Requirements for cable hoisting and cable tray replacement

Proper cable hoisting and tray replacement require adherence to safety standards, load handling procedures, and compliance with IEC 61537, BS EN 61537, and NEMA VE 1 guidelines.

Safety and Competency

All cable tray installation, hoisting, and replacement work should be performed by competent personnel familiar with electrical installation practices and safety requirements. Cable trays and ladders are designed to support cables, not personnel, and misuse can cause injury or system damage (BEAMA guide) . Workers should use appropriate personal protective equipment (PPE) and follow safe lifting and handling procedures.

Material Handling and Hoisting

• Bundling and Support: Cable trays and ladders should be packed in bundles with adequate banding, preferably non-metallic to prevent corrosion or contamination. Long sections (≥5 meters) require at least three timber bearers for forklift handling, while shorter sections need at least two bearers .
• Lifting and Hoisting: Trays should be hoisted using balanced lifting points to prevent bending or damage. Ensure the load does not exceed the tray's rated capacity and that lifting equipment is rated for the weight.
• Storage: Bundles should be placed on flat, level surfaces, aligned vertically if stacked, and kept dry to prevent corrosion .

Installation and Replacement

• Support Systems: Cable trays must be mounted on support elements such as wall brackets, suspended supports, or ceiling mounts, designed to withstand mechanical loads, environmental factors, and the weight of cables .
• Load Considerations: Trays must accommodate the weight of cables, equipment, and environmental loads (wind, snow, ice) without exceeding the safe working load .
• Tray Types and Materials: Selection of tray type (ladder, ventilated, solid bottom, wire mesh) and material (steel, stainless steel, aluminum) should consider corrosion resistance, mechanical strength, and environmental conditions .
• Replacement Procedure: When replacing trays, remove cables carefully, support the tray during removal, and ensure new trays are aligned and securely fastened. Maintain proper spacing and bend radius for cables to prevent damage .

Compliance and Standards

• IEC 61537 / BS EN 61537: These standards define construction, testing, and performance requirements for metallic cable tray systems, ensuring durability and safety .
• NEMA VE 1 / CSA C22.2: Provides specifications for metal and non-metallic trays, including load/span designations, fittings, and installation practices .
• Inspection and Maintenance: After installation or replacement, inspect trays for alignment, secure fastening, and absence of damage. Periodic maintenance ensures long-term safety and performance .

Key Recommendations

• Use tested and compatible system components to ensure structural integrity.
• Avoid using trays as walkways or ladders.
• Maintain minimum bend radius and proper cable spacing to prevent mechanical stress.
• Document all replacements and modifications for compliance and future maintenance. By following these guidelines, cable hoisting and tray replacement can be performed safely, efficiently, and in compliance with international and national standards.