Construction of Mali Trough-type Cable Trays

Mali Trough-type cable trays are robust steel or aluminum systems designed for secure, accessible, and code-compliant cable management in industrial and data center environments.

Materials and Design

Mali Trough-type cable trays are typically constructed from high-strength steel or aluminum, with steel often galvanized (G90 or equivalent) to resist corrosion and maintain structural integrity over time . Aluminum trays use 5000 series alloys for lightweight durability. The tray is formed from a single sheet of material, incorporating internal flanges (commonly 7/8”W x 1/2”H) to enhance rigidity and support . Rolled or rounded edges are standard to prevent cable damage and ensure installer safety . The open trough design allows easy cable access, cooling, and the addition of new cables without disassembly. Covers, either solid or louvered, can be installed for additional protection and security . Accessories include bends, tees, elbows, drop-outs, and splice connectors, which are often pre-fabricated to minimize on-site fabrication .

Standards and Compliance

Installation and construction must comply with ANSI/NFPA 70 (NEC), NEMA VE 1 and VE 2, and ASTM standards such as A123, A653, A1011, A1008, and B633 for steel and zinc coatings . UL, CSA, and ETL certifications may also apply, ensuring safety, load capacity, and fire resistance . Compliance with these standards ensures proper support, grounding, and protection against electromagnetic interference (EMI), particularly important for fiber optic and sensitive data cabling .

Installation Guidelines

1. Field Survey and Layout: Conduct a detailed survey to verify dimensions, routing, and support locations before installation .
2. Support Spacing: Steel or aluminum trays are typically supported at maximum 10-foot centers using threaded rods and trapeze systems .
3. Joining Sections: Sections are connected using U-splice connectors with hex bolts and flange nuts, allowing for thermal expansion .
4. Cable Protection: Rounded edges and integrated side rails prevent cable snagging, crushing, or improper bend radius issues .
5. Covers and Accessories: Install covers and fittings as required, ensuring secure attachment with self-tapping screws or pre-fitted fasteners .

Practical Considerations

• Thermal Management: Open trough design promotes airflow, keeping cables cool.
• EMI Protection: Steel trays can be properly earthed to reduce interference for sensitive copper or fiber optic cables .
• Ease of Installation: Pre-fabricated bends and splices reduce jobsite labor and training requirements .
• Durability: Steel retains shape and color over time, requiring fewer supports than plastic alternatives . Mali Trough-type cable trays provide a professional, durable, and code-compliant solution for managing power, control, and data cabling in demanding environments, balancing accessibility, protection, and long-term reliability .