Mastering Cables in Trunking for UAE & GCC Projects

Installing cables in trunking for projects in the UAE and wider GCC region is more than organizing wires; it’s about engineering a system for safety, compliance, and long-term resilience. In the face of intense local heat and dust, a robust trunking installation is a non-negotiable component of any reliable electrical infrastructure, serving as the first line of defence against environmental and mechanical damage.

Handling Cable Management in the GCC Climate

In dynamic commercial hubs like Dubai, Abu Dhabi, or across Saudi Arabia, managing cables in trunking is a critical engineering challenge. The region's extreme ambient temperatures make heat dissipation a primary concern for electrical components in the UAE. Incorrect sizing or overfilling trunking traps heat, which can degrade cable insulation, reduce conductor efficiency, and pose a significant fire risk. Standard installation methods are insufficient; a localized approach is essential.

For engineers, panel builders, and electricians, the objective is to build a truly resilient system. This requires a strong understanding of several key factors:

• Choosing the Right Materials: Trunking materials like galvanized steel or GRP are vital. They are specified to withstand high temperatures, humidity, and corrosion prevalent in the GCC, ensuring long-term durability.
• Managing Thermal Loads: The 45% space factor rule is not a mere guideline but a critical requirement for an effective energy management solution in Dubai. It ensures sufficient airflow to prevent cables from exceeding their maximum operating temperature.
• Adhering to Local Regulations: Compliance with standards from local authorities like DEWA or ADDC is mandatory. These include specific requirements for earthing, fire-stopping, and the segregation of different cable types.
• Designing for the Future: Proactive design should account for future expansion. Leaving adequate space for additional cables and selecting systems that can withstand the harsh local climate for years is a hallmark of professional installation.

A well-designed trunking system is more than a passive container for cables. It is an active, essential part of your electrical installation's safety and performance, especially in the demanding climate of the GCC.

This guide provides practical, actionable advice to navigate these challenges. We will cover selecting the best materials, accurately calculating trunking size to prevent overheating, and segregating cables to avoid interference. Adhering to these best practices ensures your electrical installations are not only efficient and compliant but also built to last in the unique conditions of this region.

Selecting the Right Trunking System for Your Project

Choosing the correct trunking system is the foundational step toward a reliable and durable electrical installation. For projects in the UAE and the broader GCC region, this decision extends beyond a simple choice between PVC and metal; it demands a thorough analysis of the application and the specific environmental challenges.

The material directly impacts the protection of the cables in trunking. For instance, in high-traffic industrial facilities or commercial spaces, the mechanical strength of galvanized steel is essential to protect against physical damage. We explore this further in our guide to GI trunking for electrical installations. Conversely, for coastal projects or chemical plants where corrosion is a primary concern, Glass Reinforced Plastic (GRP) trunking is the superior choice due to its exceptional resistance.

Matching Materials to Environmental Demands

The significant growth in regional infrastructure necessitates solutions built for longevity. The cable management market in the Middle East and Africa was valued at USD 946.37 million in 2023 and is projected to reach USD 1,814.42 million by 2032. This growth reflects the demand for robust, metallic materials capable of withstanding harsh local conditions. You can find more on these trends in this detailed research on the MEA cable management market.

For any project in the GCC, the Ingress Protection (IP) rating is a critical specification. It defines an enclosure's resistance to solids (like dust) and liquids.

• IP54 Rating: Provides solid protection against dust ingress and splashing water, suitable for indoor commercial or light industrial applications where direct water exposure is not a concern.
• IP65 Rating: Indicates the trunking is completely dust-tight and can withstand low-pressure water jets. This is essential for outdoor installations or indoor areas subject to regular washdowns or high humidity.

When selecting trunking, it's crucial for engineers and procurement teams in the GCC to balance material performance with the project's unique environmental demands and budget.

Trunking Material Comparison for GCC Applications

Material Type	Best Use Case	IP Rating Suitability	Corrosion Resistance	Cost Factor
Galvanized Steel (GI)	High-traffic commercial, industrial, indoor applications	IP54 – IP65	Good	Medium
Stainless Steel	Food processing, pharmaceutical, hygienic environments	IP66 – IP68	Excellent	High
PVC (Plastic)	Residential, light commercial, low-impact areas	IP4X – IP54	Excellent	Low
GRP (Glass Reinforced Plastic)	Coastal areas, chemical plants, corrosive environments	IP65 – IP67	Superior	High

This table helps illustrate that the "best" material is always relative to the installation's specific requirements, from budget constraints to the level of environmental exposure.

For engineers and procurement teams, the decision must balance material performance, budget, and specific environmental exposure. Choosing an under-specified trunking system to cut costs upfront often leads to premature failure and expensive rework down the line—a common but avoidable mistake in many projects.

Ultimately, selecting the right trunking is about safeguarding the long-term integrity of the cables inside. By carefully matching the material and IP rating to your project's needs—whether in Dubai, Abu Dhabi, or KSA—you ensure the system remains safe, compliant, and functional throughout its service life.

Calculating Trunking Size and Cable Capacity Accurately

Incorrect trunking size is one of the most critical failures in electrical installations, directly impacting system safety and lifespan, especially in the demanding climate of the UAE. Sizing cables in trunking is not merely about fitting them in; it is a matter of compliance, performance, and long-term reliability.

The guiding principle is the 45% space factor rule, a non-negotiable requirement in wiring regulations like BS 7671. This is a critical safeguard ensuring sufficient free air space inside the trunking for proper heat dissipation. Overfilling trunking traps heat, which degrades cable insulation, impairs conductor efficiency, and creates a significant fire hazard. It also complicates the installation process, increasing the risk of cable damage during pulling.

A Practical Sizing Example

To perform this calculation correctly, you must first determine the total cross-sectional area (CSA) of all cables to be installed. The CSA for any cable is available in the manufacturer’s datasheet.

Consider this real-world scenario for a Dubai project:

• Cables: 10 circuits using 4mm² single-core PVC insulated cables. From the datasheet, the overall CSA of one cable is 13.9mm².
• Total Cable Area: Multiply the number of cables by their individual CSA: 10 cables × 13.9mm² = 139mm².
• Applying the 45% Rule: This total cable area must not exceed 45% of the trunking's internal space. To calculate the minimum required trunking area: 139mm² / 0.45 = 308.9mm².

You must select a standard trunking size with an internal area greater than 308.9mm². A common 50mm x 25mm trunking, with an internal area of approximately 1250mm², provides ample space and complies with the rule.

This image demonstrates a clean, compliant installation inside the trunking.

Organizing cables this way not only meets the 45% rule but also simplifies future maintenance and additions.

Future-Proofing Your Installation

In rapidly expanding commercial centers like Dubai or Abu Dhabi, client requirements can change quickly. An installation sized for today's needs may be at full capacity within a few years. A practical tip is to incorporate a buffer for future growth.

After calculating the minimum required trunking size, add a 25% capacity buffer. This foresight provides invaluable space for future circuits, avoiding the significant disruption and cost of installing new trunking runs later.

By calculating accurately and planning for expansion, you deliver an electrical installation that is safe, compliant, and adaptable. This methodical approach distinguishes professional work and provides tangible long-term value to clients across the GCC.

Best Practices for Cable Installation and Segregation

With the trunking selected and sized, the next phase is the installation of the cables. This stage is a true test of craftsmanship and is where a high-performing system is differentiated from a setup prone to future failures.

Properly managing cables in trunking is about more than aesthetics; it’s about protecting the integrity of each cable to ensure reliable system operation for years.

During the cable pulling process, care must be taken to avoid twists, kinks, and nicks in the insulation, as these can create weak points and potential safety hazards. For long or congested trunking runs, a high-quality cable-pulling lubricant is indispensable. It significantly reduces friction, allowing cables to be pulled smoothly without the force that can stretch conductors or damage sheathing.

The Critical Role of Cable Segregation

Proper segregation is a fundamental principle for any safe and functional installation. Co-mingling power, data, and Extra-Low Voltage (ELV) circuits without physical barriers can lead to poor performance and regulatory violations. The primary reason is electromagnetic interference (EMI).

EMI from high-voltage power lines can induce 'noise' in adjacent data cables, such as Cat 6 or Cat 7. This interference can corrupt data, reduce network speeds, and cause intermittent connection failures—a significant operational issue for any modern facility in the UAE.

To prevent this, physical separation is required. The most effective method is using multi-compartment trunking with built-in dividers. If using standard single-compartment trunking, a dedicated, solid metallic divider that is properly earthed along its entire length must be installed. This creates an effective shield between different circuit types.

Maintaining Separation and Ensuring Integrity

The massive rollout of fibre optic cables alongside traditional power lines for telecommunications and industrial automation makes correct installation more critical than ever. Neatly installed cables in trunking form the backbone of your network's performance, impacting all your network infrastructure components, from routers to switches.

Here are practical tips for a clean and compliant installation:

• Maintain Distance: Position data cables as far from power cables as possible within the trunking.
• Cross at 90 Degrees: If data and power cables must cross, ensure they do so at a right angle (90°) to minimize the area of potential interference.
• Secure Bundles: Use cable ties or clips to organize cable bundles within their designated compartments. This prevents sagging and tangling, simplifying future maintenance.
• Ensure Proper Termination: Professional work extends to the termination points. Using the correct tools and high-quality components, like those covered in our guide on different types of electrical cable lugs, is essential for a secure and reliable connection.

By following these best practices, panel builders and electricians in Dubai, Abu Dhabi, and across KSA can deliver installations that are not just clean and compliant but also guarantee optimal performance for years.

Ensuring Compliance and Safety with UAE Standards

In the UAE, compliance with electrical standards is a strict requirement. For every panel builder and electrician, ensuring that cables in trunking are installed correctly is critical for project sign-off, operational safety, and system longevity. Deviations can result in costly rework, project delays, and significant safety risks.

Familiarity with the regulations from local authorities such as the Dubai Electricity and Water Authority (DEWA) and the Abu Dhabi Distribution Company (ADDC) is essential. These standards are specifically designed to address the region's unique environmental challenges and ensure every installation is robust and durable.

Earthing and Bonding Metallic Trunking

One of the primary inspection points is the earthing and bonding of metallic trunking. This is a non-negotiable safety measure to prevent electric shock and must be executed perfectly.

• Continuous Protective Conductor: The entire metallic trunking run must serve as a continuous protective conductor (cpc), meaning every section must be electrically bonded.
• Secure Joint Bonding: Relying solely on fixing screws is insufficient. A dedicated earth continuity link or strap must be used across every joint to guarantee a reliable earth path.
• Main Earthing Terminal Connection: The completed trunking run must be securely connected to the main earthing terminal of the distribution board it serves.

A properly earthed trunking system is a critical safety feature. If a live conductor contacts the metal casing, the fault current has a direct, low-impedance path to the ground, causing the protective device to trip instantly.

Fire Safety and Protective Integrity

Fire safety is another critical consideration, particularly where trunking penetrates fire-rated walls or floors. Incorrectly sealed penetrations can compromise a building's fire compartmentation strategy.

Anytime trunking passes through a fire barrier, the surrounding gap must be sealed with certified fire-stopping materials. This maintains the wall's fire rating and prevents the spread of fire and smoke.

Equally important is maintaining the trunking’s integrity. All lids must be securely fastened with all supplied screws. A loose or missing lid is a common but dangerous oversight that leaves cables exposed to damage and compromises the system's IP rating and overall safety.

Using Certified and Approved Products

To ensure a smooth inspection and approval process, only certified components should be used. Verify that your trunking, cables, and accessories carry recognized conformity marks, such as IEC or GCC certifications. Sourcing materials from a trusted supplier like GoSwitchgear helps ensure you are working with components that meet local standards.

The demand for durable, high-quality electrical infrastructure continues to grow. When robust systems are integrated into a broader strategy for energy efficiency solutions, the performance of the entire building is enhanced. Adhering to these compliance points ensures your projects are safe, reliable, and ready for swift approval.

Common Questions About Installing Cables in Trunking

Even with careful planning, questions often arise on-site. Here are answers to some of the most common queries from professionals installing cables in trunking across the UAE and GCC.

What Is the 45 Percent Rule for Cables in Trunking?

The 45% rule is a fundamental guideline from wiring regulations like BS 7671. It stipulates that the total cross-sectional area of all cables must not occupy more than 45% of the trunking's internal space.

This is a critical safety requirement, not just a matter of neatness. The remaining space allows for air circulation, which facilitates heat dissipation from the cables. Without it, you risk overheating, insulation failure, and potential hazards. Adherence to this rule is non-negotiable for compliance and the long-term health of your electrical system.

How Do I Correctly Segregate Power and Data Cables?

Proper segregation is essential to prevent electromagnetic interference (EMI) from high-voltage power lines affecting data signals. The most effective method is to use multi-compartment trunking with built-in physical barriers.

If using single-compartment trunking, a solid, earthed metallic divider must be installed to separate the cable groups. Always maintain physical separation between power cables and sensitive data lines like Cat 6a or fiber optics. If they must cross, ensure they do so at a 90-degree angle to minimize potential interference.

Intermittent network issues are often a nightmare to diagnose, and many times the root cause is improper cable segregation. Taking the time to do it correctly from the start will prevent significant frustration and operational downtime later.

Can I Mix Different Circuit Cables in One Compartment?

Yes, it is permissible to run cables from different final circuits in the same compartment, but only if all cables are insulated to the highest voltage present in that group.

For example, if you have 230V power circuits alongside 24V control circuits, the insulation on the 24V cables must be rated for 230V. However, be aware that regulations in the UAE and KSA often impose stricter rules, requiring complete segregation for life-safety systems like fire alarms. Always verify the specific project regulations.

What Are the Earthing Requirements for Metal Trunking in the UAE?

In line with DEWA and other local standards, all metallic trunking must be properly earthed for safety and compliance. The trunking must either act as a continuous protective conductor (cpc) or be connected to one.

This requires that every section is securely bonded to the next. Best practice dictates using an earth continuity link or strap across each joint to ensure an uninterrupted connection. The entire trunking run must then be connected back to the main earthing terminal at its source distribution board. This is what protects personnel from electric shock in the event of a fault.

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For a comprehensive selection of certified trunking systems, electrical components, and all parts needed for a compliant, professional installation, explore the extensive catalogues at GoSwitchgear. Our team in Dubai is ready to support your projects across Abu Dhabi and the entire GCC with the right products and expert technical advice. Contact us for project support. https://goswitchgear.com