Cable trays support insulated electrical cables in industrial and commercial settings. There are several types of cable trays, including ladder, perforated, solid bottom, basket, and channel trays.
Each cable tray type performs a different function and comes in various materials such as aluminum, galvanized steel, and FRP.
What is Cable Tray?
A cable tray is a unit, or set of units, with their fittings forming a rigid structure to support cables and assist in channeling them.
The cable trays consist of a thin metallic plate and electro-welded steel rods. Their construction is based on the international standard IEC 61537, which specifies the requirements for cable tray systems, tests, and specifications.
Purpose of Cable Trays
Cable trays, or carrier trays, are mechanical support systems for cables. They provide a robust structural that accommodates and safely transports cables from one point to another.
These include power, armored, control, instrumentation, telecommunication, and fiber optic cables.
Cable trays provide an efficient, safe, and cost-effective solution for channeling electrical cables.
Additionally, their simple installation reduces costs, making maintenance, and future expansions much easier. The primary purpose of a cable tray is to organize cables systematically. The cable trays keep the area clean and maintain the aesthetic look.
Types of Cable Trays
The following are common cable tray types.
- Ladder type
- Perforated type
- Solid bottom type
- Wire basket type
- Channel type
The project engineer or designer selects the type of cable tray for the project, based on the specific situation and environmental conditions. The cable tray selection depends on the number of cables, cable sizes, spacing between them, and total cable weight in the tray.
Ladder Cable Tray
As their name implies, these trays resemble ladders.
Its structure consists of two longitudinal side rails connected by individual cross members. Perforated rungs on a ladder-type tray securely fasten cables using cable ties.
These trays ensure maximum airflow around the cables, promoting effective ventilation and heat dissipation to keep cable temperatures within safe limits.
Additionally, their open design prevents moisture buildup.
This type of cable tray is useful because the ladder rungs allow easy access to the cables from the top or bottom.
These trays are commonly installed in the upper section of buildings.
Real-World Example: Ladder trays are extensively used in petrochemical plants, refineries, and thermal power stations where long horizontal runs and large power cables are routed overhead.
Perforated Cable Tray
The bottom part of the perforated cable tray has openings, which provide ventilation and prevent overheating. It has about 60 % flat area which supports the cables laid within the longitudinal side rails. It offers greater support to cables than the ladder type.
Their enclosed design enhances security, prevents buckling or sagging, and helps maintain safe cable temperatures even in confined spaces.
These trays are used for instrumentation and power cables and can be installed on any surface.
Real-World Example: Perforated trays are widely used in commercial buildings, control rooms, and indoor industrial panels to support both power and instrumentation cables securely.
Solid bottom Cable Tray
A solid or smooth bottom tray has no openings and is placed between the longitudinal side rails. It protects and supports all types of cables, preventing buckling or sagging.
Solid trays serve as electromagnetic shields and protect control and data cables from RFI interference.
However, they can accumulate moisture. This issue can be addressed by adding perforations for continuous drainage, provided the trays are not used as a shield.
These trays are mainly used for small-capacity cables. Their hermetic closure system completely isolates cables and prevents heat buildup.
Real-World Example: Solid bottom trays are often used in data centers or laboratories to protect sensitive signal or communication cables from EMI and physical interference.
Basket Cable Tray
Basket cable trays are welded wire structures that support electrical cables in an orderly manner, especially control and data cables. People also call basket trays wire mesh cable trays.
Installers prefer them for routing communication cables due to their versatility. Their structure allows horizontal and vertical adjustments by cutting the tray as required. The lightweight, open-mesh design improves ventilation and helps in effective heat dissipation.
This type of tray simplifies cable layout, reduces installation time, and supports future modifications with ease.
Real-World Example: Basket trays are commonly used in IT offices, data centers, and hospitals to route multiple data or communication cables above ceiling panels.
Channel Cable Tray
Channel trays are narrow and cost-effective, designed to support drop cables routed from the main tray to nearby equipment.
They are typically used for carrying one or two cables and help prevent cable sagging in compact installations.
Real-World Example: Electricians commonly install channel trays in control rooms, HVAC units, and compact electrical panels where minimal cable runs branch off from the main trunk line.
Materials of Cable Tray
Cable trays come in both in metal and non-metal types.
1. Metallic
Metallic trays are available in Steel, Stainless Steel, Galvanized Iron, Low-carbon steel, and Aluminum.
Aluminum trays are widely used due to their corrosion resistance, excellent strength, and lightweight nature.
Steel trays provide good electric shielding and have low thermal expansion. Stainless steel trays resist corrosion and can withstand high temperatures.
2. Non-Metallic
Fiberglass reinforced plastic (FRP).– It is lightweight, non-conductive & resists corrosion.
Real-World Example: Chemical processing plants often choose aluminum trays for their corrosion resistance. Marine and coastal facilities rely on stainless steel trays due to high humidity and salt exposure. Acid and fertilizer plants use FRP trays because they withstand chemical corrosion and prevent electrical conduction.
Accessories of Cable Trays
The picture below shows cable tray accessories.
Technicians use the following accessories with cable trays.
- Fastener
- Clamps
- Bends
- Reducers
- T-joint
- Internal risers
- External risers
- Short straight lengths
- Coupler plates
- Tray covers
- Tray crosses
- Tray supports, and
- Endcaps
Ladder vs Perforated Cable Tray
The following table compares ladder and perforated cable trays based on design, application, airflow, cost, and cable support:
| Factor | Ladder Cable Tray | Perforated Cable Tray |
| Structure | Two side rails with rungs (ladder-like) | Bottom plate with small ventilation holes |
| Ventilation | Excellent airflow and heat dissipation | Moderate airflow with limited ventilation |
| Cable Support | Less surface support for cables | Better continuous support for cables |
| Applications | Power cables and long horizontal runs | Control, instrumentation, and power cables |
| Cost | Generally lower cost | Slightly more expensive |
| Installation Area | Preferred in overhead installations | Suitable for indoor wall-mounted layouts |
Advantages of Cable Trays
Cable trays offer several key benefits:
- Easy Installation: Quick and easy to install. No special training or expertise is needed.
- Easy Maintenance: Since cables are visible, inspecting and repairing faults becomes easier.
- Cost-Effective: Cable trays are more economical than other wiring protection methods.
- Improved Safety: Cables remain organized and secure, reducing the risk of electrical hazards.
- Flexibility: New cables can be added without major rework or modifications.
Disadvantages of Cable Trays
- Moisture Accumulation: Solid bottom trays can trap moisture, which may lead to corrosion or cable damage over time.
- Limited Protection in Harsh Environments: Open-type trays like ladder or perforated trays offer less protection in areas exposed to dust, water, or chemicals.
- Mechanical Damage Risk: Since cables are exposed in open trays, they are more prone to physical damage if not installed or maintained properly.
- Not Ideal for Small Spaces: In compact or confined installations, trays may be difficult to install and maintain.
- Initial Installation Planning Required: You must plan the design and layout properly to avoid clutter and inefficiency in future expansions.
Precautions
- Material Selection: Cable trays exposed to open atmospheric conditions must withstand harsh environments, including corrosion and chemical fumes. Therefore, choosing corrosion-resistant and durable materials is essential for long-term reliability.
- Routine Inspection: Regularly inspect trays for dust, debris, or foreign material buildup. Accumulated debris can become a fire hazard, especially in industrial setups.
- Protective Coating: Apply protective finishes or coatings to metal trays to enhance corrosion resistance in outdoor or chemical-prone environments.
- Avoid Overloading: Ensure that cable trays are not overloaded beyond their rated capacity, as this can cause structural failure or cable damage.
Conclusion
Cable trays play a vital role in organizing and supporting electrical cables across industrial and commercial facilities.
Each type of cable tray—ladder, perforated, solid bottom, basket, or channel—serves specific needs based on the installation environment, cable type, and load capacity. Material selection, including metallic or non-metallic options, adds flexibility to handle various conditions such as corrosion or heat.
With the right fittings and proper planning, cable tray systems ensure safety, improve cable management, and simplify future upgrades.
Choosing the appropriate tray type helps maximize system efficiency and reliability—whether you’re comparing ladder vs perforated cable trays or selecting accessories for complex layouts.
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