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Cable Trays for Offshore Projects: Corrosion Protection and Longevity

Offshore infrastructure places special demands on cable systems. Salt mist, constant humidity and vibrations destroy standard materials, accelerating corrosion and increasing the risk of damage to cables. This leads to increased operating costs and reduced system reliability. Therefore, marine cable trays must ensure durability, electrical safety and resistance to aggressive conditions. Today, reliable cable tray manufacturers and cable tray suppliers in UAE are in demand, which develop solutions specifically for offshore and offshore facilities. 

Corrosion and Its Consequences

Salt air speeds up electrochemical reactions, and metals don’t stand a chance for long. Surfaces begin to weaken, sometimes much faster than expected. 

  • For carbon steel, the story is even harsher: rust sets in quickly, strength fades, and before long there’s a real risk of the structure giving way under its own weight.
  • Corrosion creeps into the insulation, stripping away its protection and leaving the system vulnerable — short circuits, fire hazards, the works. 

Lab tests in salt mist chambers (ASTM B117) confirm what experience already suggests: without a proper protective coating, cable trays lose their integrity in surprisingly little time.

Materials for Marine Conditions 

To extend the service life of cable systems, materials with high resistance are used: 

  • 304 and 316 stainless steel — 316 grade is additionally alloyed with molybdenum, which protects against pitting and crevice corrosion.
  • Hot-dip galvanizing at 450 °C forms a durable zinc layer resistant to the marine atmosphere.
  • Aluzinc (55% aluminum, 43.4% zinc, 1.6% silicon) provides long-term protection against atmospheric corrosion.
  • FRP/GFRP (fiberglass) — lightweight, non-conductive materials with a lifetime of more than 20 years in conditions of constant moisture
  • Aluminum forms a natural protective oxide layer, and is in demand where low weight and chemical resistance are important.

Design Solutions and Tray Types

Offshore projects use different types of cable trays: 

  • Cable Ladders — ladder structures with high load-bearing capacity and ventilation; a reliable cable ladder supplier or cable ladder manufacturer ensures quality.
  • Perforated — convenient for fixing cables, provides ventilation.
  • Full-bottomed — protects from dust, moisture and interference, but requires thermal control.
  • Wire Mesh Cable Trays — in demand with high cable density; modern solutions from wire mesh tray and wire mesh cable tray manufacturer allow flexible route changes. 

Dimensions: standard sections, 3000 and 6000 mm; height: 50-150 mm; width: 50-600 mm (for FRP up to 1200 mm). The bending radii are 300, 600, and 900 mm.

Mounting and Supports 

The fastening of the cable runs is performed using: 

  • Cantilever brackets
  • Trapezoid-type suspensions
  • Central supports 

The recommended occupancy rate should not exceed 40–50% to maintain proper ventilation and prevent overheating. Expansion connectors are installed every 25–30 m to compensate for the thermal expansion of the metal. For installation, cable tray and accessories are essential, including Cable Tray Accessories, electrical cable tray accessories, and cable basket accessories. High-quality cable tray accessories, offered by leading cable tray suppliers in Dubai, are especially in demand. 

Protective Coatings and Fire Resistance 

For marine cable trays, the following are used: 

  • Epoxy coatings and powder coatings that create a barrier against moisture and chemicals
  • Fire-resistant solutions that can withstand temperatures up to 500 °C for an hour, while maintaining the integrity of the structure

Application Areas 

Marine cable trays are used on: 

  • Oil and gas platforms
  • Shipyards
  • Offshore wind farms
  • Ports
  • Desalination plants 

In such projects, Cable Trunking Systems are also in demand, including underfloor and electrical floor trunking, which are offered by leading cable trunking suppliers and cable trunking manufacturer.

Standards and Regulations 

Cable systems for offshore and offshore facilities must comply with international requirements: 

  • IEC 60092 (electrical installations on ships)
  • IEC 61537 (strength of cable trays)
  • NORSOK and DNV
  • Standards IMO for fire resistance and smoke generation 

Conclusion 

The use of marine cable trays is the key to the reliability and durability of the entire electrical infrastructure. The use of 316 stainless steel, hot-dip galvanized at 450°C, Aluzinc and FRP protects against corrosion, humidity and salt mist. Compliance with filling standards (40-50%), installation of expansion connectors and the correct choice of cable tray accessories allow the systems to be operated safely and stably. Collaboration with leading cable tray suppliers in UAE, as well as reliable wire mesh tray supplier and GI trunking suppliers in dubai, guarantees the creation of infrastructure that will last for decades even in the harshest conditions.

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