Cables need to be laid somewhere, and it isn’t anybody’s plan to leave them loose in the sand long-term. It’s for the reason that cable troughs exist: a man-made concrete trough to keep power, telecom and data lines organised, protected and, importantly, visible when an eventual repair is required. So, if you’re comparing the top precast cable trough manufacturers in the UAE, this guide explores how these cable troughs work, what the actual specifications are, the UAE manufacturers who rule this space, and the common mistakes you’ll want to avoid that will make your cable routing job a costly rework.
What is a Precast Cable Trough?
Precast Cable Trough is a precast concrete trough of generally rectangular shape, used to contain and protect cables of electrical, telecom or data communications placed at or below grade in the ground. Instead of pouring concrete on site, waiting it to set around existing infrastructure, contractors use pre-cured sections and only join them together end to end.
The design concept is simple but very practical. These troughs are a long-term solution to the danger of accidental damage, provide easy repair or cable addition access and help to keep utility lines tidy and not buried and forgotten!
The majority of systems are made up of a series of rectangular channel modules produced in standard sizes, and attached to a removable or hinged cover that provides either complete access for major work, or partial access for routine inspection. Internal ducting can also be used to split power, data, and communication cables into the same trough, helping to minimize the interference among the various types of cables.
Standard Sizes and Load Ratings
Cable Troughs are available in a truly great size, depending on the number of cables that must run through it and whatever rests on top of it. Typically, manufacturers provide units in modules, usually a single or two metres in each unit, ensuring that transport and alignment remain manageable on site. Cross-sections also vary widely, and for larger industrial applications, from approximately 300mm to over a metre of width and depth depending on the project, are available; and can be custom sized if the volume of cable to be installed does not fit within a standard mould.
Just as important as size are load ratings, particularly where vehicles are going to drive straight through a trough, such as under a road or drive way, or in an industrial yard. A good manufacturer will specify the load bearing capabilities of a trough and its cover to one of the following guidelines: AASHTO guidelines or BS EN 1433 load classifications indicate that the cover and trough can withstand a certain weight without cracking or shifting.
The type of material has a direct impact on the durability. The mixes used for fibre-reinforced concrete may also contain synthetic fibres, such as polypropylene, to increase tensile strength and minimise cracking throughout the life of the trough, which can last for many years and will remain unsupervised for most of the time.
Why UAE Conditions make this not a generic Concrete Product
Cable troughs in UAE perform the same basic functions as those found elsewhere, but the environment in which they are in use is definitely more challenging. Buried infrastructure is more stressed than it is in milder climates because of high humidity, for example, along coastlines, sandy or reclaimed soils, and high temperatures.
In such an environment, corrosion resistance is a very important factor. The high quality of precast concrete, made in the factory and cured, is conducive to stopping moisture from passing through the concrete, while the site concrete that is cast at high speed, is more porous and will be affected directly by the moisture in such places as near coastal roads and in high humidity industrial areas throughout Emirates.
There is another specific compliance layer that is worth of consideration by UAE projects, the Telecom one. Telecom cable infrastructure in the UAE is usually designed based on cable chamber standards set by UAE’s Etisalat – namely the JRC 4, 12 and 14 versions.The UAE’s Etisalat standards – JRC 4, 12 and 14 – are commonly used when designing precast telecom cable chambers, as the operators demand high durability and access levels before they will approve an operator network.
This is also where the paperwork that must be completed to be compliant for a supplier is no longer a formality. The authentic RTA and DEWA compliance certificates indicate that the product has actually passed tests and approvals for use on regulated infrastructure, not merely that it appears to be similar to a product that is approved in a picture in a catalogue.
A leading precast cable trough manufacturer in UAE
The UAE precast industry has developed significantly and a few precast producers regularly appear on infrastructure, utility and industrial projects.
Gulf Precast is one of the biggest companies in the country, with several factories manufacturing thousands of cubic metres of precast elements every day. Having been established for more than four decades in the UAE and Saudi Arabia, Gulf Precast is usually able to secure substantial projects in the fields of infrastructure and utilities, where the quality of the product is not the only important factor, but rather the volume supplied.
Exeed Precast has a strong presence in Abu Dhabi based in the Industrial City of Abu Dhabi (ICAD) and is well connected within the heavy infrastructure, bridge and oil and gas industries, all of which experience high demand for cable troughs for the large utility services under ground.
Since 2001, Abu Dhabi Precast has established a long history of producing prestressed concrete products and a reputation for reliable execution of a wide range of projects with various scopes in the capital, making it a popular choice of established utility and infrastructure clients.
Alcon Concrete Products specialises in the power generation, power distribution and cable laying markets with precast concrete sizes that can be customized as infrastructure contractors are often required to lay cables in non-standard sizes.
Since 2003, Naran Precast Concrete Co. (NPCC) has been active in Ajman, with a comprehensive range of services that span from concept to installation, the company serves the commercial, residential, and civil sector with precast applications throughout Dubai, Sharjah, Ajman, and the Northern Emirates.
There are a number of other suppliers, such as HPI Precast and local manufacturers who manufacture telecom specific chambers that can meet Etisalat and DU specifications too, and are frequently the same on the same project site as cable troughs.
Selecting the appropriate manufacturer for your project
Choosing a supplier is more than just about the first one that comes up in search results. A couple of nitty-gritty tests differentiate a reliable manufacturer from a shady one.
Ensure compliance certifications, not claims. Do specify what documentation you need that is current and relates to your type of project for compliance with RTA or DEWA, as a product that is not compliant by the middle of the project will result in significantly more time and expense.
Scale manufacturer to project. With a large capacity supplier, such as Gulf Precast or Exeed Precast, a mega infrastructure project is able to benefit greatly, while a smaller commercial or residential project may be just as well served and responded to by a mid-sized regional supplier.
Inquire about customizable size options. Don’t assume that the standard dimensions of a trough will accommodate your cable volume and consult your chosen supplier to see if they can flex cross-section or length to make it work.
Read the load rating documentation for your particular application. A trough that will be used for a pedestrian walkway will have different load requirements than a trough under a vehicle access road, and this issue should be confirmed prior to manufacture, not after installation.
Ask your contractor for references of similar projects they have worked on. The performance in a factory yard test does not necessarily translate to performance in real UAE conditions. Request projects which had comparable exposure to heat, humidity or soil type.
Some of the things to watch out for are listed below
A few common problems were observed in the area in regards to cable trough projects.
One of the most common is underestimating the load requirements. An ordinary trough installed in what will be a vehicle accessible area may lead to cracking or structural failure, only discovered after a vehicle drives over it.
Another common gap is to not comply with the verification process. If DEWA or Etisalat specifications are not met and are not provided, the installation could be rejected late in the project when the replacement is more expensive than they would have been if it had been confirmed in the first place.
The first two choices on the list are based on price only, without examining the actual grade of the concrete or the type of reinforcement it contains. The long term crack resistance and fibre reinforcing content for the same size of trough can be very different between the two quotes, only being realised years into service.
Final Thoughts on precast cable trough manufacturers in uae
Precast cable troughs address a very real infrastructure challenge: a well-managed, shielded and easily accessible cable route that isn’t reliant on favourable weather conditions for installation. The UAE manufacturer’s choice depends on the scale and specialization of your work, verification of actual compliance documentation and clarifying your load needs from the outset.
For all situations from routing power cables in an industrial yard in Abu Dhabi to laying telecom infrastructure across a new development in Dubai, the smartest move is to keep it the same – check certificates, size the trough to the actual cable load and select a manufacturer with a proven history of handling projects of the magnitude you require.
