cable should be kept in a heated indoor storage trying to get cable from point A to point E. but rather
area for 48 hours prior to installation in extreme low temperature what design limits are inherent with regard to the cable
cases. being installed. Decisions can then be made about
splices and at what point should the splice be made.
Table IV
rypC or insulation Minimum Temperature The worst case is to actually get into a cable pull
or Jacket for Installation where design calculation limits are at maximum and be
forced to splice at a point in the cable pull that was not
PVC -10°C . . . . . . . . . 14°F
EP R 4 ° C . . . . . . . . 40°F given good forethought and planning. Cable tray
PE -40°C . . . . . . . . 40°F configurations that contain numerous horizontal and
XLPE 4°C . . . . . . . . 4YiF vertical bends may satisfy the maximum calculation
PVC (Arctic) -40°C ........ .AO"J
limits for tension, sidewall pressuie, and bending radii.
CSP(Hypa1on)ORCPE -20°C: . . . . . . . 4°F However, the practicality of pulling cable through the
tray system should be judged after site visits and
Trav Height
inspections. Interim steps during installation may be
considered such as spanning or bridging cable near
Height of the tray should be minimized where possible so that
bends prior to final training of cables into the cable tray
l icranes and elevated platforms do not become necessary to
configuration.
position reels of cable (See Fig.5) If this is not possible, the
installer should make necessary equipment or platform
Maximum Cable Lenaths
arrangements to reduce the tension applied to the cable when
originatvng the pull.. In some cases, cable can be installed by
Maximum cable lengths are driven by two
loading the cable reel on a crane, l i n g the cable above the tray
variables. At the factory, the mwknum length is related
and then moving the reel parallel to the tray and placing the cable
to production and testing capabilities. At the job site,
in its tray position. In rare cases, the cable reel can be l i e d by
the logistics of the site conditions andor installation
helicopter, lifting the cable reel above the tray, then moving along
equipment dictates cable lengths. The gross weight
the tray route and placing the cable in the tray Reliable breaking
and overall dimensions of the reel should always be
of the reels is recommended when using these methods.
considered at the planning stage.

7 oday, the splice designs for low and medium

voltage cable constructions are sound, easy to install,
and reliable. Splicing is a viable option when planning
and defining an installation scope of work that
responds to the best cost- effective cable tray
installation.

Pull Preparation

The dynamic and mechanical forces that exist

Tray Obstacles
Where design allows, trays should be installed so that
obstacles do not exist to inhibit installation of sheaves and rollers.
In addition, thought should be given to support structure. Many
times an installation requires that the sheavelroller apparatus be
attached and suspended. The support structure must have
adequate mechanical strength to handle the tensions applied to
the cable when making the pull Cable tray is not designed for
support structure of sheaves.
during cable movement should be recognized and
respected. The installation crew, inspectors, and
visitors to the jobsite should be trained and briefed on
the planned operations.
Confirm the direction of the pull derived from
tension, and sidewall pressure calculabons, and if
pulling equipment can be set up (See examples
below )
Two-way communications and adeqdate
manpower should be provided at both feeding and
pulling ends of the cable pull
Manpower should be placed strategically (at bend
locations) along the pull route to ensure the cable
maintains alignment in the rollers and sheaves. Two-
way communications at the sheaves should be
prowled

71
 Establish that the pulling equipment is adequate for the
anticipated tensions and can provide a smooth uninterrupted pull
and speed control. Variations in speed will cause "galloping."
Establish adequate tension monitoring.
Lubricate all rollers and sheaves and coifirm they are all free-
turning
Consideration should be given to the last piece of cable
coming off the reel. This section of cable is generally not secured
to the reel drum by a tether: personnel safety must be addressed.
Pullina the Cable
The start of the pull should be slowly accelerated to be sure
damage is not incurred while the cable is being fed into the cable
tray fron the reel.
After entry into the tray, the pull should be accelerated to a
constant pulling speed in the range of 15 feet per minute
(4 5 7 m V " ) to 50 feet per minute (15 2 4 m l m i ~) The pull should
be contiriuous without stopping
Ret ord pulling tension reading at frequent intervals
particula ly after exiting conveyor sheaves
Summary
As inore cable tray installabons are being utilized it is
imperative that installation guidelines be employed so that reliable,
trouble free service ltfe is obtained
Limits of pulling tension, sidewall pressure, and minimum
bending radii have been described showing that installation
calculaticns are the basis of avoiding violations of these limits.
Frequently, these calculations are ignored resulting in cable
damage which can ultimately reduce the service life of the cable
For a successful cable tray installation to rake place,
equipme i t must be properly sized and utilized From calculations,
the size lating, and location of the equipment with respect to the
cable alii1 cable tray layout can be made
In l a w cable tray design, the cable to be installed should be
considert-d with regard to its installation limits Proper pre-design
can alleviate most field installation problems C oordination
between Dwner, designer, and installer is paramount for a
successf 11 installation
Example - Calculations Cable in Tray See Fig. 6
A 3/C-531 kcmrl copper 15KV-133% level armared cable (Type
MV-90 0 1 MC approved for cable tray use per NEC)
Approximate OD=3 60 inches (91.4")
Net Weight Per Foot = 8.67 Ib ( 3 9 . 3 ~ g )
Minimurn Bend Radius is equal to 7xOD (during installation) 01
larger to satisfy the maximum allowable sidewall pressure limit
Minimum bend radius =7 X 3 6 in = 25 2 ' (640 08")
Effective :able Weight wt = 8 67 X 15 = 1 30 Ib
72
Maximum Sidewall Pressure: 1000 Ib (453.6kg) per
foot of bend radius for three conductor cable.
With a radius of 3 feet for all sheaves the maximum
pulling tension is 3000 Ibs. (1360.8kg)
A precise calculation of the effective distance
between cable reel and sheave shown in Fig 6 may be
made at the start of the pull, (if reel and sheave
dimensions, A-frame or reel jack details are known and
if the mounting height of rollers on the cable tray is
established). The actual height will change as
successive layers are removed from the reel. In
general, it is sufficiently accurate to treat the cable tray
elevation above the floor as the reel elevation, unless
the cable reel is elevated above normal floor mounting
height.
Ths following calculations assume that properly
sized st-eaves are installed securely to accommodate
changes in direction along the cable tray route
3 f t (0.9 ' m ) for all sheaver ihe maximum pulling lenston is
3000 Ib (81 4 4 8 k d
t ._ m.&.&lAhL
Case A
Tr=25w=25x8.67 lb=217 Ib. (98.43kg)
This assumes that cable is removed from the reel
under tension from the pulling end.
Ta=125 bs (56 7kg) Assumed tension adder for
bends
Tw=wt/ft of cable times height
T1=Tr+Tw+Ta=217+30 x 8 67+125 = 602 Ib (273.06kg)
T2=T1+ 3OOx 1 3+ Ta = 602 + 390 + 125 = 1,117 Ib
(506 6kg)
T3=T2+Tw+Ta= 1,117 + 30 x 867 + 125 = 1,502 ih
(681 3kg)
T4=T3+ 230 x 1 3 = 1,502 + 260 = 1,762(799 2kg\
Use pulling eye on conductors and install basket
grip over metal sheath securely attached to pulling line
Case B
Tr=25w = 217 Ib. (98 43kg)
T4=Tr+yw+Ta = 217 + 60 x 8.67 + 125 = 862 Ib (391 Okg)
T3=T4+ 200 x 1.3 + 125 = 1,247 Ib (565.6kg)
T2=T3-Tw+Ta = 1,247 - 30 x 8.67 + 125 = 1,112 Ib. (504.4kg)
Tl=T2 + 300 x 1.3 = 1,502 Ib. (681 30kg)

Use pulling eyes on conductors and install basket grip over

metal sheath securely attached to pulling line.
Difference in tension =1762-1502 = 260 Ib. (1 17 9kg)
Even though the bends are not treated as tension multipliers the
direction of pull affects the total tension. In CASE A the cable is
raised 60 ft vertically. In CASE R the cable ISraised a net height of
only 30 ft with respect to pulling tension.

Acknowledgment

The authors would like to acknowledge Robert Cotton

(Southirvire Company) for his help in the preparation, editing,
contributions, and support in the writing of this paper

References

1. T 4. Kommers, Electric Cable Installation in Raceways,

Technical Paper, June 1980, Pulp & Paper Conference
Portland, Oregon.

2. T P.Arnold and C D Mercier, Power Cable Manual,

Southwire Company, 1991

3. The Okonite Company, Installation Practices for Cable

-
Raceway Systems, 1988.

Biography

Bob H. Finke (M'65) received the B.S.E.E degree from

Texas A & I College, Kingsville, Texas in 1964. He joined PPG
Industries, Chemical Division, Lake Charles, LA in 1964 with
assignnients in plant engineering, project design and construction,
and maintenance. In 1971, he joined The Okonite Company in
their sales department He joined Okonite's applications
engineering department in 1992. tie is a member of Power
Engineering Society and Industry Applications Society of IEEE and
the PE:; Insulated Conductor Committee and the IAS Pulp &
Paper Technical Committee.

Sid Ticker - A graduate of New York Institute of Applied Arts

& Sciences, began his career as a military instructor at Fort
Monmouth, NJ, Microwave Radio School, Signal Corp. In 1960,
he joined Phelps Dodge Wire 8 Cable Company, working as a
senior lab technician in the area of UL and GovernmentfMilitary
Specifications. In 1973, he became Quality assurance manager
for Phe ps Dodge Cable & Wire, responsible for four
manufacturing plants and providing technical assistance in the
area of installation, splicing and terminations. IP 1978, he became
Assistaiit Plant Manager, Pape! Insulated Cable Plant, Yonkers.
NY, ressonsible for operations. In 1983, he became District Sales
Managttr. Direct Sales New York, New Jersey, Pennsylvania and
Connecticut, In 1984, he joined Hi.Tech Cable in Starkville, MS,
as an Applications Engineer and QA Manager. In 1989, he was
promoted to Senior Applicatiovs Engineer at Southwire Company
in Carrollton, GA, responsible fcir providing technical support to
sales ai id engineering

73