Central Business District CBD EAST – Phase 1

Of the New Administrative Capital

SECTION 260536 - CABLE TRAYS FOR ELECTRICAL SYSTEMS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of Contract and
Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes cable trays, cable ladders and related installations and accessories
necessary to support and protect cables, feeders, sub-feeders, branch circuit wiring and
wiring of low current systems, communications and signal cables. Supporting accessories
shall include but not limited to necessary carriage bolts with nut below head, roofing bolts
with nut, channel withstanding threaded rod, wall bracket, uni-strut, fish plate, washers, etc.

B. Related Sections include the following:

1. Division 07 Section "Penetration Firestopping" for fire stopping materials and

installation requirements.
2. Division 26 Section "Basic Electrical Materials and Methods" for cable tray / ladder
supports not specified in this Section.

1.3 SUBMITTALS

A. Technical Data: Submit data for approval including, but not limited to, the following:

1. Manufacturers' catalogues with specifications of cable trays / ladders and related

accessories.
2. Samples of each type of tray / ladder and accessory.

B. Shop and Construction Drawings: Submit drawings for approval including, but not limited
to, the following:

1. Detail fabrication and installation of cable tray / ladder, including plans, elevations,
and sections of components and attachments to other construction elements.
Designate components and accessories, including clamps, brackets, hanger rods,
splice-plate connectors, expansion-joint assemblies, straight lengths, fittings and
earthing connections.

C. Point-wise compliance statement to the specifications, duly signed by the manufacturer/

manufacturer’s authorized representative and the contractor.

D. Approved Third Party Test Certificates: Submit to verify compliance with the IEC 61537 or
NEMA VE-1, as applicable.

E. Coordination Drawings: Include floor plans and sections drawn to scale. Include scaled
cable tray / ladder layout and relationships between components and adjacent structural and
mechanical elements.

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F. Manufacturer Seismic Certification: For cable trays, accessories, and components, Submit a
signed certificate by the manufacturer of seismic restraints certifying that the products
furnished comply with the project specifications requirements..

G. Design Calculations: Submit design calculations to verify the following:

1. Loading capacities for supports.

2. Perforation base area for cable trays according to the specified Class.
3. Free base area for cable ladders according to the specified Class.

H. Factory Test: Submit Factory tests including safe working load, deflection tests and
measurement of steel and galvanization thicknesses.

I. Maintenance Data: For cable trays to be included in the maintenance manuals specified in
Division 01.

J. As-Built (Record) Drawings: At Project close-out, submit Record Drawings of installed

cable trays in accordance with requirements of the Specification, Division 01.

1.4 QUALITY ASSURANCE

A. Source Limitations: Obtain cable trays and components from at most two manufacturers for
one building. Different brands can be used for different buildings. .

B. Comply with the following standards:

1. IEC 61537.
2. ISO 1461.
3. ISO 12944-2.

C. As an alternative, cable trays in compliance with NEMA VE1 are acceptable.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Materials shall not be stored in damp and open environment and shall be stored in covered
places only.

1.6 COORDINATION

A. Coordinate layout and installation of cable tray / ladder with other installations to ensure
clear access to the cable trays to facilitate maintenance, checking and further pulling of
cables.

1. Revise locations and elevations from those indicated as required to suit field
conditions and as approved by the Engineer.

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1.7 FACTORY VISIT

A. Approved supplier’s manufacturing facilities of locally assembled products under this

Contract are subject to factory visit by the Engineer. Factory visit shall include checking of
quality assurance and factory’s capabilities along with witnessing of factory production tests
including but not limited to: safe working load, deflection tests, measurement of steel and
galvanization thicknesses, review calculations of perforation base area for cable trays and
free base area for cable ladders according to the specified Class. Visit program shall be
submitted for approval prior to the scheduled visit by at least 14 days.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Approved Manufacturers: Subject to compliance with requirements, provide products by

one of the following or approved equal:

1. B-Line Systems, Inc.

2. Thomas & Betts
3. Swifts
4. Wibe
5. EMECO
6. El-Sewedy (EGYTRAY)

B. Locally manufactured cable trays / ladders are acceptable subject to compliance with design
requirements.

2.2 CABLE TRAYS AND LADDERS

A. Cable trays and ladders shall comply with IEC 61537 or NEMA VE-01.

B. Cable trays shall meet Class C requirements for perforation free area as per IEC 61537 or
NEMA VE-01 as a minimum.

C. Cable ladders shall meet Class Y requirements for free base area as per IEC 61537 or
NEMA VE-01 as a minimum.

D. Components: To include cable trays or ladders (as shown on the Drawings), bends, elbows,
tees, couplings and plates, rubber grommets, hangers, bracket supports and other system
accessories required for safety and protection of the cable installations. All fittings and
accessories shall be purpose made from the manufacturer. Field fabricated fittings and
accessories are can be accepted for non standard accessories and subject to the engineer
approval on site.

E. Trays: Provide to carry the maximum load of cables with a factor of safety 300%,also shall
be able to support 90 kg concentrated load at mid span over and above stated cable load.

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F. Trays: Heavy gauge perforated sheet steel, heavy duty, hot-dip galvanized after
manufacture, minimum 1.5 mm thickness for cable trays up to 300 mm width and 2 mm
thickness for cable trays exceeding 300 mm width, with sides not less than 60 mm depth for
cable trays up to 300 mm width, 85 mm depth for cable trays exceeding 300 mm width and
up to 600 mm width and 110 mm depth for cable trays exceeding 600 mm width with
outwards return flanges, unless otherwise recommended by manufacturer and approved by
the Engineer. Fittings shall be made of the same material as tray. Covers, where shown on
the Drawings, shall be minimum 1.0 mm thick for cable trays up to 600 mm width and 1.5
mm thick for cable trays exceeding 600 mm width and shall be made of sheet steel hot-dip
galvanized after manufacture, snap-on or bolt type, forming a rigid assembly with the tray.
For uncovered cable trays, U-Type cable trays can be used.

G. Trays Perforation: Cable trays perforation size and direction shall be properly designed to
suit cable ties or cleats to be used for cable fixation. Contractor shall submit method of cable
fixation for Engineer’s approval prior to installation.

H. Ladders: Hot-dip galvanized after manufacture, fabricated from 2 mm mild carbon steel.
Ladder side channels shall be minimum 125 x 22 mm, strengthened by reinforcing inserts
for torsional rigidity. Rungs shall be slotted to take cable cleats or ties and conduit clamps.
Rungs shall be minimum 50 x 25 mm channels, spaced at 300 mm centers.

I. Fully controlled, stringent pretreatment process including, alkaline de-greasing, rinsing,

pickling, fluxing and drying shall be carried out before hot dip galvanizing.

J. Galvanizing shall be in accordance with ISO 1461, applied after fabrication with local coat
thickness of 45 µm (local coating mass of 325 g/m2) and mean coat thickness of 55 µm
(mean coating mass of 395 g/m2). Cable trays manufactured to NEMA VE1 shall have
galvanization in accordance with ASTM A123/ A123M requirements.

K. Cable trays / ladders installed in corrosive atmosphere shall be provided with powder
coating over hot dip galvanization of high chemical resistant polyster / epoxy to meet the
requirements of the below classification. High bonding between the galvanizing and the
paint finish shall be certified by the manufacturer with a guaranteed life of 20 years.

1. For installations in outdoor industrial areas and coastal areas with moderate salinity
and indoor in swimming pools, chemical plants, coastal ship and boatyards; use
galvanization and powder coating in compliance with corrosion risk category C4 to
ISO 12944-2.
2. For installations in outdoor industrial areas with high humidity and aggressive
atmosphere and in indoor areas with almost permanent condensation and with high
pollution; use galvanization and powder coating in compliance with corrosion risk
category C5-I to ISO 12944-2.

L. Bolts and Screws: Cadmium plated or electrolytically galvanized.

M. Sizes: Trays and ladders shall be standard metric sizes, 150, 300, 450, 600, 750 and 900 mm
wide, and at least 3 m length of section. Size of tray or ladder shall be determined by
number and sizes of cables in accordance with the Regulations and / or as shown on the
Drawings. Tray or ladder shall have strength and rigidity to provide support for cables
contained within. Deflection between supports shall comply with IEC 61537 requirements.

N. Earthing connector for trays or ladders shall be provided on each coupling between adjacent
sections .

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O. Seismic Performance: Cable trays and supports shall withstand the effects of earthquake
motions determined according to the Egyptian Code (EPC 201-2012).

P. Products shall be provided with stamped markings by manufacturers.

Q. Cable trays and ladders shall be provided with galvanized ventilated sunshade covers when
installed in outdoor locations. Sun shade and fixings shall be from the same manufacturer of
cable tray/ladder.

R. Finish of the cable trays/ladders used outdoors shall be certified to be UV stabilized.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install cable tray / ladder level and supporting system according to manufacturer's written
instructions, Coordination Drawings, original design, and referenced standards.

B. Spare capacity shall be 15 % for vertical installations and 15% for horizontal installations
and fill factor for Telecommunication cable trays shall not exceed 40%..

C. Each run shall be completed before installation of cables. Submit calculations taking into
consideration the maximum cables load on cable trays with a factor of safety 300%.

D. Remove burrs and sharp edges from cable trays / ladders. Fix trays / ladders using approved
suspension rods or uni-struts or angle brackets at spacing not exceeding 1.5 m and as per the
approved supports calculations.

E. Cables Fixation: Secure cables to tray / ladder with purpose made straps, cleats or saddles as
specified in Division 26 Section "Low Voltage Electrical Power Conductors and Cables"
and Division 26 Section "Medium Voltage Cables". Cable cleats and ties shall be correctly
sized and tightened to secure the cable without indenting the insulation sheath.

F. Cables Arrangement: Arrange cables in one layer only, with minimum spacing of one
diameter of the larger of the two adjacent cables or of a trefoil formation of single core cable
circuit, unless otherwise shown on the Drawings.

G. Cables Bending Radius: Cables installation on trays / ladders shall ensure that the minimum
cable bending radius as recommended by the manufacturer is not violated.

H. Fasten cable tray / ladder supports securely to building structure [and install seismic
restraints as specified in Division 26 Section "Basic Electrical Materials and Methods,"
unless otherwise indicated.

1. Design supports, including fastenings to the structure, to carry the total load of cables
and trays multiplied by a safety factor of 3. Submit calculations for
approval. Comply with seismic-restraint details according to Division 26 Section
"Vibration and Seismic Controls for Electrical Systems."

I. Cables Installation on Trays / Ladders: Use necessary rollers and pulleys at proper spacing
for installation of large and long run cables. Pulleys / rollers shall be fixed to structural
elements and not cable trays / ladders. Necessary pulling tools such as basket grips or
pulling eyes shall be used with a proper force and speed to ensure not exceeding the
manufacturer’s recommended maximum cable pulling tension.

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J. Make connections to equipment with flanged fittings fastened to cable tray / ladder and to
equipment. Support cable tray / ladder independently of fittings. Do not carry weight of
cable tray / ladder on equipment enclosure.

K. Install expansion connectors where cable tray / ladder crosses a building expansion joint and
in cable tray / ladder runs that exceed39 m, unless otherwise calculated by the manufacturer
and approved by the Engineer considering a maximum movement of 25 mm.

L. Make cable tray / ladder connections, changes in direction and elevation using standard
fittings. Fittings shall be properly curved / designed to satisfy the minimum bending radius
requirements and avoid sharp edges / corners.

M. Locate cable tray / ladder above piping, unless accessibility to cable tray / ladder is required
or unless otherwise indicated.

N. Seal penetrations through fire zones or smoke barriers as specified in Division 07 Section
"Penetration Firestopping."

O. If cable trays / ladders are sized for future cables, furnish necessary provisions for
penetrations with capped sleeves for future cables through fire-rated partitions, or use
"repairable" fire stopping-penetration sealing material.

P. Workspace: Install cable trays / ladders with sufficient space to permit access for installing
cables. Minimum clearance of 250 mm shall be maintained between top of tray / ladder and
ceiling, beams and other services and between tray / ladders in multi-tier formation unless
otherwise indicated on drawings.

Q. Barriers: Where tray / ladders carry conductors of different systems, such as power,
communications and data processing, or different insulation levels, such as 600V, 5000V,
and 20,000 V use separate cable tray / ladders. In case of absolute necessity, install
insulating barriers to separate the systems after obtaining the Engineer’s approval. Barriers
and spacing between system’s cables shall be in accordance with relevant codes, standards
and manufacturers’ recommendations.

R. Install covers after installation of cable is completed.

S. Labeling of trays shall be provided at every change in direction and at every 12 meters on
straight runs. Size of letters and color of labels, marking and references shall be as per the
relevant standard regulations.

T. Cable trays/ladders shall not be installed in lengths below water/sewage pipes.

U. Electrical continuity strips / links shall be provided by the manufacturer of the tray/ladder.

3.2 CONNECTIONS

A. Ground cable trays / ladders according to manufacturer's instructions.

1. Tighten electrical connectors and terminals according to manufacturer's published

torque-tightening values.

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3.3 WARNING SIGNS

A. After installation of cable trays / ladders is completed, install warning signs in visible
locations on or near cable trays / ladders.

3.4 FIELD QUALITY CONTROL

A. Perform the following tests and inspections in coordination with the contractor as proper
and applicable:

1. Visually inspect cable insulation for damage. Correct sharp corners, protrusions in
cable trays, vibrations, and thermal expansion and contraction conditions, which may
cause or have caused damage.
2. Verify that the number, size, and voltage of cables in cable trays meet specification
and the approved Shop Drawings requirements. Verify that communications or data-
processing circuits are separated from power circuits by barriers or are installed in
separate cable trays.
3. Verify that there are no intruding items such as pipes, hangers, or other equipment in
the cable tray.
4. Remove dust deposits, industrial process materials, trash of any description, and any
blockage of tray ventilation.
5. Visually inspect each cable tray joint and each ground connection for mechanical
continuity. Check bolted connections between sections for corrosion. Clean and re-
torque in suspect areas.
6. Verify that no corroded units are present.
7. Check for improperly sized or installed bonding jumpers.
8. Check for missing, incorrect, or damaged bolts, bolt heads, or nuts. When found,
replace with specified hardware.
9. Perform visual and mechanical checks for adequacy of cable tray grounding; verify
that all takeoff raceways are bonded to cable trays. Test entire cable tray system for
continuity. Maximum allowable resistance is 1 ohm.

B. Grounding: Do not use metal trays / ladders as earth continuity conductor. Connect trays /
ladders by flexible tinned copper straps to nearest bare earthing conductor and at maximum
30-m spacing.

C. Replace malfunctioning units and retest until satisfactory results are achieved.

D. Prepare test and inspection method for Engineer’s approval. Submit test reports after
completion on site.

3.5 CLEANING

A. On completion of cable tray / ladder installation, including fittings, inspect exposed finish.
Remove burrs, dirt, and construction debris and repair damaged finishes, including chips,
scratches, and abrasions.

3.6 PROTECTION

A. Provide final protection and maintain conditions, in a manner acceptable to manufacturer

and Installer that ensure cable tray / ladder is without damage or deterioration at the time of
Substantial Completion.

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1. Repair damage to galvanized finishes with zinc-rich paint recommended by cable tray
/ ladder manufacturer.
2. Repair damage to PVC or paint finishes with matching touchup coating
recommended by cable tray / ladder manufacturer.

END OF SECTION 260536

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