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You are here: HomeSearch for "why use a cable cleat"

Search Results for: why use a cable cleat

Cable Theft Prevention

October 15, 2013 by admin

At its peak, cable theft was estimated to cost the UK economy £770 million per year. Even though a £5 million funded crackdown from British Transport Police (BTP) has helped dramatically reduce the level of cable theft, in the first half of this financial year, (up to 14th September 2013) there has been 95 incidents of cable theft within the UK’s rail network alone. Causing 30,928 minutes of delays and an estimated compensation cost of over £1 million.

These figures do not include the cost of staff time to repair and replace the stolen cable, replacement of the cable itself and the cost of extra security measures implemented to try to prevent future thefts. The total cost of these measures in the 12 months up to April 2013 reaching £12.7 million.

Causes Behind Cable Theft

It’s easy to see why cable theft has seen an increase in the past decade up to its peak, with the price of copper soaring since 2002. From £1000 to around £6000 per metric tonne at its peak.

Price of Copper 2000-2013

With copper becoming so valuable and with its abundance within rail networks, copper theft via cables spiralled out of control.

Combatting Cable Theft

There are a number of methods than can be implemented to help fight cable theft.

Existing Technologies

Tamper Proof Cable CleatsEllis Patents Tamper Proof Cable Cleats – Ellis’s tamperproof cleats are designed to make removing copper cables almost impossible. Its box design makes the task of detaching the cleat from the cable as difficult and as time consuming as possible.

This added to the requirement (for short-circuit protection) to fit cleats at regular intervals along the length of the cable means thieves will simply not have the time to remove the cleats, and therefore the cable, in time before the authorities arrive.

RedWeb Technologies – Working alongside the BTP, RedWeb Security have designed an indelible fluid that’s applied to the surface of cables. The spray will transfer to skin, clothing or hair of the thief and remain detectable for over 6 months.

Each batch of spray contains a unique forensic code which is traceable to the location of where it was applied to the metal. By glowing bright red under a UV light, signalling the suspected criminal had an involvement with the theft by being contaminated with the dye.

SmartWater – Similar to RedWeb’s forensic fluid, Smartwater asigns trackside cables with a uniquely coded chemical signature that is identifiable by police. The liquid is almost impossible to remove and can even withstand burning. Once detected the Smartwater provides the police with irrefutable proof of involvement with a particular cable theft. It has been proven to cut cable theft on key national rail routes.

Combatting Cable Theives

Anti-Vandal Guards – These galvanised steel anti-vandal guards provide protection from vandalism and theft. Designed primarily for 25x3mm earthing tape, the guard is also suitable to secure and protect smaller cable systems. Easy to fix and with long lasting corrosion resistance, it is a further deterant to copper cable theives. Please contact us for price and availability.

New Legislation

The new Scrap Metal Dealers Act has now come into force, making it harder for metal thieves to sell on stolen metal. Replacing the 1964 act, it requires all dealers to have a licence, which it makes tougher to get, as well as requiring sellers to provide ID at the point of sale and have it recorded by the dealer.

It is hoped the new traceability deters criminals from carrying out copper theft.

These preventative technologies and innovations, along with tougher legislation and police crackdowns have helped reduce cable theft from its peak. Time will only tell whether or not this new scrap metal law will have the desired effect, however we believe the combination of these tactics, although incurring additional costs, will be beneficially in the long run compared to downtime, replacement cable and labour costs. Learn more about our offer of power cable lugs.

Video: Cable Thefts Reach Crisis Point

If you found this article helpful or interesting, please share it!

Filed Under: Industry

The Importance of Correctly Cleating Cables

May 8, 2013 by admin

The importance of correctly cleating cables in a trefoil formation within electrical installations is frequently underestimated, often due to a lack of understanding. Many people assume cleats are used purely to hold the power cables to the desired route, but for an installation of single core cabling system to be deemed safe, it is vital these cables are restrained in a manner which is able to withstand the forces generated in potentially lethal short-circuit situations.

The below video shows an example of the extreme force that can be generated by a short-circuit:


More awareness yet inferior products

In recent decades, the demand for electrical power has risen dramatically and specifiers are becoming more aware of the issues involved with incorrectly cleating trefoil cable formations, but issues still occur with inferior quality products within the market-place.

To address the issue of inferior products, in addition to the existing European Standard (EN 50368), there is now an international standard which provides global recognition of the need to provide suitable restraint for power cables; IEC 61914:2009.

Up-to-date international accreditation

Coupled with the International standard, it is equally important that any product specified is capable of demonstrating its suitability for the required task. It is no longer acceptable that in-house testing certificates are used as proof of a products pedigree and this is why current, third-party testing is vital.

Here at ETS, we continue to believe that only the highest quality, UK-manufactured, EN and IEC standard conforming cable cleats should be used. Our expertise and extensive cleat range allows us to supply cleats designed specifically for the task and third-party accredited as such.

We also provide a service that can recommend which type of cleat should be used and importantly, the spacing interval the cleat should be fixed for each project application. This is calculated from the short-circuit withstand installation requirement and the diameter and construction of the cable being installed.

If you found this article helpful or interesting, please share it!

Filed Under: Knowledge

Guest Blog: Bold Test

September 30, 2022 by admin

Should you be using cable cleats instead of stainless cable ties for your next project? ETS stocks both product types and we’re often asked which is the most suitable for a particular installation. ETS recently caught up with Richard Shaw from Cleat manufacturer Ellis for his thoughts on cable ties and cable cleats.

“Claims have recently begun to emerge from certain quarters that imply stainless steel cable ties can be placed on an equal footing with cable cleats.

Amongst the claims being made are:

  • ‘Metal ties actually provide as much protection in the event of a short circuit as cleats.’
  • ‘Stainless steel cable ties are less expensive on average than cable cleats.’
  • ‘Stainless steel cable ties provide an equal or better level of risk mitigation at lower cost and quicker time to install.’

My problem with these assertions is that although stainless steel cable ties and cable cleats are complementary products, the area of overlap is extremely small – and when explored fully, it’s immediately apparent that it’s an area of considerable risk. What this means is that the kind of claims being made about stainless steel cable ties are, at best, extremely misleading.

Product v Product

Cable cleats are made in a variety of materials to accommodate a wide range of installation conditions and locations. Our product range alone features stainless steel, mild steel, extruded aluminium, cast aluminium and a wide range of polymers. Many of our cleats combine metals and polymers to deliver the best solution.

Cable cleats also come in a number of different varieties. Again using our product range as an example, we supply cable saddles, cable straps, flexible cable cleats, hinged cable cleats and even the most straightforward of cable clamps.

In contrast, a stainless steel cable tie is just that – a cable tie available solely in stainless steel.

Creating an analogy about the two products highlights the scale of the differences between them perfectly: A stainless steel cable tie manufacturer may claim their wrench is as good, if not better, than the cable cleat manufacturer’s. But the cable cleat manufacturer retorts by pointing out they don’t just have one wrench, they have an entire tool kit.

Price

Before even considering the question of price, we first have to decide which of the many types of cable cleat we should compare the stainless steel cable tie with.

In the examples I’ve seen, the price comparisons between the two tend to pit cable cleats at the upper end of their range against cable ties. While this may seem unfair, the comparison has been made so let’s see how it stands up to scrutiny.

First, it’s obvious that a single stainless steel cable tie will be cheaper than what is the strongest of stainless steel cable cleats – after all, you get what you pay for.

But even so, would the entire cost of both product and installation be cheaper if you used cable ties rather than cleats? It may surprise you to discover that the answer is almost certainly no – but why?

When considering the strongest stainless steel cable cleat it is ludicrous to try and equate it to a single stainless steel cable tie. Yes, both products are made from similar material, but there is, of course, a lot more steel in a cleat than a tie.

Therefore, in order to make a direct comparison you need to consider the cross sectional area of the material being used – a calculation based on width, thickness and the number of times it is wrapped round the cables.

Cable ties are typically less than 20mm wide and less than 0.4mm thick and so have a cross sectional area of less than 8mm2.

If the strap is wrapped round twice we have material with a maximum cross sectional area of 16mm2 securing the cables. In comparison, a top of the range stainless steel cleat will have a cross sectional area of 100mm2.

Harking back to simple physics, the ultimate tensile strength of a material is proportional to its cross sectional area – and that’s something you simply can’t argue with.

Using the information above, and all relevant supporting short circuit test data, if the calculated fault level for a system required the installation of an Ellis Emperor cleat every 300mm, it would come as a great surprise if the cost of the equivalent appropriate number of cable ties was less than the cost of the cleats – and that’s before you even take into account the time it would take to install them all.

Short-Circuit Testing

The final point I’d like to address is short-circuit testing, and in particular the question of whether the data gathered from a test is transferable to a real life installation?

As far as cable cleats are concerned, the answer is usually yes. This is because, under fault conditions, a cable cleat constrains all the forces generated between the cables. The mounting structure has no influence on the cleats performance and so it should perform at the level indicated on the short-circuit test certificate.

The situation is nowhere near as cut and dried when it comes to stainless steel cable ties – mainly because of the difference in fixing methods. Typically there are three ways in which a cable tie is used to attach cable to ladder:

  • The cable tie can be wrapped around both the cable and the rung.
  • The cable tie can be installed using a mounting bracket, which fixes to the rung.
  • The cable tie can be fed through perforations on the ladder rung if they are present.

Of these three methods, both option 1 and option 3 introduce significant variables that will have an impact on likely performance during a fault. In both cases a foreign body is being introduced to the loop that contains the cable.

As such everything from ladder material to rung profile; types of hole and sharpness of edges; and even surface finish and cable diameter can have an impact on the whole arrangement.

As such, it’s impossible to say that the result of a short-circuit test on a stainless steel cable tie is transferrable to the real world, unless the installation is identical to the testing set-up.

Of course, installation option 2 is more likely to deliver real-life performance that matches short-circuit testing performance for a cable tie. But in this scenario both the cost of the parts required, and the installation time will increase significantly, making it even less competitive when the number of ties to cleats ratio is taken into account.

The Final Decision

What needs to remembered when considering the respective merits of both stainless steel cable cleats and cable ties is that the primary concern for all those involved in electrical cable installations should be safety.

In order for an electrical installation to be deemed safe, cables need to be restrained in a manner that can withstand the forces they generate, including those generated during a short-circuit.

Yes, both cable ties and cable cleats have their place in the specification picture. And yes, there is a minimal amount of overlap where it is feasible that an installer or specifier could choose one over the other. But it is minimal, and the specification decision shouldn’t be made based on misleading claims aimed squarely at undermining the sales of a tried, tested and trusted solution.

All cable cleats designed and manufactured by Ellis Patents undergo a thorough testing program prior to launch, including short-circuit testing. Even after launch, products are regularly short-circuit tested and will perform at the level on the relevant certification during a real life short-circuit scenario.

Not one of our installed cable cleats has ever failed. Therefore, make sure you make the correct specification decision on your next electrical installation.

If you don’t the dangers posed by a short-circuit are plentiful – costly damage to cables and cable management systems, plus the risk to life posed by incorrectly installed live cables.”

Official Suppliers

ETS Cable Components are the official suppliers, stockists and distributors of Ellis Patents cable cleats.
ETS also supplies a range of stainless steel cable ties as well as tooling.

If you would like any help with choosing the right product for your next project, please get in touch with the knowledgeable ETS sales team: +44 (0) 20 8405 6789 | sales@etscablecomponents.com

Cable Cleats Brochure

Cable Cleats

A brochure is available setting out ETS’ wide range of cable cleats. To find out more click here.

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Filed Under: Uncategorized

Need to Order Stainless Steel Ties?

Need to Order Stainless Steel Ties?

ETS stock both highly engineered power cable accesories and those which are simple but extremely useful, like stainless steel ties.

Because of its excellent resistance to rust and stains, stainless steel is great for outdoor applications. Unlike carbon steel, it won’t rust even in wet environments, which is why it’s so popular for use as a construction material.  

Available in standard, heavy and extra heavy-duty variants, our stainless steel ties are also available in polyester coated or un-coated stainless steel.

Typical ties that we stock, include these medium-duty, high specification, 316 stainless steel rollerball cable ties . These cable ties have a retained, locking ball bearing which grips the tie strap and locks the tie as it’s tensioned. This makes them extremely easy to apply and remove if needed.

We also have all the tools need to install these cable ties to the highest standards, such as the DSTG cable tie tool, a budget, operator controlled tension tool for use with rollerball stainless steel cable ties. 

If you need to order stainless steel cable ties, simply get in touch today and we can discuss various options suitable for your application.  

020 8405 6789 or email: sales@etscablecomponents.com

Galvanic Corrosion Protection and Prevention in Harsh Environments

August 14, 2013 by admin

When specifying products for use within harsh environments, choosing the correct materials is vital. For example, in offshore oil and gas installations, equipment experiences exposure to high levels of seawater and salt-spray, which are highly corrosive due to the dissolved chlorides within. Offshore installations are not the only projects that experience harsh, corrosive environments, other corrosives that affect a wide range of industries include: chlorine, ammonia and hydrochloric acid.

In May we reviewed the effects of galvanic-corrosion between two dissimilar metals, in that example we explored the use of stainless steel cleats with galvanised steel support structures. Corrosion can take many different forms and choosing the correct materials and finishes is key to minimising its effects. We have outlined common corrosion control methods, explaining how and where they should be implemented.

Choosing materials based on their galvanic characteristics

Different metals have different electrode potentials, therefore when two different metals are electrically connected in the presence of an electrolyte, such as seawater, the more active metal will become anodic leading to loss of electrons and increasing oxidisation in a process known as galvanic-corrosion.

Metals and alloys are ranked in order of noble to active, in what is called the galvanic series. A more noble metal, such as stainless steel, will have much better corrosion-resistance than a more active metal such as cast iron.

Galvanic Series MetalsGalvanic Series of Metals

Galvanic corrosion can be controlled and minimized by selecting metals in similar positions within the galvanic series. A more active metal can also be used as a sacrificial anode, attracting corrosion in order to protect the more noble metal from corrosive attack. Alternatively, depending on the installation, a cleat separation washer can be installed between the dissimilar metals increasing the distance between each metal and removing the electrical and physical contact points, critical to causing corrosion.

Passivation

During manufacturing, certain metals form a layer of metal oxide on the surface in a process known as passivation. Although the process occurs naturally, it can be enhanced through chemical passivation treatments and anodising. The layer protects against corrosion as it is tightly bound to the surface, preventing further penetration of oxygen and corrosive molecules.

The most common examples include aluminium and stainless steel. Usually, if these metals are damaged the layer reforms quickly, however this process is not without its faults. Pitting corrosion can occur in aluminium when chloride ions interfere with the reforming process and high chromium carbides can affect welded stainless steel.

If the products are properly selected for the intended application, passivated metals can provide high levels of corrosion-resistance. This is why stainless steel cleats are the preferred product within offshore installations.

Protective Finishes and Coatings

Various protective coatings can be applied to metals to help shield metallic surfaces from the surrounding environment, including epoxy power coating, oven-baked enamel, hot-dipped galvanisation and PVC-type coatings. Care must be taken when installing products with these coatings as any damage during installation and fitting, drilling and cutting etc. must be re-protected to ensure the integrity of the rest of the coating.

Hot-dipped galvanised products offer two forms of protection as the zinc coating protects the surface of the steel and becomes a sacrificial anode if damaged.

Non-metallic components

In highly corrosive environments, where metals are not suitable due to high levels of corrosion, non-metallic products are commonly being specified as an alternative. It is important to remember that plastics are not completely impervious to chemicals and often suffer from UV exposure, which should be taken into consideration when specifying project materials.

The possibility of corrosion may not be at the forefront of material specifications and in times of economic hardship, may be over looked. However, with the World Corrosion Organisation estimating the annual cost of corrosion, throughout all industries, at $2.2 trillion, it truly is a global issue. We believe any short-term savings made from overlooking the extensive effects of corrosion will be more costly in the future and the figure from the WCO backs this up.

If you are concerned about potentially corrosive environments affecting products you may be specifying, we are able to offer expert advice on the best product to suit your specific requirement.

Have you had any experience with corrosion and would like to share your experiences then please leave a comment below. Learn more about our offer of electrical lugs.

If you found this article helpful or interesting, please share it!

Filed Under: Knowledge

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