A Comprehensive Guide to Cable Cleats for Cable Trays: Ensuring Safety, Efficiency, and Longevity

Cable management systems, particularly cable trays, play a vital role in organizing and supporting electrical wiring in commercial, industrial, and residential settings. These trays help protect the cables and provide a streamlined pathway for their installation. However, just having a cable tray isn't enough; cables need to be securely fastened and supported within the tray to prevent issues like damage, wear, or accidents. This is where cable cleats come into play.

Cable cleats are small, but extremely important components designed to secure cables in place within a cable tray. In this comprehensive guide, we’ll explore why cable cleats are necessary, the various types available, and how to choose the right cleats for your specific application.

What Are Cable Cleats?

Cable cleats are mechanical devices designed to secure electrical cables within a tray, duct, or other cable management systems. They are typically made from materials such as aluminium, steel, plastic, or even stainless steel, depending on the required strength and environmental conditions. Their primary function is to prevent cables from moving or slipping out of place, thus ensuring a safe and reliable electrical system.

When cables are installed in a tray without proper support, they are more likely to become damaged by vibrations, thermal expansion, or physical forces. This can lead to short circuits, electrical failures, or even fires. Cable cleats help prevent such risks by securing cables, protecting their insulation, and reducing mechanical strain.

Why Are Cable Cleats Important?

1. Preventing Cable Damage: Without cleats, cables may move within the tray, causing friction or contact with rough surfaces. This can lead to damage to the cable insulation, exposing the wires inside, which can result in short circuits or system failures.
2. Ensuring Compliance with Safety Standards: Various industrial and electrical standards require the use of cable cleats to meet safety codes. For instance, the IEC 61914 standard outlines the specifications for cable cleats, ensuring they provide adequate support and protection in electrical installations. Compliance with these regulations is critical to ensure safety and avoid legal and financial consequences.
3. Stabilizing Cables Against External Forces: In industrial settings, vibrations, mechanical shocks, or wind pressure can displace cables if they are not secured. Cable cleats hold cables firmly in place, preventing them from moving, reducing the chances of accidents.
4. Reducing Risk of Fire: If cables are not properly secured, they may rub against each other or the tray, which could result in sparks or heat build-up. Proper cleat installation ensures cables are spaced out and organized, reducing the potential for overheating and fire hazards.
5. Improved Aesthetic and Organization: Cleats not only serve a functional purpose, but they also contribute to the overall organization of the cable system. Neatly secured cables help improve the appearance of the installation and make future maintenance or repairs more manageable.
6. Extending Cable Life: By securing cables in place and preventing damage, cable cleats help extend the lifespan of the cables. This leads to fewer replacements, reduced maintenance costs, and minimal downtime in the system.

   

Types of Cable Cleats

Cable cleats come in various designs to accommodate different types of installations. Here are the most common types used in cable tray systems:

1. Single Cable Cleats

These are the most basic type of cable cleats, designed to secure a single cable at a time. Single cleats are typically used in installations where cables are spaced out and not bundled together. They are ideal for smaller installations or systems with a limited number of cables. Single cleats are usually fixed at intervals along the tray to ensure proper cable support and alignment.

Advantages:

• Cost-effective for small installations
• Simple design, easy to install
• Suitable for low to medium load applications

2. Double Cable Cleats

Double cleats are designed to hold two cables at once. These cleats provide added support and stability, making them ideal for systems with multiple cables running side by side. They are often used when the number of cables is higher, or when the cables need to be securely supported to prevent shifting or rubbing.

Advantages:

• Suitable for installations with multiple cables
• More efficient than using individual single cleats
• Provides improved cable alignment and load distribution

3. Triple and Multiple Cable Cleats

As the name suggests, these cleats are designed to hold three or more cables at once. Triple cleats and similar designs are used in environments where many cables need to be routed together in a compact and organized manner. This design is common in high-density installations such as power plants, data centres, or manufacturing facilities.

Advantages:

• Ideal for high-density installations with many cables
• Helps save space and improve organization
• Provides strong support to prevent cable movement

4. Ladder Cable Cleats

Ladder cable cleats are specifically designed for use with ladder-type cable trays. These cleats are placed along the rung of the ladder, securing cables in place while maintaining a clean and organized appearance. They are especially useful in systems where cables need to be tightly secured in a linear pattern.

Advantages:

• Designed for ladder-type trays
• Provides a tight grip on cables
• Helps ensure a safe and organized installation

5. Spacer Cable Cleats

Spacer cleats are designed to separate cables that need to be kept apart. This is important when cables are large and generate heat, or when interference between cables could impact performance. Spacer cleats are commonly used in high-voltage installations or systems where thermal expansion needs to be considered.

Advantages:

• Keeps cables at a fixed distance from each other
• Reduces the risk of overheating or interference
• Ideal for high-voltage or high-performance systems

6. High-Performance Cable Cleats

These cleats are built to withstand extreme environmental conditions such as high temperatures, corrosive environments, or mechanical stresses. High-performance cleats are often made from stainless steel or other corrosion-resistant materials and are used in offshore, chemical, or hazardous industrial environments.

Advantages:

• Ideal for harsh environments
• Made from corrosion-resistant materials like stainless steel
• Can withstand extreme mechanical and thermal stresses

  

Key Considerations When Choosing Cable Cleats

When selecting the right cable cleats for your installation, several factors should be taken into account:

1. Cable Type and Size

The type of cables being used will determine the cleat style, size, and material. For example, larger cables may require more substantial cleats, while smaller cables may be adequately supported with standard single cleats. Make sure the cleats are designed to fit the specific cable diameter and type you're working with.

2. Material of the Cleats

The material of the cleats is an important factor to consider, particularly in environments subject to corrosive elements, extreme weather, or high mechanical stress. Materials such as stainless steel, galvanized steel, and aluminium are commonly used for high-strength and corrosion-resistant cleats, while plastic cleats are more suitable for lightweight applications or environments with less exposure to harsh conditions.

3. Load and Vibration Resistance

Certain installations, particularly in industrial settings, are subject to vibrations, mechanical shocks, and heavy loads. Ensure the cable cleats you choose can handle the specific load requirements of your system and provide adequate resistance to external forces like vibrations and shocks.

4. Compliance with Standards

It is essential to ensure that the cable cleats you choose comply with industry standards. For example, IEC 61914 and other local electrical codes specify requirements for cable cleats regarding load capacity, spacing, and material. Using cleats that meet these standards ensures the safety and longevity of your cable installation.

5. Ease of Installation

Some cleats are easier to install than others, thanks to features like adjustable sizes or quick-fit designs. Choosing cleats that are easy to install can save time and reduce labour costs during installation.

6. Environmental Considerations

Lastly, the environment in which the cables are being installed plays a significant role in selecting the right cleats. If the cables are exposed to extreme temperatures, chemicals, or moisture, it’s crucial to choose cleats that can withstand such conditions without compromising performance.

Conclusion

Cable cleats are essential components for ensuring the safety, stability, and longevity of cable tray systems. By securely fastening cables, cleats reduce the risk of cable damage, prevent electrical failures, and improve the overall organization of your installation. Whether you're managing a small installation or a complex industrial system, selecting the right cleats can help you avoid costly repairs, minimize downtime, and ensure the smooth operation of your electrical network.

Incorporating cable cleats into your cable tray system might seem like a small detail, but it is crucial for the safety, compliance, and efficiency of your entire cable management system. Take the time to assess your requirements, choose the right cleats for your environment, and ensure that they are properly installed to safeguard your cables and electrical system.