The manufacturing process for FRP cable trays is a continuous method called pultrusion that provides high strength, and a quality process. The procedure for fabrication, involves pulling either fiberglass roving and mats through a bath of resin, which will be either polyester, vinyl ester or epoxy resin, to saturate them with resin. The continuous lengths of resin-wetted fibre (generally fiberglass), are pulled through a heated steel die to shape/process the plastic fibres into the cable tray profiles and to cure the resin into a solid object.
After the curing process is complete, trays are cut to length and finished with operations such as coating, or drilling for the installation of mounting accessories. This process combines accuracy, consistency, and improved characteristics of performance, such as corrosion resistance, electrical insulation, and structural integrity that make FRP cable trays ideal for severe use industrial applications.
Raw materials used in FRP cable tray manufacturing
The raw materials used in the manufacturing of cable trays in FRP (Fiberglass Reinforced Polymer) construction are high-strength fiberglass reinforcements and thermosetting resins used as a matrix. These support mechanical properties and chemical resistance. Fiberglass products (continuous roving, chopped strand mats, woven fabrics), offer tensile strength, structural integrity, and ability to carry loads while resins (polyester, vinyl ester, and epoxy) provide the matrix (the binding material) and provide corrosion resistance, fire retardant properties, and durability when it is exposed to extreme and harsh conditions. Additives such as UV stabilizers, fire retardants, pigments, etc., augment the performance properties of an oligomer mixture to meet designated performance specifications.
Processes used in FRP cable tray manufacturing units
FRP cable tray manufacturing facilities use technology that results in consistent manufacturing processes, strength, and quality control. The most common approach to producing FRP cable tray systems is through pultrusion. In this process, essentially glass fibre reinforcements in saturated thermosetting resins are pulled through and heated die to form continuous rigid shaped profiles. The pultrusion process is highly automated which not only ensures precision and repeatability through high volume production with minimal manufacturing variance. After the pultrusion process, we have cutting, drilling, surface finish and quality control and inspection conditions to make the trays ready for installation or export. Some units may also have separate vessels for resin mixing, automated cutting systems or whole groups of CNC machining equipment to customize forms and fittings for trays. These manufacturing operations maintain strict inspection and quality control measures throughout the process for dimensional tolerances, load performance, and meeting ASTM, NEMA or IS standards.
Quality control measures for FRP cable tray manufacturers
Quality control protocols are vitally important for FRP cable tray manufacturers to ensure product safety, reliability, and compliance, and typically, the quality control protocols start with the inspection of raw materials (such as mechanically testing the fiberglass reinforcements and verifying resin quality for consistency and chemical resistance). During the pultrusion process, manufacturers must monitor a variety of parameters such as resin saturation and curing temperature, along with critical variables of the pultrusion process (e.g., line speed) to ensure consistency of the product. After the pultrusion process is complete, the manufacturer will check each cable tray for a variety of criteria including dimensional tolerances, the overall load-bearing capacity, electrical insulation, proper surface finish (i.e., surface imperfections), as well as fire retardancy. Manufacturers will often perform UV and corrosion resistance tests required for trays that are to be exported. For each of the cable trays, manufacturers will have documented inspection reports and traceability systems, along with following the relevant standards of ASTM, NEMA, and IS, to ensure that only the best quality, durable cable trays enter into the market.
How FRP cable tray exporters ensure timely deliveries for meeting global demands?
Exporters of FRP cable trays are acquiring bulk orders and are adjusting their delivery times in order to meet global demand – they accomplish this by streamlining their production processes, ensuring effective inventory management, and implementing successful supply chain practices to guarantee timely deliveries. Many of the leading cable tray exporters utilize scalable manufacturing systems that allow them to create production runs at bulk quantities and quick turnaround times. They also depend on logistics partners coordinating delivery schedules for overseas orders, coordinating customs documentation and other customs requirements to avoid issues with shipment timing. They employ planning systems and digital tracking devices to oversee orders proactively in real time to assist in getting the cable tray to their destination on time. They also keep ready to ship stock for standard tray sizes, and their dedicated support teams can fulfil an urgent or customized export request quickly and on time, reinforcing their ability to be a reliable supplier for customers everywhere.
Application and uses of FRP cable trays in different industries
FRP cable trays are commonly used in a number of different industries. They offer a high level of durability, and are extremely resistant to corrosion and non-conductive. In the chemical and petrochemical industry, FRP cable trays provide safe, durable cable support in corrosive environments. Power plants and substations use FRP cable trays for managing high-voltage electrical cables because of their non-conductive properties and excellent insulation and fire-retardant capabilities. The oil and gas business uses FRP cable trays to manage the organization of cables in offshore oil and gas platforms, where saltwater is the most corrosive environmental challenge to consider. Water treatment and waste water treatment facilities will specify FRP cable trays and supports to resist moisture and chemicals. Moreover, FRP cable trays are commonly used in marine environments, and have provided constant and durable service in pharmaceutical plants, telecommunications networks, and renewable energy facilities such as solar and wind farms, where having a lightweight, weatherproof cable management system is a huge advantage.
How to find the reliable FRP cable trays exporters?
Finding a reliable FRP cable tray exporters takes time and effort to research and investigate to ensure durability, compliance and quality. However, using a reliable exporter can save time and guarantee that you are getting quality items that meet your shipping and delivery deadlines. Start off by creating a short list of exporters.
First look for FRP cable tray exporters that have an established export track record and carry export certifications of government or third-party organizations such as ISO, ASTM, or NEMA that indicates quality assurance and compliance to relevant international standards and practices. Another consideration is whether the exporter will work with you to develop a custom designed product, products that meet your specifications, including aspects of technical support, and importantly, documentation and information such as test reports, datasheets, quality assurance certificate, etc. Reading customer testimonials or case studies, and learning about export regions can also provide you with perspectives on global credibility. All exporters have limits, and it is also important to understand the exporter’s production capacity, inventory, and truck/rail capabilities to deliver products as bulk orders or urgent priority orders. After you communicate with a supplier and you intend to use them for long-term use, a sample order, or factory audit in person, if possible, will assist you in verifying a supplier and their exporter.
Conclusion
The production of FRP cable trays is a highly specialized, highly technical process that takes the best materials and cutting-edge automatic production technologies to produce high-quality, consistent products. From the meticulous selection of their raw materials (grained fiberglass reinforcements and thermosetting) to their automated pultrusion process and final quality inspections, we do it right to meet the demanding demands of industrial use. The result is a non-conductive, corrosion-resistant lightweight cable management solution without the sacrifices that can come at the expense of structural strength and durability.
FRP cable tray manufacturers can provide reliable export-grade products with the ability to supply both domestic infrastructure and growing international demand. With production powered by technology and scale, FRP cable tray manufacturers are well-positioned globally.
