Cable Cleats

Rewriting The R&D Rulebook With Ellis Patents

Ellis Patent Vulcan+ Cleat

• Article Written By Stephen Walton Technical Director At Ellis Patents

Ellis Patent Vulcan+ Cleat

Thorne & Derrick Internatonal, based in the UK, are an Ellis Patents distributor for their market-leading and innovative range of cable cleats manufactured in the UK.

At first glance, the cable cleat may not seem like a product ripe for design and manufacturing innovation.

Its role in securing electrical cables in the event of a short circuit is seemingly straightforward enough to preclude it from such activity but look more closely and you’ll quickly realise you are wrong.

Stephen Walton, Technical Director of Ellis Patents, outlines how the company has evolved from being a manufacturer of traditional, standard cable cleats to solving installation and safety issues for the likes of Siemens, while also embracing new technology to rewrite the R&D rulebook.

For a long time, Ellis banged the drum about the importance of correctly specified cable cleats. The key selling point is the fact that, without correct specification, all a cable cleat would do is add to the potentially life-threatening shrapnel during a short circuit situation.

Ellis’s drumming these days is significantly quieter. The market is now well aware of the need for cleats. As a result, it has become increasingly congested, with more manufacturers than ever making them and, in some cases, producing virtual replicas of the most popular.

Ellis has responded to these changing market conditions by subtly shifting its focus. The company’s latest change has been focused on what and how it sells – a shift of approach that was born out a growing demand for project-specific solutions.

Initially, this was confined to bespoke cable cleats being designed and manufactured to exact client specifications and short-circuit tested to exact project conditions. This now has developed to a stage where Ellis is called in, presented with a problem and asked to solve it.

For example, the company helped Siemens with the installation and subsequent restraint of seven large diameter high voltage (HV) cables on HelWin 2 – a 690MW offshore HVDC platform.

Ellis’s cable guide clamp provided low-loss transmission between the North Sea offshore wind farm, Amrumbank West and Germany’s onshore grid.

Today, Ellis has an in-house R&D facility that enables it to deliver new, production-ready products in a matter of days. It recently developed a twist foot fixing mechanism that reduces installation cost and time for its Emperor and Vulcan+ cable cleats in less than a fortnight.

Utilising its own 3D CAD rapid prototyping facilities, and Stratasys Objet 24 and 30 printers, the development process began with a brainstorm during which possible solutions were suggested and sketched.

The most popular of these were then drawn up in 3D and printed overnight. Samples were cleaned, assembled and function tested the following morning. The promising designs were then refined and reprinted over the following days until a final version was agreed on and a functional prototype printed and passed on to sales and production for feedback.

To take a product from an idea to a fully functional, production ready prototype in less than a fortnight really does rewrite the R&D rulebook.

Traditionally, creating a production-ready prototype would have required the development of injection moulding tools, which involved significant investment in time and resources, and typically took six to eight weeks to manufacture.

Once received, only small changes to the tools were feasible, meaning any major alterations added another 6-8 weeks to the entire process.

However, by harnessing 3D printing technology and bringing as many elements of the design and testing process in-house, Ellis can now work within the tight timeframes of a live project and ensure it doesn’t lose any momentum by delivering bespoke solutions to installation issues in days.

The new product Ellis’s new twist foot cleats, which are supplied pre-fitted on its Emperor and Vulcan+ cleats, are suitable for all installations using cable channel and ladder with inverted rungs. There are singlefooted versions for cables in trefoil up to 58mm and double-footed versions for cables with diameters ranging from 59-128mm.

The single version locks in place with nothing more complex than a 90º turn and the tightening of the integral securing bolt, while the double-footed version is secured with tabs that are simply rotated 90º to engage the channel nut before the securing bolt is tightened.

Stephen Walton is Technical Director of Ellis Patents. A Chartered Mechanical Engineer with over two decades of industry experience, Stephen joined Ellis in 2015 and has since played a key role in the development of a large number of new and improved products, as well as in the positioning of the North Yorkshire company as the first port of call for contractors seeking bespoke solutions to installation headaches, and project-specific cable cleat solutions. He has also been one of the driving forces behind Ellis’s early adoption of new technology, which is helping the company rewrite the R&D rulebook.

Ellis Patents Vulcan, Atlas & Emperor Cable Cleats

Ellis Patents are global leaders in the innovation and manufacture of nylon cable cleats, aluminium cable cleats and stainless steel cable cleats – Ellis satisfy the operational requirements of the construction, oil, gas, rail, utilities, wind energy and power generation industries.

Further Reading

• IEC 61914 – Cable Cleats & Short Circuit Protection Calculations
• Fire Resistance & Cable Cleats – Surviving Fire, Flame & Extreme Heat
• Triplex Cleats – Selection Guide for Cleating 11kV BS7870 Part 4.10 Cables
• Stainless Steel Cable Cleats – Preventing Galvanic Corrosion Of Cable Fixings
• Ellis Patents Cable Cleats & Cable Basket Tray for Securing High Fault Level Cables
• Stainless Steel Cable Cleats v Ties – The Myths Debunked By Ellis Patents

Thorne & Derrick

T&D are Specialist Distributors to UK Distribution Network Operators (DNO’s), NERS Registered Service Providers, ICP’s and HV Jointing Contractors of an extensive range of LV, MV & HV Jointing, Earthing, Substation & Electrical Eqpt – this includes 11kV/33kV/66kV joints, terminations and connectors for both DNO and private network applications.

Contact our UK Power Team for competitive quotations, fast delivery from stock and technical support or training on all LV-HV products.

Key Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV 

BAND-IT Bolt Clamp & Band – Pole Mounting 5G Communications Equipment

BAND-IT Bolt Clamp and Band

BAND-IT Bolt Clamp & Band

Supporting the Rollout of 5G Wireless Networks

Roll-out of the next generation of cellular communications hardware, known as 5G, requires equipment to be upgraded and additional towers added to provide the wireless service.

The BAND-IT Bolt Clamp and Band are extensively specified for securing the new communications equipment boxes to poles and towers. The advantage to installers is that the bolt clamp can be installed with just a wrench or ratchet and is adjustable to various mounting hardware and pole diameters.

With an estimated 400 times as many 5G towers needed the time savings at installation translates to major cost savings for installers.

BAND-IT Band

The BAND-IT Banding Edge

• Easy to install, BAND-IT banding systems require no special tooling
• Cut to length to attach hardware to poles of various sizes
• Quicker installation than Band & Buckle system
• Galvanized carbon steel and aluminum for corrosion resistance extending life of product

Stainless Steel Product Features

• Available in two sizes: 3/4” for lighter duty and 1-1/4” for heavy duty
• Pairs with BAND-IT Band or Giant Band, sold in rolls and cut to length on-site

Stainless Steel Band Strapping & Clamping Systems | BAND-IT

THORNE & DERRICK are national distributors of LV, MV & HV Cable Installation, Jointing, Duct Sealing, Substation & Electrical Equipment – we service UK and global businesses involved in cable installations, cable jointing, substation earthing, overhead line and electrical construction at LV, 11kV, 33kV and EHV.

Since 1985, T&D have established an international reputation based on SERVICE | INTEGRITY | TRUST.

Contact us for 3M Electrical, ABB, Alroc, AN Wallis, CATU Electrical, Cembre, Centriforce, CMP, CSD, Elastimold, Ellis Patents, Emtelle, Euromold, Filoform , Furse, Lucy Electric & Zodion, Nexans, Pfisterer, Polypipe, Prysmian, Roxtec, Sicame, WT Henley.

Ellis Patents Lead The Way With Cable Cleat Calculator Innovation

Ellis Patents Cable Cleat Calculator

Ellis Patents Cable Cleat Calculator

by Thorne & Derrick | Ellis Patents UK Distributor 

Tool To Help With Cable Cleat Selection 

Ellis Patents has once again demonstrated why they stands alone as the cable cleat market’s leading innovator – having developed an online calculator that will provide users with completely accurate specification information for any project in a matter of seconds.

The cable cleat calculator provides correctly specified cleat spacings with respect to short circuit conditions; and recommends the ideal products for that specific project. This is achieved through a pre-programmed calculation that takes into consideration cable formation, cable size, short circuit current and the installation environment.

The questions asked in this calculator are designed to provide Ellis with the proper information to specify the correct cable cleat for your project. The questions consider cable formation, cable size, short circuit forces and the installation environment only.

It should be noted that issues such as cable weight for vertical cable runs, thermo-mechanical forces, extreme environmental conditions (e.g. extreme temperatures, industrial pollutants etc.) and any other non-standard cable installation factors have not been considered.

Thorne & Derrick distributors for Ellis Patents should be made aware of these issues should they be present for your project.

PEAK VS RMS CURRENT

The formula uses peak current, however this is often unavailable with a Root Mean Square (RMS) value given instead. To calculate the peak current from the RMS, IEC 61439-1 Low voltage switchgear and controlgear assemblies is commonly referred to, which uses the following multiples:

10kA < I ≤ 20kA             Multiply by 2

20kA < I ≤ 50kA            Multiply by 2.1

50kA < I                         Multiply by 2.2

INTERMEDIATE Cable STRAPS

The use of intermediate straps are not considered within the calculator.

The below table details the straps suitable for each cleat whereby the cleat to cable strap spacing is the same as the calculated cleat spacing.

FLEXI-STRAP (SD) and PROTECT: VULCAN+, VULCAN+ QUAD, TRIDENT, ALPHA, VARI-CLEAT
FLEXI-STRAP (HD): EMPEROR, COLOSSUS

FIXED INTERVAL SPACING

For fixed interval spacing applications such as cable ladder, the calculated cleat spacing should be rounded down to the closest possible interval. In the example of standard cable ladder which provides a cleat mounting surface every 300mm, should the calculated spacing be 0.8m the spacing to suit cable ladder should be rounded down to 0.6m.

CALCULATION ASSUMPTIONS

1. Multiplication factor of 2.2 used to convert RMS to peak (based on IEC 61439-1).
2. Spacings given may only be suitable for a category 1 short circuit for certain products. Refer to Ellis to confirm whether category 2 criteria can be applied to the product spacing calculation provided.
3. Spacings for No Bolts Cleat assume a worst case scenario of a stacked formation. Larger spacings can be achieved if the cleat is fastened separately, refer to Ellis for more details.
4. Spacings for the 2F+ clamp assume the strength throughout the range is consistent. In reality it changes considerably and larger spacings may be achievable for larger cleats as the lowest strength has been assumed in this calculator.
5. Ellis have strived to ensure that the results generated by the calculator are accurate and correct at the time of use, it is however recommended to contact Ellis to confirm the calculated spacing is suitable prior to order placement. All calculated spacings are based on the results of short circuit testing to IEC 61914.

Stephen Walton, Technical Director of Ellis Patents, said: “Correctly specifying cable cleats and the spacing that the cleats need to be installed at is vital in ensuring they function properly when called onto cable management systems. Until now, specifiers and planners needed to make the calculation using a complex formula, and then interpret these results into product type, quantity and exact spacing.”

“Our cable cleat calculator removes this complicated mathematical element from the specification process; and replaces it with a fool proof option that provides the correct cleat specification quickly and easily.”

Ellis Patents designs and manufactures all of its cable cleats in North Yorkshire, and has a global reputation for both its products, and its proven ability to solve problems through innovative thinking. This has seen the company create new products in live project situations for the likes of Balfour Beatty and Siemens; and cure a major health and safety installation headache for Network Rail.

“Our innovative approach to product and service development has served us well over the years; opening many doors that would have remained firmly shut to more traditional manufacturers,” continued Stephen.

“With the cable cleat calculator I’m confident this single online tool will have the biggest impact of any of our innovations to date; as it really does have the potential to be adopted as an industry essential across the globe.”

Ellis Patents Cable Cleats | UK Manufactured Cable Restraint & Support Products

FURTHER READING

• IEC 61914 – Cable Cleats & Short Circuit Protection Calculations
• Fire Resistance & Cable Cleats – Surviving Fire, Flame & Extreme Heat
• Triplex Cleats – Selection Guide for Cleating 11kV BS7870 Part 4.10 Cables
• Stainless Steel Cable Cleats – Preventing Galvanic Corrosion Of Cable Fixings
• Ellis Patents Cable Cleats & Cable Basket Tray for Securing High Fault Level Cables
• Stainless Steel Cable Cleats v Ties – The Myths Debunked By Ellis Patents
• Cable Cleats from Ellis Patents | Better By Design

Thorne & Derrick | Ellis Patents UK Distributors

Thorne & Derrick

T&D are Specialist Distributors to UK Distribution Network Operators (DNO’s), NERS Registered Service Providers, ICP’s and HV Jointing Contractors of an extensive range of LV, MV & HV Jointing, Earthing, Substation & Electrical Eqpt – this includes 11kV/33kV/66kV joints, terminations and connectors for both DNO and private network applications.

Contact our UK Power Team for competitive quotations, fast delivery from stock and technical support or training on all LV-HV products.

Key Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV 

Fire Rated Cable Cleats | CMP Solace, Themis & Helios

Fire rated cable cleats

Themis, Solace & Helios

This range of fire rated cable cleats from CMP launches as the use of fire resistant power cable and control cable systems for life safety and fire-fighting applications has become more prevalent in everyday use.

This product range is not only suitable for fire safety applications, but also highly corrosive environments where high grade stainless steel products should be used, or applications where high axial / lateral loads are required, such as the vertical installation of large high voltage cables (Themis only). All CMP cable cleats hold LUL 1-085 approvals.

Accessories are available for the fire rated cable cleats such as C-clamps (for unslotted rungs) and separation pads (to isolate dissimilar metals) are available for all products excluding the intermediate restraint.

London Underground Cable Joints

Tested to the Highest Industry Fire Safety Standards

Fire tested to EN50200, BS5839, BS8491, BS8434 and AS 3013, CMP’s fire-rated range has been specifically designed for use with fire performance cables to ensure the safe retention and securing of cables in the event of a wiring system being affected by fire.

BS 5839 ‘Fire detection and fire alarm systems for buildings.

Code of practice for design, installation, commissioning and maintenance of systems in non-domestic premises’ states that;

“Methods of cable support should be non-combustible and such that circuit integrity will not be reduced below that afforded by the cable used, and should withstand a similar temperature and duration to that of the cable, while maintaining adequate support.”

To adhere to this, BSI standard fire rated Cable Cleats must be used to support the cable in the event of a fire.

High Quality Material & Temperature Rating

Available in cast and fabricated 316L stainless steel, the one and two bolt range has been rigorously tested to withstand temperatures of over 1000°C, whilst providing the superior corrosion resistance that 316L stainless steel affords, making it suitable for not only indoor and outdoor applications but highly corrosive environments too.

Extreme Axial & Lateral Load Retention

As well as offering superior fire-resistance, both the Themis and Solace have been designed with a unique twin arc internal patent pending design profile, offering extreme axial and lateral load retention. Please visit the individual product pages for 3rd party test data.

Solace

CMP Solace | Fire Rated Cable Cleats

The Solace heavy duty, one bolt, high temperature, stainless steel single cable cleat is a cast metallic fire rated cable cleat which has been designed, constructed, and tested in accordance with the International Standard ‘Cable Cleats for Electrical Installations’ (IEC 61914).

These fire rated cable cleats can be used with fire performance cables to ensure the safe retention and securing of single cables in the event of a wiring system being affected by fire. These fire resisting supports help to maintain the electrical system’s integrity for any critical circuits during an emergency situation to enable safe evacuation.

The cable cleat is manufactured from stainless steel 316L making it suitable for both indoor and outdoor applications. A unique twin arc internal patent pending design profile it exhibits excellent retention, limiting both the axial and lateral movement.

The Solace one bolt cable cleat is available in twelve sizes suitable for cable diameters of 10mm up to 71mm. It has an M10 clearance hole for securing it to a mounting surface.

Features

• 316L Stainless Steel
• Operating temperature -60°C to +250°C
• Surpasses requirements of Fire testing BS5839 / BS8491 / EN50200 / BS8434 / AS-NZS 3013 (1,200°C) (Fire, shock & water)
• 10 – 71mm cable range
• Single bolt fixing design
• Can be stacked
• Excellent axial & lateral load retention
• Corrosion resistant

Themis

CMP Themis | Fire Rated Cable Cleats

The Themis heavy duty, two bolt, high temperature fire rated stainless steel single cable cleat which has been designed, constructed, and tested in accordance with the International Standard ‘Cable Cleats for Electrical Installations’ (IEC 61914). It ensures the retention and securing of single cables, without damaging or deforming the cable.

These fire rated cable cleats can be used with fire performance cables to ensure the safe retention and securing of single cables in the event of a wiring system being affected by fire. These fire resisting supports help to maintain the electrical systems integrity for any critical circuits during an emergency situation to enable safe evacuation. The cable cleat is manufactured from stainless steel 316L making it suitable for both indoor and outdoor applications.

Due to its unique twin arc internal patent pending design profile it exhibits excellent retention, limiting both the axial and lateral movement. The Themis two bolt cable cleats have an excellent range take and are suitable for cable diameters of 38mm up to 97mm in only five sizes.

These cable cleats feature two M12 clearance holes for securing it to a mounting surface, which allows for either M10 or M12 fasteners to be used.

Features

• 316L Stainless Steel
• Operating temperature -60°C to +250°C
• Surpasses requirements of Fire testing BS5839 / BS8491 / EN50200 / BS8434 / AS-NZS 3013 (1,200°C) (Fire, shock & water)
• 38 – 97mm cable range take in 5 sizes
• Can be stacked
• Excellent axial & lateral load retention
• Corrosion resistant

Helios

CMP Helios | Fire Rated Cable Cleats

Helios standard duty, one bolt, high temperature fire rated single stainless steel cable cleat is a fabricated metallic cleat which has been designed, constructed, and tested in accordance with the International Standard ‘Cable Cleats for Electrical Installations’ (IEC 61914).

These fire rated cable cleats can be used with fire performance cables to ensure the safe retention and securing of single cables in the event of a wiring system being affected by fire. These fire resisting supports help to maintain the electrical systems integrity for any critical circuits during an emergency situation to enable safe evacuation. The cable cleat is fabricated from stainless steel 316L making it suitable for both indoor and outdoor applications.

The Helios high temperature stainless steel 316L cable cleat is available in eleven sizes suitable for cable diameters of 10mm up to 65mm. The cable cleat has an M10 clearance hole for securing it to a mounting surface.

Features

• Fabricated Stainless Steel 316L
• Operating temperature -60°C to +250°C
• Surpasses requirements of Fire testing BS5839 / BS8491 / EN50200 / BS8434 / AS-NZS 3013 (1,200°C) (Fire, shock & water)
• 10 – 65mm cable range take in 11 sizes
• Single bolt fixing design
• Can be stacked
• Corrosion resistant

Flameproof hazardous area cable glands with ATEX Certification for terminating armoured SWA cables in Zone 1 & Zone 2

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LV, MV & HV Jointing, Earthing, Substation & Electrical Eqpt

Thorne & Derrick International are specialist distributors of LV, MV & HV Cable Installation, Jointing, Duct Sealing, Substation & Electrical Equipment – servicing UK and global businesses involved in cable installations, cable jointing, substation, overhead line and electrical construction at LV, 11kV, 33kV and EHV.

THORNE & DERRICK Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV 

Minimising Effects Of Electromagnetic Interference On High Voltage Cables In Electric Vehicles

High Voltage Cables In Electric Vehicles

Electromagnetic Interference

BAND-IT began serving the automotive high voltage cable market in 2007 and has supplied millions of clamping solutions to many of the largest and most well-known cable harness manufacturers in the Hybrid and Electric Vehicle Industry.

Vehicle manufacturers use a quick connector and wire mesh shield to minimize the effects of Electromagnetic Interference on high voltage cables in electric vehicles.

With previous solutions, the wire mesh could bunch or gather in one area creating an inconsistent installation. The reduced diameter clamp from BAND-IT can minimize the effects and provide a tight fit with a single stock commodity unit.

With 3 decades of EMI/RFI Shield termination dominance in the Miltary and Aero industry, BAND-IT is consistently selected for the shielding of high voltage cable in automobiles.

The BAND-IT Edge

• Consistent clamp force around the entire circumference of the part
• One BAND-IT clamp can meet many sizes and variation – reducing SKUs
• BAND-IT installation tools minimize variation and provide consistent installation of clamping application

BAND-IY Product Features

• Tamper resistant
• High clamping force securely locks the shielding to the connector
• Designed for high-volume installation
• Robust strength and resistance to vibration, thermocycling, and corrosion

Further Reading

• Cable Clamps: The BAND-IT BAND-FAST Range – IEC61914 Tested
• Solar Farms Replace Nylon Cable Ties With Metal Cable Ties

THORNE & DERRICK SPECIALIST ELECTRICAL DISTRIBUTOR

The LV HV Cable Accessory Specialists

Thorne & Derrick distribute the most extensive range of Cable Installation & Electrical Distribution Equipment to the renewable energy sector – we service UK and international clients working on underground cables, overhead lines, substations and electrical construction at 11kV and up to and EHV transmission and distribution voltages.

• Key Products: MV-HV Cable Joints & Terminations, Cable Cleats, Duct Seals, Cable Transits, Underground Cable Protection, Copper Earth Tapes, Cable Jointing Tools, Feeder Pillars, Cable Ducting, Earthing & Lightning Protection, Electrical Safety, Cable Glands, Arc Flash Protection & Fusegear.

• Distributors for: 3M Cold Shrink, ABB, Alroc, Band-It, Catu, Cembre, Centriforce, CMP, Elastimold, Ellis Patents, Emtelle, Furse, Lucy Zodion, Nexans Euromold, Pfisterer, Polypipe, Prysmian, Roxtec.

LV – Low Voltage Cable Joints, Glands, Cleats, Lugs & Accessories (1000 Volts)

MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)

Cable Laying – Underground Cable Covers, Ducting, Seals & Cable Pulling Equipment

T&D, CATU Electrical Safety & Arc Flash Protection Specialists for SAP’s, Linesmen, Jointers & Electrical Engineers – Largest UK Stockist