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Welcome to CABLEFLX CABLEFLX from Terad Fabricating Inc is an innovative and cost effective structural Cable tray and wire management system. The proprietary CABLEFLX system is designed to provide quick cable installation in addition to the ability to contour around corners, hills and adapt to any elevation change.

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26314 Olympic Ave.
Carroll, Iowa 51401
Phone: (712) 792-6443
Fax: (712) 792-6421

CableFLX Featured in
“Automated People Movers and Transit Systems 2013”!



The primary purpose for cable tray on this project is to provide a continuous accessible and NEC compliant raceway for train system communications, controls, signaling, low voltage power (non-propulsion) and emergency walkway lighting. Partitioning within the cable tray separate fiber Optic cable (communications), low voltage emergency lighting, control conductors ( <50V), and low voltage AC ( 480V/208VIl20V). On this project, the cable tray also serves as a landing or step down for passengers egressing from a vehicle in an emergency and as such is capable of supporting 223 kg/m (150lbs/lt).

As part of the guideway mockup, the contractor performed a detailed analysis evaluating lighting options, weight, constructability, lead time, and long term operating costs. As a result, changes to the cable tray were made to include a 45 degree slant on the walkway side for optimal lighting dispersion and installation which can be seen in many of the following figures in this section.

The initial cable tray system consisted primarily of galvanized sheet metal tray and fluorescent fixtures.Fixtures, ballasts, wiring were to be mounted to the underside of the cable tray on both sides of the emergency walkway in order to achieve the specified lighting levels of .25Fc. all along the egress pathway. The exact details were to be determined by the contractor and its electrical installer.

In the process of evaluating the initial cable tray concept, it was determined that the specified product had several limiting factors foremost being weight,cost, constructability and lead time. Based on the weight of the trays, lids, partitions, live and dead loads, structural supports were required at estimated intervals of 60.96cm (24 in) requiring approximately II ,500 individual supports. Further investigation indicated the product did not accommodate some of the tighter turning radiuses nor did it provide (or manufacture) custom pieces (blank-off plates & transition) necessary to navigate through the complex switch areas. From a procurement standpoint, purchase and acquisition of the specified cable tray product was accompanied by significant shipping costs and time including a quoted 8 week shipping cycle after fabrication.

In response, the contractor elected to propose a more creative cost effective alternative substituting aluminum cable tray and an LED lighting array system in lieu of the specified sheet metal with florescent lighting. At a 57% reduction in weight, the aluminum tray option reduced the number of supports by an estimated 27% saving substantial labor and material costs without compromising performance.

Description Competitor System CableFLX System

Cable Tray Materials

Sheet Metal

5052 Aluminum

Weight (2mm thickness) excludes cable

16Kg/Sqm )3.27lbs/Sqft)

6.8Kg/Sqm (1.39lbs/Sqft)

Weight per Assembled Fit

7.98Kg/Ft (17.56lbs/Ft)

3.4Kg/Ft (7.5lbs/Ft)

Qty. of Trays Supports


8400 (Est.)

Fixture Type

32W Florescent


Qty. of Fixtures



Qty. of Ballasts




4' OC (Both Sides)

4' OC (one side)

Design Load

174 KW


Design Voltage



Current @ System Design Voltage (Instantaneous)



Lamp Life

7000 Hr/1.6Yrs


Annual operating Costs
(@.10 per kWH)



Other advantages of the LED Option included hot swappable low voltage snap-in fixtures that allowed for variability in the installation angle to customize dispersion oflight onto the walkway without tools. Because LED assemblies are low voltage, DC Assemblies (LED) can be replaced without power shutdown impacting system availability.

The approved cable tray design with the LED lighting option consisted of rectangular 11.43cm x 50.8cm (4.5 in deep x 20 wide) nominal width tray partitioned in three sections and constructed of 5052 high tensile aluminum with a .254cm (.100 in) polished aluminum diamond tread plate. Cable tray support frames consisted of threaded rods varying from 1.58cm to 2.54cm (5/8 in to 1 in) diameter depending upon support height welded to a 5.08 cm (2 in x 2 in) angle spanning a width of 45.72cm (18 in). Leveling and height adjustments were made in the field with the use of bolts threaded onto the vertical support rods prior to epoxy grouting bolts into 10.16cm (4 in) drilled shafts. Cable tray height was fixed with the top of the running surfaces. As part of the mock up effort, the contractor was able to determine the absolute minimum cable tray heights necessary to accommodate minimal plinth heights on the downhill side of the plinth. In areas with super elevation, plinth heights were reduced to bare minimum structurally allowed and as such so was the cable tray and related supports.

Emergency lighting requirements along the emergency walkway are established by ASCE 21-00 which requires .25 foot candles over the entire emergency egress route. The emergency walkway lighting system was tested using a light meter in August 2012 and was determined to meet or exceed the above specified requirements.

Project Schedule and Sequencing

The experience with the mock-up played a primary role in the development and
maintenance of the overall project schedule. The Guide way was divided into 10 sections each differing in length, site conditions and complexity. The elevated guide way sections offered more challenging logistics impacting production and scheduling. Sections with switches and crossovers provided increased level of complexity not typical with normal guide way sections requiring greater quality and flatness control over large varying concrete areas.

Guide way construction was conducted in an efficient assembly line fashion in 45m (150 Ft) section lengths whereby each phase of work would give way to the next phase and move onto the next section. Break points were generally established at control joints or expansion joints in the owner provided deck. Eastbound and westbound lanes were staggered to maintain access to the least accessible lane(s) generally maintaining a lead distance of 45m to 9lm (150Ft to 300Ft) ahead of the opposing lanes. As work progressed to the elevated guide way sections, staggering and phasing became more important in order to maintain access for labor, materials and equipment. As the schedule above shows, there were multiple sections under construction simultaneously. Below is a generic example (snap shot) of the assembly line work activities proved out as part of the mock up effort months earlier.

Survey & Construction Layout : 2 Days
Concrete Subcontractor
Formwork : 2 Days
Rebar Subcontractor
Drill Epoxy Rebar : 2 Days
Form QA- Verify Cut/Fills
Concrete Subcontractor
Pour Concrete : 1 Day
Strip Forms : 1 Day
(Move to Next Section)
General Contractor
Running Surface Flatness QA
Concrete Contractor
Surface Grinding/Acid Etching : 1 Day
Survey- Reestablish PGL : 1 Day
Drill Epoxy Pedestal Rebar : 1 Day
Steel Fabricator
Set Steel Guide Beams/Base Pits : 1 Day
Set Guide Beam Jigs (6' O.C.) : 1 Day
Concrete Contractor
Form Pedestals (22-25ea.) : 1 Day
Beam Go/No Go Alignment
Pour Concrete : 1 Day
Pedestal Cure Time : 3 Days
Torque Base Plates Bits. : 1 Day
General Contractor
Torque QA : 1 Day
Guide Beam Alignment QA

Total Duration : 20- 25 Days per 150' Section

Leder, William H., and William J. Sproule. Automated People Movers and Transit Systems 2013: Half a Century of Automated Transit -- Past, Present, and Future : Proceedings of the Fourteenth International Conference, April 21-24, 2013, Phoenix, Arizona. Reston: American Society of Civil Engineers, Virginia. Print.

Peskin, Dave, Carl Ekstrand, and Scott Sedberry. "PHX Sky Train - Mean and Methods." Automated People Movers and Transit Systems 2013. Proc. of 14th International Conference on Automated People Movers and Automated Transit Systems, Mesa Marriott, Phoenix, AZ. Reston: American Society of Civil Engineers, 2013. 564-88. Print.

CABLEFLX Components
Cable Tray Lid Expansion Joint Step Up Assembly
Cable Tray Lid Major Expansion Joint Step-Up Assembly
View Full GalleryCABLEFLX Applications
Adjusts and Adapts to Virtually Any Corner and Elevation Change. Ensures Vital Electrical Connections Are Shielded From the Elements Such as Rain, Snow, Dust and UV Sunlight. ECO Friendly LED Emergency Egress Lighting Available!
26314 Olympic Ave.
Carroll, Iowa 51401
Phone: (712) 792-6443
Fax: (712) 792-6421
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