Everything electricians need to know about cable tray — types, materials, support spacing, earthing, fill ratio, ordering and cutting, and the complete sequence for a typical commercial installation.
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Key Takeaways
1Cable tray is an open-top metal or plastic channel used to support and route multiple cables in commercial and industrial installations — it reduces installation time significantly compared to threading cables individually through conduit.
2Hot-dip galvanised steel cable tray is the standard specification for most commercial installations. Stainless steel is used in food production, pharmaceutical, and marine environments where corrosion resistance is critical.
3Support spacing for cable tray is typically 1500mm for straight runs of standard perforated tray, reducing to 900mm at bends and tee-pieces. Heavy cables or widely spaced supports can cause permanent deflection.
4Cable tray must be earthed as a system by bonding sections together with earth bonds and connecting the system to the main earthing terminal. The tray must not be relied upon as the sole circuit protective conductor for cables installed within it.
5The fill ratio for cable tray should not exceed approximately 40% of the tray cross-sectional area to allow heat dissipation and future cable additions, and to maintain cable current ratings.
01 · Installation Guide
What is Cable Tray?
Cable tray is an open-top channel or ladder-shaped support system used in commercial and industrial electrical installations to route and support multiple cables. It provides a rigid, accessible, and cost-effective alternative to threading cables through conduit where large numbers of cables run along a common route.
Cable tray is found in virtually every commercial and industrial building in the UK — from office blocks and retail units to hospitals, data centres, and manufacturing facilities. Electricians installing commercial systems will encounter cable tray regularly, and the ability to plan, order, and install it efficiently is a core commercial skill.
Speed — cables can be laid in tray quickly without threading through conduit. Multiple cables can be installed simultaneously. This makes tray significantly faster to install on large commercial projects.
Accessibility — cables in open tray can be inspected, added to, and removed without disturbing the tray structure. This is a significant advantage over enclosed conduit for installations that change over time.
Heat dissipation — perforated tray allows air circulation around cables, maintaining their current-carrying capacity better than enclosed conduit systems.
Cable tray installation must comply with BS 7671:2018+A4:2026 and the relevant sections of the IET Wiring Regulations covering cable support, grouping factors, and protection against mechanical damage.
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02 · Installation Guide
Types of Cable Tray
The three main types of cable tray used in UK commercial and industrial installations each have different characteristics that make them suitable for different applications.
Perforated cable tray — the standard choice for most commercial installations. A pressed steel tray with punched holes in the base and sides for ventilation and cable tie fixing. Available in light, medium, and heavy duty ratings. The most versatile and widely available type.
Solid bottom (return flange) tray — pressed steel tray with a solid base without perforations. The sides fold inward at the top to form a return flange that adds rigidity. Used where cables need additional protection from below, in areas with falling debris, or in outdoor/semi-exposed locations.
Ladder cable tray — consists of two parallel side rails connected by rungs, similar in appearance to a ladder. Provides very good ventilation and is used for large power cables in industrial installations. The open structure between rungs allows easy access to individual cables.
Wire mesh (basket tray) — formed from welded wire mesh. Very lightweight, flexible, and easy to cut and modify on site. Widely used for data and communications cables, and increasingly used for power cables in commercial and data centre applications. See the cable basket guide for full details.
03 · Installation Guide
Materials and Finishes
Cable tray is manufactured from several materials with different corrosion resistance and cost profiles. Selecting the correct material for the environment is essential for a durable installation.
Hot-dip galvanised (HDG) steel — the standard specification for commercial and industrial installations. The zinc coating provides excellent corrosion protection for indoor and sheltered outdoor use. HDG tray to BS EN ISO 1461 is the most cost-effective and widely available option.
Pre-galvanised (mill-galvanised) steel — lighter zinc coating than HDG, applied before the tray is formed. Cheaper than HDG but offers less corrosion protection. Suitable for dry indoor installations only. Cut edges are unprotected.
Stainless steel (304 or 316 grade) — used in food production, pharmaceutical manufacturing, marine environments, and wet areas where galvanised steel would corrode. Grade 316 offers greater corrosion resistance than 304 in chloride-rich environments. Significantly more expensive than galvanised steel.
PVC (uPVC) tray — non-conductive, lightweight, and completely corrosion-resistant. Used in chemical environments where metallic tray would corrode, and in telecommunications rooms where metallic tray could cause interference. Not suitable for power cable applications requiring earthed cable management.
04 · Installation Guide
Support Spacing for Cable Tray
Cable tray must be adequately supported to prevent deflection under cable loading. Excessive deflection is unsightly, can cause stress on cable sheaths at low points, and may indicate that the tray is inadequately supported for the load it carries.
Straight horizontal runs — typically 1200mm to 1500mm support centres for light and medium-duty tray with modest cable loading. For heavy-duty tray or heavily loaded tray, reduce to 900mm. Always check the manufacturer's load/span tables for the specific product.
At bends and fittings — support within 300mm either side of bends, tees, reducers, and crosses. Fittings create point loads and concentrate stress in the tray structure.
Vertical runs — support at 1200mm to 1500mm centres. Cable weight on vertical tray must be managed with cable cleats or ties at regular intervals — cables must not be allowed to sag down in vertical tray sections.
Suspended installations — threaded rod hangers, channel brackets, and wall brackets are the common support methods. All supports must be fixed into structural elements (concrete, steel, blockwork) — not into lightweight partitions or suspended ceiling grids.
05 · Installation Guide
Earthing Cable Tray Systems
Cable tray is an extraneous conductive part under BS 7671 and must be bonded and earthed. This is a mandatory requirement — unearthed metallic cable management systems are a common EICR observation.
Section bonding — fit earth bonds (green/yellow conductor or braided earth strap) at every joint between tray sections, whether the physical joint is a bolted splice plate or a tray fitting. Paint and corrosion on joint faces increase contact resistance — earth bonds bypass this.
System earth connection — connect the tray system to the main earthing terminal with an appropriate earth conductor. The run length and prospective fault current determine the required conductor cross-section per BS 7671 Regulation 543.
Not a circuit CPC — the tray earthing system is not a substitute for the circuit protective conductor within each cable. Every cable installed in the tray must have its own CPC as required by BS 7671.
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The fill ratio of cable tray affects cable current ratings due to heat dissipation, future maintenance, and the practical ability to install cables without damaging existing ones.
40% maximum fill — the tray cross-sectional area occupied by cables (including cable sheaths) should not exceed approximately 40%. This allows adequate air circulation, space for cable ties, and future additions.
Grouping derating — cables installed in groups on tray have their current ratings reduced by the grouping factors in BS 7671 Appendix 4 Table 4C1. The more cables grouped together, the lower the derating factor. This must be accounted for in cable sizing calculations.
Segregation — power cables and data/communications cables should be run on separate tray systems, or separated by a divider within the same tray, to prevent electromagnetic interference.
07 · Installation Guide
Ordering and Cutting Cable Tray
Efficient ordering and cutting of cable tray reduces waste and installation time. Taking off quantities accurately from drawings before ordering is a key commercial skill.
Standard lengths — cable tray is typically supplied in 3m lengths. Order fittings (bends, tees, reducers, crosses) separately and include in the take-off.
Cutting — cut cable tray with an angle grinder with a cutting disc, a hacksaw, or a jigsaw with a metal-cutting blade. Always deburr cut edges with a file to prevent cable sheath damage.
Touch-up after cutting — apply cold zinc spray or touch-up paint to all cut edges on galvanised tray to restore corrosion protection. Bare steel edges will rust rapidly in humid environments.
08 · Installation Guide
Typical Commercial Cable Tray Installation
A typical commercial cable tray installation in an office or retail building follows a structured sequence to ensure a neat, correctly supported, and compliant result.
1. Set out the route — mark the tray route on walls, columns, and ceilings. Coordinate with other services (HVAC, plumbing, structural steel) to avoid clashes before fixing supports.
2. Fix supports — install wall brackets, ceiling drops, or channel (Unistrut/Strut) supports at the required spacing. Fix into structural elements only. Use M8 or M10 threaded rod for suspended drops.
3. Install tray sections — lay tray sections onto supports and connect with splice plates and M6 bolts. Install bends, tees, and reducers at changes of direction and size.
4. Earth bond and connect — fit earth bonds at every joint. Connect the tray to the MET. Test continuity of the earthing system before installing cables.
5. Install and secure cables — draw cables into position and tie at regular intervals using cable ties or strapping. Maintain segregation between power and data circuits.
09 · Installation Guide
For Electricians: Certifying Commercial Installations
Commercial installations involving cable tray must be certified with an Electrical Installation Certificate (EIC) covering all circuits installed. The EIC must include verification of earth continuity for the tray earthing system and correct grouping derating applied to cable sizing.
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Use the Elec-Mate EIC app to complete Electrical Installation Certificates for commercial projects on site. Record test results, circuit details, and cable tray earthing continuity — issue the PDF before you leave.
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