Comparative Analysis: FRP and Galvanized Steel Cable Trays in Corrosive Environments
In industrial and coastal regions with high humidity and aggressive chemical conditions, the correct choice of cable tray material directly affects the reliability and cost of infrastructure operation. Modern cable tray manufacturers and suppliers in UAE offer a wide range of systems, including wire mesh cable trays, cable ladders, cable tray accessories and cable trunking systems, adapted to the harsh climatic conditions of the region. FRP (Fiberglass Reinforced Plastic) and galvanized steel remain the main solutions today, both options have strengths, but their behavior in corrosive environments differs fundamentally.
Corrosion Resistance
- Corrosion is a quiet but merciless enemy of metal systems. Especially where humidity exceeds 80%, salt is in the air, and the pH jumps as it wants.
- FRP behaves surprisingly well in such conditions. It easily withstands acidity from pH 2 to 12, losing less than 0.01 mm of thickness per year. This material is not afraid of salts, alkalis and most organic acids, so it is often chosen for chemical industries and offshore platforms - places where metal simply gives up.
- Hot-dip galvanized steel, from which galvanized steel channel and C channel steel are made, is protected by a zinc layer 60-150 microns thick. It works well as long as the surface is not damaged. But once a scratch appears, the rust takes its toll.
- Pre-galvanized steel with a coating of 10-30 microns degrades faster, especially when in contact with moist air or chemical vapors. In marine or chemical areas, the service life of such systems rarely exceeds 5-10 years, while FRP retains integrity for more than 25-30 years.
Mechanical Strength and Temperature Stability
Despite its lower weight (FRP density is 1.8—2.1 g/cm3, about 4 times lighter than steel), the material has high strength:
- Longitudinal tension —> 300 MPa
- Transverse bending — ≥ 200 MPa
- The static load for a 300 mm tray is up to 200 kg/m.
FRP does not lose rigidity at temperatures from -50 °C to +120 °C, has low thermal conductivity and does not conduct electric current. Metal structures, including ladder cable tray and galvanized lintels, react more strongly to temperature fluctuations and are subject to linear expansion, which requires the installation of compensation joints.
Fire Safety and Operation
Modern FRP trays are made with flame retardants. The flammability index (LOI) is ≥32, smoke generation is not more than 75 SDR, which meets the requirements of IEC and ASTM standards. Metal structures do not burn, but when heated, they lose their bearing capacity, and in case of coating destruction, zinc oxides are released. Additional protection is provided by cable tray and accessories and electrical cable tray accessories, designed for the safe distribution of cables in critical areas.
Life Cycle Cost
- The initial cost of FRP trays is usually 15-25% higher, but maintenance costs are minimal.
- FRP: no repainting, replacement or repair of the coating, the service life is up to 30 years.
- Galvanized steel: requires regular inspection, re-coating and replacement of elements every 7-10 years.
As a result, cumulative maintenance savings reach up to 40% over the entire lifecycle. Additionally, FRP systems provide ~ 40% faster installation due to their lightness and modular design, reducing labor costs and installation time. Similar advantages are demonstrated by wire mesh tray, mesh cable tray, and wire mesh cable tray accessories, which increase installation and maintenance efficiency.
Environmental Sustainability
FRP has low VOC emissions (up to 60% lower than metal) and a recycling rate of about 85%. Zinc coatings require an energy-intensive production process and are difficult to recycle after prolonged use in aggressive environments. Underfloor trunking and electrical floor trunking are suitable for concealed laying systems, providing convenient cable distribution with minimal environmental impact.
For facilities located in corrosive areas - offshore platforms, chemical plants, tunnels and cooling stations - FRP cable trays and modern wire mesh type cable tray systems become the optimal choice. They combine lightness, electrical insulation, high mechanical strength and long service life without maintenance.
Galvanized steel remains an economical solution for dry rooms and temperate climates where the risk of corrosion is minimal. However, when taking into account the full life cycle cost, repair costs and downtime, FRP wins in terms of efficiency, durability and environmental friendliness, confirming its role as the new standard for the industrial infrastructure of the future, supported by leading cable tray suppliers in UAE and cable ladder manufacturers.