Wire Mesh Cable Tray Installation Guide: How to complete cabling quickly and efficiently?

The Wire Mesh Cable Tray system has become the preferred wiring solution for modern data centers, commercial buildings, and industrial facilities due to its superior flexibility, lightweight nature, and rapid installation characteristics.

1. Detailed Planning and Preparation

Efficient installation begins with meticulous planning. Thorough preparation reduces on-site rework and wasted time.

• Cable Routing and Load Calculation (Load Management):
  • Route Design: Use CAD drawings or BIM models to precisely plan the cable tray route, marking all horizontal bends, vertical risers, tees, and reducers.
  • Load Review: The total weight of all cables (static load) must be accurately calculated. Determine the required tray width, depth, and support span based on the manufacturer’s load charts. A safety factor generally requires the tray capacity to exceed the actual load by 1.5 times.
• Tools and Material Preparation:
  • Cutting Tools: High-quality hydraulic or electric bolt cutters are essential. They ensure clean, burr-free cuts, which is paramount for cable safety. The use of angle grinders is discouraged as they produce sparks and hazardous debris.
  • Measurement Tools: Laser level, tape measure, plumb line, ensuring precise horizontal and vertical alignment of the support system and tray runs.
  • Fastening Tools: A Torque Wrench must be used to ensure all bolts and connectors are tightened to the specified force, preventing loosening.
• Accessory Pre-sorting: Keep all quick couplers, brackets, clamps, and grounding jumpers organized and readily accessible so they can be used instantly during the installation process.

2. Support System Installation and Fixing

The support system is the foundation of the entire wiring infrastructure and must be sturdy and accurately positioned.

• Determining Support Span:
  • Based on the design load and tray specifications, standard support spans typically range from 1.5 meters to 2.5 meters (5 feet to 8 feet). Heavier applications or longer spans may require reinforced supports or closer spacing.
• Choosing Support Types:
  • Ceiling Installation: Use threaded rod hangers with trapeze or beam clamps. Ensure the rod diameter meets the load requirements and use double nuts for locking to prevent loosening.
  • Wall Installation: Use L-shaped or U-shaped wall brackets. Anchors must penetrate the main structure (e.g., concrete, brick) and utilize manufacturer-recommended expansion bolts.
  • Floor Installation: Use vertical stands or ladder supports when routing cables vertically.
• Leveling and Alignment: Use a laser level to mark installation points, ensuring all supports are on the same level (or design gradient). This is crucial for the rapid coupling of trays later on.

3. Rapid Installation and Shaping of Wire Mesh Trays

The core advantage of Wire Mesh Cable Tray lies in its on-site flexibility and quick connection.

• Straight Section Coupling:
  • Place the tray sections onto the pre-installed supports. Utilize snap-on couplers (quick-connect couplers). These fittings often require no screws, relying on a clip mechanism or very few bolts to secure the connection, reducing assembly time by over 80%.
  • For areas requiring higher load capacity or rigidity, traditional bolted splice plates should be used, and a torque wrench must ensure proper tightening.
• On-Site Shaping (Cut and Form):
  • Bends and Reducers: This is the greatest efficiency advantage of the mesh tray. To create a required angle (e.g., a 90° bend) or change in size (reducer), the technician simply cuts the bottom wires of the tray using cutters, then bends the tray up or down to the specified angle.
  • Cutting Protection: All cut edges should be covered with an edge protection strip or rubber sleeving to prevent damage to cable insulation during the laying process.

For a clearer understanding, the table below compares the efficiency of key installation components:

4. Grounding, Cabling, and Safety Management

Once the tray system installation is complete, grounding must be performed, and cabling can begin.

• Bonding and Grounding:
  • Compliance: According to the National Electrical Code (NEC) or other applicable local standards, the cable tray system must be bonded and serve as an equipment grounding conductor or part of the equipment grounding path.
  • Connection: Use dedicated grounding clips or grounding jumpers to bond every individual tray section together. The entire system must be connected to the facility’s Main Grounding Busbar.
• Cable Laying (Laying-in):
  • The open design of the mesh tray allows cables to be directly laid in from the top or side, eliminating the need for strenuous pulling through conduits or threading. This is key to achieving “rapid” cabling.
  • Exits: Cables can exit the tray through the open mesh at any point, providing unparalleled flexibility. Ensure cable edge protection is used at the exit points.
• Cable Securing and Management:
  • Use nylon ties or Velcro straps to secure cable bundles. It is recommended to secure them at intervals of every 1 to 1.5 meters, and reinforce securing at all bends and exit points.
  • Segregation: If high-voltage power lines and low-voltage data lines must be laid in the same tray, dedicated dividers must be used or the minimum separation distance specified by code must be maintained to prevent Electromagnetic Interference (EMI).

By following these detailed steps, and specifically leveraging the advantages of quick couplers and on-site shaping, your Wire Mesh Cable Tray installation project will achieve maximum efficiency and longevity.