• Home
  • Blogs
  • Selecting the Right Hazardous Area Cable Tray System

Selecting the Right Hazardous Area Cable Tray System

cable tray corner

Hazardous area cable trays are critical components used to organize, support, and protect electrical wiring in environments where the risk of explosions, fires, or the release of toxic substances is high. These trays are specifically engineered for use in locations that may be exposed to hazardous materials such as flammable gases, vapors, or combustible dust. In such areas, electrical systems must be carefully designed and installed to prevent ignition sources that could lead to catastrophic incidents. The primary function of hazardous area cable trays is to provide a safe, organized pathway for wiring while mitigating potential risks associated with volatile substances.

Safety is the highest priority when dealing with electrical installations in hazardous locations, and the selection of appropriate cable management systems plays a critical role in achieving compliance with industry regulations. Hazardous area cable trays must meet stringent requirements outlined by standards such as the National Electrical Code (NEC) and other regulatory bodies like OSHA. By using the correct tray materials and configurations, installers can reduce the chances of electrical faults, overheating, or physical damage that could lead to hazardous situations.

What is a HazaWhat is a Hazardous Area Cable Tray?

Definition and Importance

A hazardous area cable tray is a specialized cable management system used in locations where the presence of explosive gases, vapors, dust, or fibers creates a significant risk to safety. These trays are engineered to organize and secure electrical cables while safeguarding them from physical damage, environmental hazards, and the risk of sparks or overheating that could ignite an explosive atmosphere. In hazardous environments, choosing the correct cable tray is essential for maintaining the safety of both people and equipment. A proper cable tray system not only helps prevent electrical faults but also reduces the risk of fires, explosions, and other dangerous incidents, ensuring continuous and safe operation of critical systems.

The design of hazardous location cable trays is integral to maintaining compliance with safety regulations. These trays are often constructed from non-combustible, corrosion-resistant materials such as steel or aluminum to withstand extreme conditions. The trays are built to minimize risks by preventing the cables from coming into direct contact with hazardous substances and providing a secure pathway for wiring that can be easily maintained.

Types of Hazardous Areas

Hazardous locations are categorized based on the type of hazardous substances present, the likelihood of their occurrence, and the potential for creating explosive or flammable conditions. The National Electrical Code (NEC) defines hazardous areas into three main classes, each with its own set of safety standards and cable tray requirements:

  • Class 1: These areas are at risk from flammable gases, vapors, or liquids that can create explosive atmospheres.
    • Division 1: Explosive substances are present during normal operating conditions, requiring the highest level of safety measures.
    • Division 2: Explosive substances are only present under abnormal conditions, and the risk of ignition is lower but still present in certain circumstances.
  • Class 2: These areas involve combustible dusts that may ignite or explode when disturbed. Examples include grain silos, chemical factories, and mining operations.
  • Class 3: These areas contain easily ignitable fibers or materials, such as textile mills, which could catch fire easily if ignited.

For each of these classes, the cable tray systems must meet rigorous safety standards to minimize risks and avoid contributing to hazardous conditions. This includes the use of explosion-proof or flameproof designs and ensuring the cable management systems do not create ignition sources.

Applications of Hazardous Area Cable Trays

Hazardous area cable trays are critical in a wide range of industries where the environment poses significant safety risks. Some of the primary applications include:

  • Chemical Processing Plants: These facilities deal with highly volatile chemicals, requiring strict safety measures, including specialized cable trays for electrical systems.
  • Oil Refineries: The presence of flammable gases and vapors demands cable trays that meet stringent explosion-proof standards.
  • Power Plants: Power generation facilities often contain hazardous areas where cables must be safely routed through explosion-proof trays to avoid electrical faults.
  • Mining Operations: The risk of combustible dust and gases in mines necessitates the use of secure cable trays that can withstand rough environments.
  • Marine Environments: Offshore platforms and ships face challenges with explosive gases and dust, requiring safe cable management systems that comply with international safety standards.

These industries must ensure that their cable tray systems are designed and installed in accordance with regulatory standards such as the NEC, OSHA, and NFPA 70, ensuring they prevent sparks, electrical faults, or overheating that could trigger an explosion. Thus, choosing the correct hazardous area cable tray system is crucial for maintaining safety, protecting infrastructure, and meeting compliance requirements in volatile environments.

Ex Proof Cable Tray Installation: Best Practices Explained

Class 1 Div 1 vs. Class 1 Div 2 Cable Requirements in Hazardous Area Cable Trays

FeatureClass 1 Division 1Class 1 Division 2
Risk of ExplosionHigh, with explosive gases, vapors, or liquids present continuously, intermittently, or under normal operating conditions.Lower, with flammable gases or vapors only present under abnormal conditions (e.g., malfunctions or leaks).
Required Cable TypesMI cables (Mineral Insulated) and Type MC cables (Metal Clad). These cables provide high protection against heat and flame and are designed to withstand extreme conditions.TC-ER cables (Tray Cable, Exposed Run) and ITC cables (Instrumentation Tray Cable), which offer flexibility and durability for less extreme, but still hazardous, conditions.
Cable ProtectionExplosion-proof cables are required to ensure maximum safety against ignition. Cables are often armored and designed for use in the most demanding environments.Cables are designed to handle occasional explosive hazards but with less stringent protection compared to Division 1.
Temperature RatingsCables must be able to withstand high temperatures commonly found in hazardous areas.Cables must also withstand temperature extremes, but the ratings may be slightly lower compared to Division 1 requirements.
Corrosion ResistanceHigh corrosion resistance is required due to the extreme conditions that may include exposure to moisture, chemicals, and gases.Cables must be resistant to corrosion but may not face as harsh conditions as those in Division 1.
Installation ConsiderationsInstallation must meet strict NEC guidelines, with proper sealing, grounding, and tray system setup to avoid creating ignition sources.Installation standards are similar, but the focus is less stringent on explosion-proofing and more on environmental protection and cable routing.

Class 1 Div 1 Locations

Class 1 Division 1 areas are environments where flammable gases, vapors, or liquids are present continuously, intermittently, or under normal operating conditions. These areas are highly hazardous because the risk of an explosive atmosphere is frequent or persistent. In such locations, it is critical to use hazardous area cable tray systems that can withstand extreme environmental conditions and minimize the potential for ignition.

To meet these stringent safety standards, NEC (National Electrical Code) mandates the use of highly durable and explosion-proof cables such as MI (Mineral Insulated) and Type MC (Metal Clad) cables. These cables are built to withstand harsh conditions, including high temperatures, moisture, and chemical exposure. MI cables are particularly suited for these environments as they are resistant to fire, corrosion, and extreme heat. Type MC cables offer additional protection with their armored design, ensuring the cables remain intact and fully functional in volatile environments.

Class 1 Div 2 Locations

In Class 1 Division 2 locations, flammable gases or vapors are present only under abnormal conditions, such as during malfunctions or leaks. Although the risk is lower than in Division 1, the possibility of an explosive atmosphere occurring under specific circumstances still necessitates careful attention to safety.

For Class 1 Division 2 environments, hazardous area cable trays are typically filled with cables such as TC-ER (Tray Cable, Exposed Run) and ITC (Instrumentation Tray Cable). These cables are designed to handle less extreme conditions but still provide protection in potentially hazardous situations. TC-ER cables offer flexibility and durability, making them suitable for areas where cables may be exposed to environmental conditions but not necessarily subjected to the same constant risk of explosion as in Division 1 areas. ITC cables are commonly used for instrumentation and control systems in these locations and are designed to provide reliable service under abnormal conditions.

Key Cable Requirements

Cables used in hazardous area cable trays must meet several essential requirements to ensure safety and compliance with NEC regulations. These include:

  • Temperature Ratings: Cables must be rated to operate under extreme temperatures, both high and low, commonly found in hazardous locations. High temperature ratings are particularly important in Class 1 Division 1 environments, where electrical equipment is often exposed to heat generated by the environment and operational processes.
  • Corrosion Resistance: Cables must be constructed from materials that resist corrosion caused by moisture, chemicals, and other hazardous substances present in the environment. Corrosion resistance is essential for ensuring the longevity and safety of electrical systems, particularly in industries like chemical processing and oil refining.
  • Sealing: Proper sealing of cables and trays is critical to preventing the ingress of flammable gases, vapors, or dust into the cable systems. This helps ensure that the cables do not become sources of ignition. In both Division 1 and Division 2 areas, sealing methods are employed to protect the cables from exposure to hazardous substances.

By ensuring that the correct cables are used in hazardous area cable tray systems and adhering to the NEC guidelines, organizations can create safer environments that minimize the risk of fire or explosion while maintaining the reliability of electrical infrastructure.

Explosion-Proof Wiring Methods for Hazardous Locations

Electrical wiring in hazardous areas must adhere to specific safety standards to prevent ignition and ensure the reliability of systems operating in volatile environments. The National Electrical Code (NEC) outlines precise wiring methods and requirements to protect against the risks of explosion, fire, or toxic releases. These methods are designed to reduce the chance of hazardous materials coming into contact with electrical systems, thereby preventing potential disasters.

NEC Wiring Methods for Hazardous Areas

The NEC provides specific guidelines for wiring methods in hazardous locations. These methods ensure that electrical installations are safe, reliable, and compliant with regulatory standards. Key components of the NEC’s wiring methods for hazardous areas include:

  • Explosion-Proof Enclosures: Explosion-proof enclosures are a critical safety feature in hazardous areas. These enclosures are specially designed to contain any sparks, flames, or heat that may arise from electrical faults. By containing the ignition source within the enclosure, these enclosures prevent the surrounding atmosphere from being exposed to the hazard. This containment feature is particularly essential in hazardous area cable tray installations where cables may run through environments prone to flammable gases or dusts.
  • Conduit and Cable Sealing: Sealing plays a crucial role in hazardous area installations. Seals are applied to electrical conduits and cables to prevent the entry of hazardous gases, vapors, or dust into the system. Sealing ensures that flammable materials cannot enter the cable tray system and ignite. For hazardous area cable trays, proper sealing techniques are essential to maintaining system integrity. The sealing process must be conducted according to NEC standards to prevent any hazardous substance from reaching the electrical components.
  • Cable Support and Grounding: In addition to sealing and explosion-proof enclosures, grounding and proper cable support are vital to prevent electrical faults in hazardous areas. Cables in hazardous area cable trays must be securely supported to avoid mechanical stress and damage. Grounding is essential to ensure the safe operation of electrical systems and to prevent dangerous situations in the event of an electrical fault. Proper grounding protects not only the equipment but also the personnel working in the area.

Explosion-Proof Cables for Hazardous Area Cable Trays

Explosion-proof cables are specifically designed to meet the stringent safety requirements of hazardous locations. These cables are built to withstand extreme environmental conditions and prevent the ignition of surrounding flammable materials. Some of the common explosion-proof cables used in hazardous area cable trays include:

  • TC-ER-HL (Tray Cable, Exposed Run, Hazardous Location): The TC-ER-HL cable is designed for use in hazardous locations where flammable materials or vapors may be present. The “ER” designation indicates that the cable is suitable for exposed runs, making it ideal for installations in open areas or where cables are not enclosed within walls or other protective barriers. The “HL” designation refers to the cable’s suitability for hazardous locations, ensuring that it can operate safely in explosive environments. TC-ER-HL cables offer excellent durability, flexibility, and resistance to chemical exposure and extreme temperatures.
  • ITC-HL (Instrumentation Tray Cable, Hazardous Location): The ITC-HL cable is specifically designed for instrumentation and control systems in hazardous areas. These cables are commonly used in environments where there are concerns about the ignition of gases, vapors, or other hazardous materials. The ITC-HL cable provides excellent protection against environmental factors such as moisture, dust, and corrosive substances, ensuring that control systems remain operational and safe in volatile settings.
  • PLTC (Power Limited Tray Cable): PLTC cables are another option for use in hazardous area cable tray systems. These cables are designed for power-limited applications and are ideal for installations in areas where lower power is required but safety remains a priority. The PLTC cable is built with a strong, protective jacket that resists flame and mechanical damage, ensuring safe operation in hazardous locations.

Importance of Explosion-Proof Wiring Methods

The purpose of explosion-proof wiring methods and cables is to create a barrier between potentially dangerous gases or vapors and the electrical systems in hazardous locations. If proper explosion-proof methods are not followed, electrical equipment can become a potential ignition source, triggering catastrophic explosions, fires, or toxic releases. By using hazardous area cable tray systems in conjunction with explosion-proof enclosures, conduit and cable sealing, and the appropriate cables, the risk of such incidents can be minimized.

As the world moves toward more stringent environmental and safety standards, professionals in industries such as chemical processing, oil and gas, and power generation must adhere to these wiring methods to maintain a safe working environment. By investing in high-quality hazardous area cable tray systems and explosion-proof wiring methods, companies can ensure the protection of both personnel and infrastructure, safeguarding the long-term viability of operations in explosive atmospheres.Location) and ITC-HL (Instrumentation Tray Cable, Hazardous Location) cables. These cables are made with robust insulation and are flame-resistant, ensuring they can withstand potential explosions without contributing to the risk.

Key Cable Types for Hazardous Area Cable Trays

When selecting cables for hazardous area cable trays, it is crucial to choose the right type of cable to meet safety standards and ensure reliable operation in volatile environments. Different hazardous areas, classified by their potential for explosive atmospheres, require specific cables that are designed to handle the challenges posed by these conditions. Below are the key cable types commonly used in hazardous area installations:

TC-ER-HL Cable

TC-ER-HL (Tray Cable, Exposed Run, Hazardous Location) cables are specifically engineered for use in Class 1 Division 2 areas, which may be exposed to flammable gases, vapors, or liquids under abnormal conditions. These cables are ideal for use in hazardous area cable trays as they offer flexibility, durability, and resistance to extreme environmental conditions.

  • Key Features:
    • Flexibility: The cables are designed to handle vibration and movement, making them ideal for use in industrial settings with dynamic conditions.
    • Chemical Resistance: TC-ER-HL cables are resistant to chemical exposure, a common concern in many hazardous locations like chemical plants and refineries.
    • Temperature Resistance: These cables can withstand extreme temperatures, both high and low, ensuring reliable performance even in harsh environmental conditions.
    • Exposed Runs: Designed specifically for exposed runs, these cables are easy to install without the need for additional protection, making them cost-effective and efficient for certain hazardous locations.

These features make TC-ER-HL cables a go-to solution for providing safe electrical transmission in hazardous areas, without the risk of sparking or causing ignition due to their robust construction.

TC-ER Cable

TC-ER (Tray Cable, Exposed Run) cables are used in hazardous area cable trays in locations where the risk of explosion is lower than in Class 1 Division 1 areas but still requires adherence to strict safety standards. These cables are commonly used for power distribution and are well-suited for applications where the exposure to hazardous materials is intermittent or less severe.

  • Key Features:
    • Exposed Run Design: These cables are suitable for exposed installations where they are not enclosed by conduit, offering flexibility and ease of installation.
    • Durability: Designed to withstand rough environmental conditions, TC-ER cables are resistant to mechanical damage and moisture, which is essential in outdoor or harsh industrial environments.
    • Temperature Tolerance: TC-ER cables maintain excellent performance even in temperature extremes, making them ideal for a wide range of hazardous industrial applications.

Although TC-ER cables are not as robust as TC-ER-HL cables for more extreme environments, they are still an excellent choice for lower-risk Class 1 Division 2 locations, providing reliable service and reducing the chance of electrical faults.

ITC-HL Cable

ITC-HL (Instrumentation Tray Cable, Hazardous Location) cables are designed for use in hazardous area cable trays where instrumentation and control systems are critical. These cables are particularly well-suited for environments where the safe transmission of signals is crucial, such as chemical plants, power stations, and oil refineries.

  • Key Features:
    • Instrumentation and Control: Designed specifically for use in instrumentation and control systems, ITC-HL cables ensure the safe and reliable transmission of electrical signals in hazardous locations.
    • Chemical and Abrasion Resistance: These cables are designed to resist chemical exposure and physical wear, which are common challenges in hazardous industrial environments.
    • Flame Resistance: ITC-HL cables are constructed with flame-retardant materials to prevent the spread of fire, making them ideal for locations prone to explosive hazards.

The high performance and reliability of ITC-HL cables ensure that critical systems in hazardous areas continue to function properly, providing real-time monitoring and control while maintaining safety standards.

Class 1 Div 1 Cable (MI Cable)

For the most hazardous environments, such as Class 1 Division 1 areas, MI (Mineral Insulated) cables are often used. These areas are classified as those where flammable gases, vapors, or liquids are present continuously or under normal operating conditions, which pose the highest risk of explosion.

  • Key Features:
    • Non-Combustible Construction: MI cables are made of a mineral-insulated material that is non-combustible, providing a safe barrier that prevents sparks or flames from escaping the cable and igniting the surrounding atmosphere.
    • Explosion Containment: These cables are specifically designed to contain any internal faults or sparks, preventing them from causing explosions in highly hazardous environments.
    • Long-Term Durability: MI cables are highly resistant to heat, chemicals, and physical damage, making them suitable for the harshest hazardous locations, such as petrochemical plants or oil refineries.

The MI cable is one of the most reliable and safe options for Class 1 Division 1 environments, offering robust protection and ensuring that critical electrical systems remain operational in the most dangerous conditions.

Additional Considerations for Cable Selection

When selecting cables for hazardous area cable trays, it is essential to consider several other factors, such as:

  • Environmental Conditions: Assessing temperature extremes, humidity, exposure to chemicals, and vibration is crucial for selecting the most appropriate cable type.
  • Corrosion Resistance: Cables used in hazardous locations must be resistant to corrosion, especially in marine, chemical, and other harsh environments.
  • Flame Retardancy: For environments where the risk of fire is present, cables must meet fire-resistance standards to prevent the spread of flames.

What Are Cable Tray Containment for Industrial Installations

Hazardous Area Cable Tray Selection and Installation

Selecting and installing the correct hazardous area cable tray system is crucial for ensuring the safety and integrity of electrical installations in environments prone to explosions, fires, or chemical exposure. A well-designed and properly installed cable tray system provides the necessary infrastructure to support electrical cables while minimizing the risks associated with hazardous environments. Below, we will explore the key factors to consider when selecting a hazardous area cable tray system and the essential installation practices that must be followed.

Selecting the Right Cable Tray System

When selecting a hazardous area cable tray system, several factors need to be carefully considered to ensure the safety, performance, and longevity of the system. The choice of materials, load capacity, and environmental conditions all play a crucial role in determining the right tray system for specific hazardous locations.

  • Material Selection:
    The material of the cable tray must be resistant to corrosion and able to withstand the harsh conditions of hazardous locations. Common materials include:
    • Steel: Often used in industrial environments where high strength and durability are required. Steel trays must be coated or galvanized to resist corrosion, particularly in outdoor or highly corrosive environments.
    • Aluminum: Ideal for environments that require a lightweight and corrosion-resistant solution. Aluminum trays are commonly used in marine and offshore applications due to their resistance to saltwater corrosion.
    • Non-Metallic Trays: In certain cases, non-metallic cable trays, such as fiberglass, are used when there is a high level of corrosion risk or when electromagnetic interference must be minimized.
  • Corrosion Resistance:
    Hazardous locations, such as chemical plants or offshore platforms, often have high levels of moisture, chemicals, or salt, which can accelerate the corrosion of metal trays. To prevent degradation and ensure longevity, hazardous area cable trays must have coatings like epoxy, polyester, or hot-dip galvanizing, or use materials like stainless steel or fiberglass.
  • Load Capacity and Cable Size:
    The selected cable tray must have adequate load-bearing capacity to support the weight of all cables. This is crucial because overloading the tray can cause physical damage to cables or the tray itself. Additionally, ensuring the tray is wide enough to accommodate the total number of cables while maintaining proper fill ratios (the percentage of space occupied by cables within the tray) is essential for preventing overheating and ensuring safe operation.
  • Explosion-Proof Design:
    In explosive atmospheres, hazardous area cable trays must meet stringent safety standards, including those outlined by the National Electrical Code (NEC) and other regulatory bodies. Explosion-proof designs are required to prevent sparks or flames from escaping the tray and igniting surrounding flammable gases or dust.
  • Compliance with Regulatory Standards:
    The cable tray system must comply with national and international standards, such as the NEC Article 392 and IECEx certification, which define safety requirements for electrical installations in hazardous areas. Ensuring compliance is not only necessary for safety but also for meeting legal and insurance requirements.

Installation Practices

Proper installation of hazardous area cable trays is vital for ensuring the safety of the electrical system and maintaining regulatory compliance. Installation must be performed in accordance with established guidelines to prevent accidents, fire hazards, and electrical faults. Below are key practices for the installation of cable tray systems in hazardous locations:

  • Securing and Supporting Cables:
    It is essential to secure cables properly to prevent movement, which could cause damage to the cables or tray system. Cables should be evenly spaced within the tray to ensure efficient air circulation and heat dissipation. Improperly secured cables may lead to abrasion, short circuits, or overheating. Use cable ties, brackets, or saddles to secure cables and maintain their position.
  • Maintaining Proper Fill Ratios:
    The fill ratio refers to the amount of space occupied by cables within the tray. A tray that is too full can lead to overheating, which increases the risk of fire or cable degradation. NEC guidelines recommend that cable trays should be filled to no more than 50-60% of their capacity, depending on the cable type. This ensures proper ventilation and reduces the chances of overheating.
  • Grounding and Bonding:
    Ensuring that the cable tray is properly grounded is one of the most important safety practices. Grounding helps to prevent electrical shocks and minimize the risk of sparks that could ignite hazardous gases or vapors. All hazardous area cable tray systems must be bonded and grounded according to the NEC Article 250 guidelines. Additionally, grounding should be checked periodically to ensure it remains intact throughout the system’s lifecycle.
  • Cable Separation:
    To maintain the safety and integrity of the system, cables in a hazardous area cable tray should be appropriately separated based on their type and function. For example, power cables should be kept separate from instrumentation cables to prevent signal interference. This also ensures compliance with NEC regulations that require distinct separation between different types of circuits in hazardous environments.
  • Sealing and Conduit Usage:
    In some hazardous locations, it may be necessary to install conduit or seal the cable tray to prevent the ingress of hazardous substances, such as flammable gases or vapors. This is particularly important in Class 1 Division 1 areas, where explosive atmospheres may be present under normal operating conditions. Proper sealing techniques must be followed to ensure that the tray system does not become an ignition source.
  • Compliance with Local Codes:
    Always adhere to local building codes and safety regulations, which may vary depending on the region. The NEC (National Electrical Code) and other international standards (such as IECEx or ATEX) provide detailed requirements for the installation of electrical systems in hazardous locations. Ensuring compliance with these standards minimizes the risk of accidents and legal penalties.

Essential Guide to Cable Tray Segregation and Compliance

Compliance with Hazardous Area Cable Tray Regulatory Standards

In hazardous environments, where explosive gases, vapors, dust, or fibers can present a significant risk to both personnel and infrastructure, it is critical to adhere to regulatory standards. These standards are designed to mitigate the risks associated with electrical systems and ensure that the installation, maintenance, and operation of systems such as hazardous area cable trays are safe, reliable, and compliant with safety regulations. The key standards for hazardous area electrical systems include the National Electrical Code (NEC), OSHA, and NFPA 70. Below is an overview of these essential guidelines and their relevance to hazardous area cable tray installations.

National Electrical Code (NEC)

The National Electrical Code (NEC) is a comprehensive set of safety standards that govern the installation and maintenance of electrical systems in the United States. It provides critical guidelines for ensuring that electrical systems, including hazardous area cable trays, are safe and capable of operating in environments prone to fire, explosion, or electrical hazards.

  • Article 392 – Cable Trays:
    Article 392 of the NEC specifically addresses the installation of cable trays in hazardous locations, providing the necessary requirements for selecting, installing, and maintaining cable trays used for electrical wiring in explosive or volatile environments. The article ensures that cable trays meet the necessary safety standards to prevent ignition sources and maintain the integrity of the electrical system.
  • Explosion-Proof and Hazardous Location Requirements:
    The NEC outlines specific requirements for electrical systems in hazardous areas, including Class 1, Class 2, and Class 3 locations. In these areas, the electrical wiring, including hazardous area cable trays, must be designed to prevent sparks, heat, or any other potential ignition sources that could ignite flammable substances. For Class 1 Division 1 areas, for example, the code specifies the use of explosion-proof cable trays and materials that can withstand extreme conditions.
  • Materials and Construction:
    The NEC also specifies the materials and construction methods for hazardous area cable trays. Trays must be made of materials that are resistant to corrosion, impact, and heat, ensuring that they will not degrade or fail when exposed to hazardous conditions. Additionally, materials must be non-combustible or suitably protected from igniting hazardous substances. The use of galvanized steel, aluminum, and fiberglass is common, as these materials provide excellent durability and safety.
  • Cable Type and Compatibility:
    Article 392 provides guidelines on selecting the appropriate cable for installation in hazardous area cable trays. Depending on the classification of the hazardous area, the NEC specifies cables such as TC (Tray Cable), ITC (Instrumentation Tray Cable), and MI (Mineral Insulated) cables. These cables must meet the specific temperature, voltage, and durability requirements of the hazardous environment.

OSHA and NFPA 70 Compliance

While the NEC sets the standards for electrical installations, OSHA (Occupational Safety and Health Administration) and NFPA 70 (National Fire Protection Association) play additional roles in regulating electrical systems in hazardous areas, particularly in relation to workplace safety and fire prevention.

  • OSHA – Workplace Safety Standards:
    OSHA enforces standards designed to protect workers from the hazards of electrical installations in hazardous environments. OSHA’s regulations are aligned with the NEC to ensure the protection of personnel working in or around hazardous areas. In particular, OSHA requires that electrical equipment, including hazardous area cable trays, be installed and maintained in a manner that does not pose a risk of ignition or electrical shock. OSHA also mandates proper grounding, bonding, and insulation to reduce the risk of electrical hazards, and ensures that proper signage and warning labels are placed to identify hazardous areas.
    • 29 CFR 1910: OSHA’s regulations under 29 CFR 1910 govern the use of electrical equipment in industrial settings, including hazardous areas. The rules emphasize proper installation practices, the correct use of explosion-proof enclosures, and other safety features critical for reducing the risks associated with hazardous electrical systems.
  • NFPA 70 – National Fire Protection Association:
    NFPA 70, also known as the National Electrical Code (NEC), is part of the NFPA’s broader fire safety standards. The NFPA 70 code provides additional guidelines for electrical installations in hazardous locations, focusing on fire prevention and protection. This includes specifying fire-resistant materials and cable coatings, as well as designing electrical systems to prevent the spread of fire or explosion. NFPA 70 also outlines the proper maintenance and inspection requirements for electrical systems in hazardous areas to ensure that systems continue to operate safely over time.
  • NFPA 70E – Electrical Safety in the Workplace:
    NFPA 70E addresses electrical safety in the workplace, providing detailed guidelines on safe work practices for personnel working around electrical installations, particularly in hazardous areas. The standard emphasizes the use of personal protective equipment (PPE), lockout/tagout procedures, and safe work practices that are crucial for protecting workers from electrical hazards. Compliance with NFPA 70E ensures that workers are protected from potential arc flash, electrical burns, and shock while performing their duties in hazardous environments.

Key Areas of Compliance for Hazardous Area Cable Tray Installations

  • Explosion-Proof Equipment:
    All electrical components, including hazardous area cable trays, must meet stringent explosion-proof requirements, especially in Class 1 Division 1 and Class 2 locations. This includes ensuring that the tray is made from non-combustible materials and equipped with sealing and grounding mechanisms to prevent sparking or the escape of hot gases that could ignite hazardous substances.
  • Grounding and Bonding:
    The NEC, OSHA, and NFPA all require proper grounding and bonding of electrical systems in hazardous areas. Grounding ensures that any excess electrical current is safely conducted to the ground, preventing potential sparks or shock hazards that could lead to fires or explosions.
  • Cable Protection and Routing:
    Hazardous area cable trays must be installed in a way that protects cables from physical damage, exposure to corrosive chemicals, and environmental factors that could compromise their integrity. Cables must be routed in a way that minimizes the risk of damage, and proper sealing and insulation must be used to prevent the ingress of hazardous gases or vapors.

Common Challenges and Solutions in Hazardous Area Cable Tray Management

Managing electrical systems in hazardous areas requires careful attention to safety and regulatory compliance. Hazardous area cable trays are crucial components in maintaining organized and safe cable management systems in these environments, but they come with their own set of challenges. Understanding these challenges and implementing effective solutions is key to ensuring that electrical systems in volatile or explosive locations remain safe, reliable, and compliant with industry regulations.

Challenges in Hazardous Area Cable Management

  • Managing Overfilled Trays

One of the most common challenges when dealing with hazardous area cable trays is overloading. Overfilled trays can lead to a range of safety hazards, most notably overheating. When cables are packed too tightly or not routed properly, they can generate excessive heat, which increases the risk of insulation breakdown and, in extreme cases, fires or explosions. Overloaded trays can also impede airflow, reducing the cooling effectiveness and increasing the chances of heat-related damage. Additionally, a cluttered tray makes future maintenance, cable modifications, or troubleshooting more difficult and hazardous.

Solution:Properly sizing and organizing the cables is essential for preventing tray overloading. It is important to calculate the expected cable load, including cable size, type, and future expansions, to select the correct tray system. The NEC provides guidelines on cable fill ratios that must be followed. Ensuring that the tray is not overcrowded allows for better airflow and cooling, reducing the risks associated with overheating and maintaining the system’s overall efficiency.

  • Environmental Concerns

Hazardous area cable trays often face challenging environmental conditions, including extreme temperatures, high humidity, and exposure to corrosive chemicals or gases. These environmental factors can degrade cables, trays, and their insulation over time, leading to system failures or dangerous situations. For example, prolonged exposure to high temperatures can cause cables to lose their insulation properties, while moisture or chemicals can cause corrosion and deterioration of metal trays.

Solution: Choosing the right materials and coatings for hazardous area cable trays is crucial to addressing environmental concerns. Materials such as galvanized steel, aluminum, or fiberglass-reinforced plastics offer high resistance to corrosion and can withstand extreme temperatures. Non-metallic coatings and weatherproof enclosures provide additional protection from moisture and chemical exposure. For areas with high moisture or potential chemical spills, ensuring the installation of waterproof or corrosion-resistant cable trays is essential. Additionally, installing drainage systems in trays and sealing gaps can help protect cables from environmental damage.

  • Corrosion and Chemical Exposure

Certain hazardous locations, such as chemical plants, oil refineries, or marine environments, expose cable trays and cables to harmful chemicals and corrosive agents. Corrosion can weaken the structure of the trays, and over time, it can compromise the integrity of the cables themselves, potentially causing shorts, fire hazards, or even catastrophic failures in electrical systems.

Solution: One of the most effective ways to combat corrosion and chemical exposure is the use of specialized materials and coatings. Corrosion-resistant alloys, such as 316 stainless steel or galvanized steel, are commonly used for tray construction. Coatings such as epoxy or polyurethane can be applied to protect against chemical exposure. Additionally, installing sealed cable trays with rubber gaskets and ensuring the proper use of chemical-resistant cable types, such as TC-ER-HL or ITC-HL, will enhance the system’s resilience in corrosive environments.

Solutions for Hazardous Area Cable Management

  • Proper Cable Sealing

Sealing cables within hazardous area cable trays is essential to prevent hazardous substances—such as flammable gases, vapors, or liquids—from entering the cable system. Without proper sealing, these substances could ignite, potentially leading to a catastrophic explosion or fire. Proper sealing also prevents the ingress of moisture, which can lead to corrosion and short-circuiting of cables.

Solution: Ensuring cables are sealed effectively at entry points and junctions is a critical safety measure. This can be achieved by using explosion-proof junction boxes, cable glands, and seals, which are specifically designed to contain any sparks or flames within the system. The use of flameproof enclosures and explosion-proof cable glands prevents dangerous chemicals or vapors from interacting with electrical components. Additionally, IP-rated enclosures provide further protection from water, dust, and other environmental hazards.

  • Regular Inspection and Maintenance

Regular inspection and maintenance of hazardous area cable trays are essential for ensuring that they continue to meet safety standards and function as intended. Over time, environmental conditions, wear and tear, or physical damage can compromise the integrity of the tray system. Regular inspections help to identify signs of corrosion, physical damage, overheating, and other issues that may not be immediately visible.

Solution: Establishing a routine maintenance schedule is crucial for ensuring the longevity and safety of cable trays in hazardous areas. During inspections, focus on checking for signs of damage, loose connections, improper grounding, and excessive wear on the cables. Maintenance should also include cleaning trays to remove dust, debris, or corrosive substances that may accumulate over time. Additionally, testing cables for electrical continuity and insulation resistance can help identify potential failures before they lead to hazardous situations. Ensuring that the installation of hazardous area cable trays meets all regulatory standards, such as those set by the NEC, OSHA, and NFPA, should be part of the inspection process.

Managing hazardous area cable trays comes with its set of challenges, but by addressing these issues proactively, it is possible to maintain a safe and reliable electrical infrastructure. Properly sizing cable trays, selecting the right materials, and ensuring that cables are sealed and protected from environmental hazards will go a long way in ensuring the safety and efficiency of electrical systems in explosive or volatile environments. Routine inspection and maintenance, coupled with adherence to regulatory standards, will help maintain the integrity of cable tray systems and reduce the risk of accidents in hazardous areas.

FAQs about Hazardous Area Cable Tray

What are the hazards of cable trays?

Cable trays, while essential for organizing and protecting electrical wiring, can present several hazards if not properly installed or maintained. The primary hazards associated with cable trays include:
Overheating: If cable trays are overfilled or improperly installed, the cables within can overheat. Overheating increases the risk of electrical fires and can damage the insulation, leading to potential short circuits or failures in the system.
Mechanical Damage: Exposed cables in a poorly secured tray can be vulnerable to physical damage, especially in environments with high vibration, impact, or harsh conditions. This damage can compromise the integrity of the electrical system.
Environmental Risks: In hazardous locations, cables within trays may be exposed to corrosive substances, extreme temperatures, or moisture. These conditions can degrade cables, potentially leading to short circuits or sparks, which may ignite flammable gases or vapors in the environment.
Grounding Issues: Improper grounding or bonding of the tray system can lead to electrical faults or the buildup of static electricity, which could result in sparks or explosions, especially in explosive atmospheres.
To mitigate these risks, it’s crucial to follow proper installation guidelines, adhere to safety regulations, and regularly inspect cable trays for damage or wear.

What is the NEC code for cable trays?

The National Electrical Code (NEC) sets specific guidelines for the installation, maintenance, and safety of cable trays used in electrical systems, particularly in hazardous locations. The most relevant sections of the NEC related to cable trays are found under Article 392, which governs the installation and use of cable tray systems.
Key provisions from the NEC code include:
Sizing and Load Capacity: The NEC requires that cable trays be sized correctly to handle the intended load without causing strain or overheating. The system must provide enough space for future expansion as well.
Separation of Cables: Different types of cables, such as power, communication, or instrumentation cables, must be properly separated to avoid interference and ensure safety. Specific guidelines are provided on the allowable distance between cables.
Grounding and Bonding: Cable trays must be properly grounded and bonded to reduce the risk of electrical shock and prevent the buildup of static electricity, which can cause sparks and ignition in hazardous environments.
Installation of Cables in Hazardous Locations: For areas with explosive atmospheres, the NEC specifies the use of explosion-proof or flame-resistant cables. This includes specific requirements for Class 1, Division 1, and Class 2 areas.
By adhering to these NEC standards, installers can ensure that the cable tray system is safe, efficient, and compliant with the law.

Which type of cable is allowed in hazardous locations?

When selecting cables for hazardous locations, it’s essential to ensure they meet specific safety and compliance standards, as these areas pose a high risk of explosions or fires. The types of cables allowed in hazardous locations depend on the classification of the environment (Class 1, 2, or 3) and the specific divisions within those classes.
Key cable types that are generally approved for use in hazardous locations include:
Tray Cable (TC): Tray cables, specifically TC-ER (Exposed Run), are often used in non-hazardous and some hazardous areas. These cables are suitable for exposed runs and are designed to resist environmental damage such as moisture, chemicals, and temperature extremes.
Instrumentation Tray Cable (ITC): ITC-HL cables are commonly used in instrumentation and control systems within hazardous areas. These cables are designed to withstand hazardous conditions while maintaining their electrical integrity.
Power-Limited Tray Cable (PLTC): These cables are designed for low-power applications and are commonly used in control systems or instrumentation in hazardous areas where flame and heat resistance are necessary.
Mineral Insulated (MI) Cables: MI cables are often used in Class 1 Division 1 locations due to their high level of fire resistance and protection against physical damage.
Explosion-Proof Cables: For locations where the risk of ignition is high, explosion-proof cables are essential. These cables are specifically designed to contain any sparks or flames that might occur and prevent them from igniting the surrounding atmosphere.
It’s crucial to ensure that the cables meet the necessary NEC or IEC (International Electrotechnical Commission) standards for hazardous locations to ensure safety and compliance.

What kind of location can the cable tray use?

Cable trays are versatile systems used to support and protect electrical cables in a wide range of locations. However, the type of cable tray and its installation will depend on the nature of the environment, especially in hazardous locations. The locations where cable trays can be used are classified based on the risk of explosive atmospheres and environmental conditions:
Non-Hazardous Locations: In general industrial or commercial spaces, cable trays can be used to organize and support electrical cables. These areas don’t have a significant risk of explosive gases or vapors, and typical cable types can be used without special flameproof or explosion-proof characteristics.
Class 1 Locations (Hazardous Gases): Cable trays are often used in Class 1 locations, where flammable gases, vapors, or liquids may be present. This includes environments like chemical plants, oil refineries, and gas facilities. In these areas, the cable tray and the cables within must be chosen based on NEC codes to prevent the risk of ignition. Class 1 Division 1 and Class 1 Division 2 locations have different requirements regarding the materials used for the tray and the type of cable allowed.
Class 2 Locations (Combustible Dusts): Cable trays can also be used in Class 2 areas, where combustible dusts may be present. This includes industries like mining, food processing, and grain handling. Dust can create an explosive atmosphere if ignited, so hazardous area cable trays used in these environments must be constructed to prevent the accumulation of dust and to prevent sparks from igniting the dust.
Class 3 Locations (Fibers and Flyings): In Class 3 locations, where easily ignitable fibers or materials are present, cable trays must be designed to prevent any damage that could create sparks or friction. These locations are typically found in textiles or woodworking industries, where flammable fibers may become airborne.
Extreme Environments: Cable trays are also used in environments exposed to extreme temperatures, moisture, chemicals, or mechanical stress, such as power plants, marine environments, and offshore oil rigs. In these cases, the trays must be made of materials resistant to corrosion and wear, and the cables must meet additional standards for durability and protection.
In all cases, selecting the appropriate hazardous area cable tray system is crucial to ensuring the safety and compliance of the electrical installation, minimizing the risk of ignition, and ensuring reliable operation in harsh or hazardous environments.

CBRO Fiberglass editor Morgan Ellis

As the editor of CBRO Fiberglass, I have years of experience and in-depth research, focusing on cable tray products, fiberglass solutions, and grille systems. I incorporate years of industry insights and practical experience into every content, committed to promoting the progress of the industry. At CBRO Fiberglass, my commitment is reflected in every product, from innovative cable trays to durable fiberglass solutions and sturdy grille systems. As an authoritative voice in the industry, my goal is to provide valuable information to professionals and businesses and promote forward-looking solutions.


    Please prove you are human by selecting the tree.