As far as industrial and manufacturing environments in countries like the UK are concerned, the effective routing of cables is of huge importance. Executing this task properly will greatly help enhance safety, protect critical assets, simplify maintenance, and support compliance with electrical standards.
There are certainly cable management products from RS that can be instrumental in this process. However, it is also essential to know how to choose the right such items, in addition to being well-versed in the associated routing principles and methods.
In this article, then, we will explore the effective cable routing techniques that those responsible for industrial settings need to know.
Why Cable Routing Matters So Much at Industrial Sites
Before we proceed further, we should be clear that cable routing is not simply the practice of “keeping cables tidy”. A better way to describe it, is as the systematic planning, installation, and management of pathways for power, control, and data cables.
Cable routing, then, is about ensuring wires are organised, safely separated, and protected from extreme conditions such as heat, chemicals, and mechanical stress.
By contrast, the absence of a structured routing strategy at a given industrial premises will heighten the likelihood of cables becoming tangled, damaged, or difficult to identify during maintenance activities.
The adequate routing of cables is also important for compliance with pertinent regulations and standards such as the Electricity at Work Regulations 1989 and BS 7671 (also known as the “IET Wiring Regulations”) in the UK.
The Crucial Approaches That Organisations Should Take to Cable Routing
Taking these steps will help organisations ensure reliability, maintainability, and safety in the demanding conditions of today’s industrial environments:
Planning And Design: The Foundation of Good Routing
Detailed planning will always need to be the starting point of effective cable routing. This necessitates mapping out routes that:
- Keep power cables separated from signal and data cables to minimise electromagnetic interference (EMI).
- Maintain minimum bend radii, often around four to eight times the diameter of the cable. However, this greatly depends on the type of cable involved; manufacturers’ data sheets always take precedence over generalised recommendations.
- Avoid high-traffic areas, heat sources, and corrosion zones to the greatest extent possible.
- Provide scope for future expansion, as well as easy access for inspection or replacement.
It will also be necessary to factor in Ingress Protection (IP) ratings for protection against dust and water ingress. This will be especially crucial in washdown areas, such as those commonly found in the food and beverage sector.
Primary Routing Methods
When it comes to the cable routing in earnest, typical processes include the use of:
- Cable trays and ladders, which are the go-to solution for open, overhead runs in factories and warehouses. They can be relied upon to provide excellent support for large cable volumes, good airflow (reducing heat buildup), and easy access.
- Conduits and trunking, with rigid or flexible conduits providing invaluable additional mechanical protection in exposed or hazardous spaces. Organisations might specify liquid-tight flexible conduits to suit vibrating machinery, while PVC or metal trunking can be indispensable for runs along walls or machinery.
- Cable ties and fixings. Securing cables at regular intervals will help prevent sagging. Ultraviolet (UV)-resistant, flame-retardant, and stainless-steel options are available to provide particular durability.
Best Practices for Installation and Maintenance
There are various other aspects of cable routing to which organisations overseeing industrial premises should pay close attention.
- Support and fixing: it is crucial to use appropriate brackets, clips, and hangers rated for the load. The over-tightening of ties will need to be avoided, too, given the damage this can cause to insulation.
- Labelling: if both ends of every cable are clearly labelled, as well as key points along the route, this will greatly help make troubleshooting quicker and easier. This is an essential move in larger facilities.
- Regular inspection: routine checks should be carried out to identify wear, loose fixings, or damage. In the UK, depending on the installation, inspection duties may arise under the Electricity at Work Regulations 1989, maintenance programmes, and where applicable, the Provision and Use of Work Equipment Regulations 1998 (PUWER).
Quality Cable Management Is a More-Than-Worthwhile Investment
Savvy cable routing is a fundamental element of industrial electrical design. When organisations combine trunking, conduit, and cable trays with secure retention methods, cable identification, and proper segregation practices, they will be helping improve safety, simplify maintenance, and extend the longevity of their installations.
