NO: AC.2006.CT.01. Office:Unit10-11,3 rd Floor,N.6,Nader Alley,Vali Asr St,Tehran,Iran. Tel: +98(21) ,Tel/Fax: ,Post Cod:

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1 NO: AC.2006.CT.01 Asia Composite Co. (Knowledge Base) SPECIFICATIONS OF GRP/FRP LADDER-TYPE CABLE TRAYS

2 THE PULTRUSION PROCESS Pultrusion is a manufacturing process for producing continuous lengths of reinforced polymer structural shapes with constant cross-sections. Raw materials are a liquid resin mixture (containing resin, fillers and specialized additives) and flexible textile reinforcing fibers. The process involves pulling these raw materials (rather than pushing, as is the case in extrusion) through a heated steel forming die using a continuous pulling device. The reinforcement materials are in continuous forms such as rolls of mat and doffs of roving. As the reinforcements are saturated with the resin mixture ("wet-out") in the resin bath and pulled through the die, the gelatin or hardening, of the resin is initiated by the heat from the die and a rigid, cured profile is formed that corresponds to the shape of the die. While pultrusion machine design varies with part geometry, the basic pultrusion process concept is described in the following schematic. The creels position the reinforcements for subsequent feeding into the guides. The reinforcement must be located properly within the composite and this is the function of the reinforcement guides. The resin bath saturates (wets out) the reinforcement with a solution containing the resin, fillers, pigment, and catalyst plus any other additives required. The interior of the resin bath is carefully designed to optimize the wet-out of the reinforcement. 1

3 On exiting the resin bath, the composite is in a flat sheet form. The performer is an array of tooling which squeezes away excess resin as the product is moving forward and gently shapes the materials prior to entering the forming and curing die. In the forming and curing die, the thermosetting reaction is heat activated (energy is primarily supplied electrically) and the composite is cured (hardened). On exiting the die, it is necessary to cool the hot part before it is gripped by the pull blocks (made of durable urethane foam) to prevent cracking and/or deformation by the pull blocks. Strong well uses two distinct pulling systems, one that is a caterpillar counter-rotating type and the other a hand-overhand reciprocating type to pull the cured profile to the saw for cutting to length. CABLE TRAY Per the National Electrical Code, a cable tray system is "a unit or assembly of units or sections and associated fittings forming a rigid structural system used to securely fasten or support cables and race ways". Composite cable trays are fabricated from components derived from a process called PULTRUSION. This process enables a high percentage of reinforcement to be incorporated into the components giving it very superior strength. The strength of it in relation to its weight therefore exceeds the performance of those of steel or aluminum. Composite cable trays are made from a selection of premium resin reinforced with reinforcements to form a strong composite which is resistance to must chemicals and ultra violet. Composite cable tray resists acids, salts, alkalis and a wide range of aggressive chemicals and solvents. They are also available in fire retardant grade. DIFFERENT TYPES OF CABLE TRAYS ARE: 1) Ladder type FRP cable trays: 2) Box type FRP cable trays:

4 APPLICATIONS Offshore/Onshore Platforms Chemical and purification plants Refineries Railway cable laying Telephone cable laying Electrical cable laying Tunnels Protection of medium and low Effluent treatment plants tension cable on walls or poles Marine industry Metallurgical plants Fertilizer plants Food & Drug industry etc. Building Oil & Gas sector

5 Benefits and Characteristics of FRP Cable Trays Corrosion Resistance Mechanical Strength Fire Resistance High Performance Non-Magnetic Easily Worked Impact Resistance Cut and drilled on site Non-sparking Easy to install Maintenance Free Light Weight Cost Saving Non-Conductive Long Life Non rust Nor do they ever require painting Low Installation Costs Resistance to most chemicals Superior Strength Very good stability to UV Gives added fire protection to the cables in case of external fire DESCRIBTION CORROSION RESISTANCE The ability of Composite Cable tray is to guard against deterioration from industrial chemicals and environmental factors makes it a logical and cost-effective alternative to carbon steel, aluminum or other conventional materials also it is resistance to weather and UV. Whether Cable tray is exposed to continuous submersion, splash, spills, fumes or gases, you can be assured that Composite Cable tray will outperform other mediums. FIRE RESISTANCE Composite Cable tray is available in various resin systems, two of which meet the Class 1 flame spread rating of 25 or less, in accordance with ASTM E-84 Tunnel Test Method. If a flame spread of 10 or less is required, it will be available in request. 4

6 NON-MAGNETIC The non-magnetic properties allow the Composite Cable tray to be used in sensitive installations where the inherent magnetic properties of metallic Cable tray would prove unsuitable. IMPACT RESISTANCE The impact resistance of Composite Cable tray allows repeated deflection without permanent deformation. A certain amount of deflection can occur with loading. However, once the load is removed, the grating will return to its original shape, unlike metallic Cable tray, which will remain deformed and require costly repairs or replacement. NON-SPARKING The non sparking qualities of Composite Cable tray systems are ideally suited for those installations where hydrogen or other combustible gases may be found and which may explode or cause a fire from sparks produced. MAINTENANCE FREE The use of Composite Cable tray virtually eliminates maintenance costs since painting is not required and UV inhibitors protect against degradation from the sun. LIGHT WEIGHT Composite Cable tray weighs about one-quarter as much as steel Cable tray. So it needs few men for handling. The lightweight design of the Cable tray reduces installation and fabrication costs. COST SAVINGS In a review of costs, Composite Cable tray showed significant savings over the use of stainless steel Cable tray, and when consideration is given to life cycle costs, the saving over the use of metal Cable tray alternatives is quite considerable. 5

7 NON-CONDUCTIVE Composite Cable trays don't conduct heat or electricity and also protects the cables. LOW INSTALLATION COSTS Composite Cable tray weighs considerably less than conventional metal Cable trays and is easier and less expensive to transport, install and remove. SUPERIOR STRENGTH The high glass-to-resin ratio of Composite Cable tray provides superior strength and load-bearing characteristics. With structural integrity protected by its unique corrosion resistance capabilities, Composite Cable tray lasts longer than traditional materials. MECHANICAL STRENGTH Breaking strength under a lateral force is exceptional. The uni-directional continuous Composite reinforcement offers numerous advantages, including rigidity, shock-resistance and no permanent deformation after overloading. These factors provide excellent mechanical strength and a generous factor of safety. Composite Cable tray is designed for maximum safety in intensive industrial use. HIGH PERFORMANCE Composite structural Composite Cable tray materials have demonstrated a proven ability to withstand the harsh side effects of corrosive conditions better than galvanized steel. For many years, composites have been reliably used in traditionally corrosive industries while the cost of material is an important criteria in the design of a project, it does not reflect the total cost of the project. Beyond material purchase price, the engineer also should consider the related costs of installation, maintenance over time and replacement of debilitated materials. 6

8 The cable trays & ladders and covers are produced according to below dimensions according to requested lengths by costumers. This company will produced vertical elbow, horizontal elbow, tee, cross, reducers and etc as well. NO Description Dimension(mm) 1 2 GRP/FRP Cable Trays Cable ladders W50*H50 W100*H50 W150*H50 W200*H50 W300*H50 W100*H100 W150*H100 W200*H100 W300*H100 W400*H100 W600*H100 In different widths with Height=100, 150 mm 3 GRP/FRP Covers W50, W100, W150, W200, W300, W400, W600, W900 W: Width, H=Height This company (knowledge base) is able to produce other dimensions and designs according to customer s enquiry. 7

9 FIBERGLASS CABLE TRAY/LADDERS SELECTION Cable ladder straight Cable Tray straight Cable ladder Horizontal Bend 45º Cable ladder Horizontal Bend 90º Cable Tray Horizontal Bend 45º Cable Tray Horizontal Bend 45º

10 Cable Ladder Horizontal Cross Cable Tray Horizontal Cross Cable Ladder Horizontal Tee Cable Tray Horizontal Tee Cable Ladder Reducer Cable Ladder Left Hand Reducer

11 Cable Ladder Right Hand Reducer Cable Ladder Vertical Inside 45 Cable Tray Vertical Inside 45 Cable Ladder Vertical Inside 90 Cable Tray Vertical Inside 90

12 Cable Ladder Vertical Outside 45 Cable Tray Vertical Outside 45 Cable Ladder Vertical Outside 90 Cable Tray Vertical Outside 90

13 Cable Tray/Ladder Chemical Resistance Guide CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Oper. Temp F Acetic Acid Acetic Acid Acetone N/R N/R Aluminum Chloride SAT 170 SAT 200 Aluminum Hydroxide SAT 160 SAT 170 Aluminum Nitrate SAT 150 SAT 170 Aluminum Sulfate SAT 180 SAT 200 Ammonium Chloride SAT 170 SAT 190 Ammonium Hydroxide Ammonium Hydroxide 28 N/R Ammonium Carbonate N/R N/R SAT 150 Ammonium Bicarbonate SAT 130 Ammonium Nitrate SAT 160 SAT 190 Ammonium Persulfate SAT N/R SAT 150 Ammonium Sulfate SAT 170 SAT 200 Amyl Alcohol ALL N/R ALL 90 Amyl Alcohol Vapor Benzene N/R N/R Benzene Sulfonic Acid SAT 200 Benzoic Acid SAT 150 SAT 200 Benzoyl Alcohol 100 N/R 100 N/R Borax SAT 170 SAT 200 Calcium Carbonate SAT 170 SAT 200 Calcium Chloride SAT 170 SAT 200 Calcium Hydroxide Calcium Nitrate SAT 180 SAT 200 Calcium Sulfate SAT 180 SAT 200 Carbon Disulfide N/R N/R N/R N/R Carbonic Acid SAT 130 SAT 180 Carbon Dioxide Gas Carbon Monoxide Gas Carbon Tetrachloride N/R N/R Chlorine, Dry Gas Chlorine, Wet Gas - N/R Chlorine Water SAT 80 SAT 180 Hydrogen Bromide, Wet Hydrogen Chloride CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Oper. Temp F Chromic Acid Citric Acid SAT 170 SAT 200 Copper Chloride SAT 170 SAT 200 Copper Cyanide SAT 170 SAT 200 Copper Nitrate SAT 170 SAT 200 Crude Oil, Sour Cyclohexane N/R N/R N/R N/R Cyclohexane, Vapor ALL 100 ALL 130 Diesel Fuel Diethy Ether N/R N/R N/R N/R Dimethyl Phthalate N/R N/R N/R N/R Ethanol Ethyl Acetate N/R N/R N/R N/R Ethylene Chloride N/R N/R N/R N/R Ethylene Glycol Fatty Acids SAT 180 SAT 200 Ferric Chloride SAT 170 SAT 200 Ferric Nitrate SAT 170 SAT 200 Ferric Sulfate SAT 170 SAT 200 Ferrous Chloride SAT 170 SAT 200 Fluoboric Acid N/R N/R SAT 165 Fluosilicic Acid SAT N/R SAT 70 Formaldehyde Formic Acid SAT N/R Gasoline Glucose Glycerine Heptane Hexane Hydrobromic Acid Hydrochloric Acid Hydrochloric Acid Hydrochloric Acid Hydrofluoric Acid N/R N/R Hydrogen Bromide, Dry Potassium Hydroxide N/R N/R Potassium Nitrate SAT 170 SAT

14 CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Oper. Temp F CHEMICAL ENVIROMENT POLYESTER Wt. % Oper. Temp F VINYL ESTER Wt. % Hydrogen Peroxide Potassium Permanganate Hydrogen Sulfide, Dry Potassium Sulfate SAT 170 SAT 200 Hydrogen Sulfide, Wet Propylene Glycol ALL 170 ALL 200 Hypocholorous Acid Phthalic Acid - - SAT 200 Isopropyl Alcohol N/R N/R Sodium Acetate SAT 160 SAT 200 Kerosene Sodium Benzoate SAT 170 SAT 200 Lactic Acid SAT 170 SAT 200 Sodium Bicarbonate SAT 160 SAT 175 Lead Acetate SAT 170 SAT 200 Sodium Bisulfate ALL 170 ALL 200 Lead Chloride SAT 140 SAT 200 Sodium Bromide ALL 170 ALL 200 Lead Nitrate SAT - SAT 200 Sodium Carbonate Linseed Oil Sodium Chloride SAT 170 SAT 200 LithiumChloride SAT 150 SAT 190 Sodium Cyanide SAT 170 SAT 200 Magnesium Carbonate SAT 140 SAT 170 Sodium Hydroxide N/R N/R Magnesium Chloride SAT 170 SAT 200 Sodium Hydroxide N/R N/R Magnesium Hydroxide SAT 150 SAT 190 Sodium Hypochloride N/R N/R Magnesium Nitrate SAT 140 SAT 180 Sodium Monophosphate SAT 170 SAT 200 Magnesium Sulfate SAT 170 SAT 190 Sodium Nitrate SAT 170 SAT 200 Mercuric Chloride SAT 150 SAT 190 Sodium Sulfate SAT 170 SAT 200 Mercurous Chloride SAT 140 SAT 180 Sodium Thiosulfat ALL 100 ALL 120 Methyl Ethyl Ketone N/R N/R N/R N/R Stannic Chloridee SAT 160 ALL 190 Mineral Oils Styrene N/R N/R N/R N/R Monochlobenzene N/R N/R N/R N/R Sulfated Detergent 0/ / Naphtha Sulfur Dioxide Nickel Chloride SAT 170 SAT 200 Sulfur Trioxide Nickel Nitrate SAT 170 SAT 200 Sulfuric Acid 93 N/R 93 N/R Nickel Sulfate SAT 170 SAT 200 Sulfuric Acid 50 N/R Nitric Acid Sulfuric Acid Nitric Acid Sulfurous Acid SAT 80 N/R N/R Oleic Acid Tartaric Acid SAT 170 SAT 200 Oxalic Acid ALL 75 ALL 120 Tetrachloroethylene N/R N/R FUM 75 Paper Mill Liquors Toluene N/R N/R N/R N/R Perchlorethylene 100 N/R 100 N/R Trisodium Phosphate N/R N/R SAT 175 Perchloric Acid N/R N/R Urea SAT 130 SAT 140 Perchloric Acid N/R N/R Vinegar Phosphoric Acid Water, Distilled Phosphoric Acid Water, Tap Potassium Aluminum Sulfate SAT 170 SAT 200 Water, Sea SAT 170 SAT 190 Potassium Bicarbonate Xylene N/R N/R N/R N/R Potassium Carbonate 10 N/R Zinc Chloride SAT 170 SAT 200 Potassium Chloride SAT 170 SAT 200 Zinc Nitrate SAT 170 SAT 200 Potassium Dichromate SAT 170 SAT 200 Zinc Sulfate SAT 170 SAT 200 Oper. Temp F 14

15 Mechanical and Physical Properties Of Ladder - Type Cable Tray Properties Test Method Unit Value Ultimate Tensile Strength ASTM D638 PSI 30,000 Ultimate Compressive Strength ASTM D695 PSI 30,000 Ultimate Flexural Strength ASTM D790 PSI 30,000 Tensile Modulus PSI Compressive Modulus PSI Flexural Modulus PSI Ultimate Shear Strength PSI 5,500 Ultimate Bearing Stress PSI 30,000 Izod Impact Strength (sample thickness 1/8") ASTM D256 Ft.-LBS. Per Inch of notch Barcol Hardness ASTM D Electric Strength, Short Term in Oil 1/8" ASTM D149 VPM 200 Electric Strength, Short Term in Oil KV Per Inch 35 Dielectric Constant ASTM D150 60HZ 5.6 Dissipation Factor ASTM D150 60HZ 0.03 Arc Resistance ASTM D495 Second 120 Thermal Coefficient of Expansion ASTM D696 Inches / Inch / F Thermal Conductivity ASTM C BTUPer Sq. Ft./Hr./ F/In Specific Heat BTU / Lb. / F 0.28 Density ASTM D792 Lbs. / In Specific Gravity ASTM D792 gr/cm 3 2 Water Absorption (24 hour Immersion) ASTM D570 % by weight

16 SPLICE PLATES, CONNECTORS & ACCESSORIES FIBERGLASS CABLE TRAY SYSTEMS Standard Splice Plate Expansion Splice Plate Horizontal Adjustable Splice Plate

17 Vertical Adjustable Splice Plate Holding clamp For Ladder Hold down clamp For Tray Clips for Covers

18 STANDARDS OF FRP COMPOSITES The Following Standards are used in composite productions: ASTM C ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D b ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM D ASTM E ASTM E ASTM E ASTM F ASTM G ASTM G Heat Flux Dielectric Strength Testing Rigid Sheet for Electrical Insulation (Ladder) Impact Resistance Electrical Resistance Water Absorption Flammability Tensile Strength Compressive Strength Thermal Expansion Specifications for Laminated Thermosetting Materials Shear Strength by Punch Flexural Strength Specific Gravity Bearing Strength Weathering Density Interlaminar Short Beam Shear Strength Hardness Ignition Loss Classifying Pultruded Shapes In-plane Shear Strength In Plane Shear Tensile Dimensional Tolerances Pultrusion Terms Visual Defects Short Beam Shear Strength Flexural Properties Tunnel Beam Test Smoke Chamber Linear Thermal Expansion (CTE) Handrails Weathering Weathering 18