Cable trays are structural support systems used to route and support electrical cables across buildings and industrial sites. In EV charging installations, cable trays provide an organized, maintainable way to carry power and communication cables from switchboards to chargers—especially in parking garages, depots, and large commercial sites with many circuits.
What Are Cable Trays?
Cable trays are open or enclosed support structures that hold cables above ground or along walls/ceilings. Common tray types include:
– Ladder trays (high ventilation, common for power cables)
– Perforated trays (more continuous support for smaller cables)
– Wire mesh trays (flexible routing, often used for data/control cables)
– Solid-bottom trays (more protection, less ventilation)
– Raceway/trunking systems (fully enclosed, more protection)
Cable trays are usually mounted on brackets, hangers, or supports and can include bends, tees, and risers for routing around obstacles.
Why Cable Trays Matter in EV Charging
EV charging sites often require multiple cable runs and future expansion. Cable trays matter because they:
– Keep cable routing clean and serviceable, reducing installation clutter
– Improve safety by preventing loose cables and trip hazards
– Speed up installation compared to running many individual conduits
– Support scalable rollouts: add circuits later without re-building routing
– Improve heat dissipation compared to bundled cables in conduit (design-dependent)
– Simplify inspections, troubleshooting, and maintenance access
– Help manage segregation between power and communication cables
In multi-storey car parks, trays are often the backbone for distributing circuits to multiple charger locations.
How Cable Trays Are Used in Charging Installations
A typical EV charging routing approach includes:
– Main feeder and branch circuits routed from distribution boards to the charging area
– Trays running along ceilings or walls to reach rows of bays
– Drop conduits or flexible connections from tray to each charger or pedestal base
– Separation of high-voltage power cables and low-voltage data cables where required
– Proper supports, labeling, and fire-stopping at penetrations
Cable tray design must consider current levels, cable weight, bending radius, and ventilation.
Typical Use Cases
– Parking garages distributing many EV charger circuits across long distances
– Fleet depots where chargers are spread across a wide yard or building
– Industrial sites with structured cable routing standards
– Retrofit projects where trenching is costly and overhead routing is preferred
– Sites planning additional charger provision using spare tray capacity
Key Benefits of Cable Trays
– Faster and cleaner installation for multi-charger sites
– Easier expansion and modifications as demand grows
– Better maintenance access and clearer fault tracing
– Improved ventilation compared to tightly packed conduits (often beneficial for derating)
– Reduced material use compared to many separate conduits in some designs
– More organized compliance and labeling for inspections
Limitations to Consider
– Requires careful mechanical support and corrosion protection (especially outdoors)
– Cable grouping on trays can increase heating and require derating checks
– Fire rating and penetration sealing requirements vary by building regulations
– Exposed trays may require additional protection against vandalism or impact
– Tray routing must respect clearance, aesthetics, and other services (sprinklers, lighting)
– Not always suitable in environments requiring full cable enclosure
Related Glossary Terms
Cable Sizing
Cable Derating Factors
Conduit System
Branch Circuit
Distribution Board
Voltage Drop
Busbar Trunking
Charging Station Installation
Additional Charger Provision
Site Design Standards