Cable Tray Sizing Calculator
Size cable tray, ladder and basket runs for every service on the bracket (power, fire, data, AV, specialist lighting), arrange them by tier, check the supports, and print the record that proves it.
How this works
- Add a run. A run is one containment on the bracket serving one service: a tray, ladder or basket sized here, or a trunking already sized in the Trunking Size Calculator and added here for the tier arrangement, the fill check and the bracket loading. Drop its cables in, or pick a typical arrangement and edit it.
- Each run is sized single-layer: width from the cable mix and spacing plus your spare capacity, rounded up to the next standard size (with a parallel or stacked split when it exceeds the largest standard tray), and checked for load, grouping derating (Cg), fixing spacings and fault restraint.
- Arrange the tiers and read the bracket. Assign each run to a tier, and the support check sizes the drop rods for the whole bracket (BS 8519 Annex I and Table E.2 on fire-rated routes), with the segregation checks for the mixed services.
Free to run for everyone. Engineering Toolkit subscribers get the computed grouping, fixing and support panels, the editable Excel / Word / CSV / Text exports and My Projects.
Cable grouping derating (Cg): BS 7671 Tables 4C1 / 4C4 / 4C5
Cable fixing & fault restraint: OSG Appendix D / BS EN 61914
Support system: bracket drop-rod loading
- 2,553brackets enumerated against an independent calculation on 2.8.1, no difference
- 56hand calculated checks re-run before every release
- 142cables in the shared data store, from published datasheets
- 8cases printed to PDF and measured on 2.8.1, every sample arrangement included: text size, page use, repeated sentences and page numbers
- Last reviewed
- September 2026
- Data basis
Show the full record
Containment self-weights: Legrand Swifts, Unitrunk Speedway, Cablofil catalogues. Cleats: Ellis Patents datasheets (Vulcan+ DS03E iss. 06, Atlas DS13E iss. 03, Emperor 07/2026). Cables: 142 in the shared store, from Prysmian and supplier datasheets. SWA to BS 5467 from the Eland Cables dimensions tables, with the 5-core 70 and 95mm² sizes from the Cleveland Cable BS 5467 datasheet (the Eland table stops at 50mm²). Singles: 6491X PVC and 6491B LSZH, 15 sizes each from 2.5 to 300mm², from the Cleveland Cable datasheets. Cat 6A from Brand-Rex and Leviton datasheets, AV and control from Belden technical data. Rod capacities: BS 8519:2020 Table E.2.
- Validated against
Show the full record
18/09/2026 (2.8.1): a sample was added to the list of typical arrangements, a dedicated life safety bracket for the primary supply with FP600 power cables on a heavy-duty ladder and FP500 control cables on a tray above it; the secondary supply is left for a separate route (BS 8519:2020 7.1). BS 8519 is applied when the sample is chosen and every check on it is a pass. The owner ruled the same day that a fire alarm or emergency lighting run beside a life safety run does not raise the 7.3 line, because those installations are subject to BS 5839-1 and BS 5266-1; the tool already worked that way and did not change. The printed report check now prints the sample as well, and once more with its second run changed to the secondary supply, eight cases in all, and measured the text size, page use, repeated sentences and page numbers with no finding. The automated check of the life safety services, the 2,553-bracket enumeration, the 27 random brackets, the 56 hand-calculated checks and the audit checks were re-run on the final build with no difference; the calculations, the wording shown in the tool, the printed report and the exports are unchanged; verified live after upload. 18/09/2026 (2.8.0): two services were added to the Service list on a run, Life safety, primary supply and Life safety, secondary supply, for the supplies to life safety and fire-fighting equipment; BS 8519:2020 6.1 recommends a secondary power supply independent of the primary supply. BS 8519 is applied to the bracket when either service is chosen and stays applied while a run serves life safety. The tool now states when the primary and the secondary supplies share one bracket (7.1, diverse cable routes), when life safety cables share a bracket with other services (7.3, a dedicated cable support system) and, for Engineering Toolkit users, when a cable on a life safety run is not a fire-resistant type (clause 11); each line reads the same in the tool, in the printed report and in the report data. Every clause quoted was read in BS 8519:2020, and a new automated check reads them again from the standard on every run. The same check built 144 brackets on 2.7.8 and on 2.8.0, for every earlier service with BS 8519 off and at each category, and found no difference in the wording shown in the tool, the drawing, the printed report or the report data; it compared the figures of a life safety run with those of an Other run on 162 brackets and found them equal, and it fails on the 2.7.8 build. The 2,553-bracket enumeration, the 27 random brackets, the 56 hand-calculated checks, the printed report check and the audit checks were re-run on the final build with no difference; no width, load, reaction or rod value changed for any earlier service; verified live after upload. 16/09/2026 (2.7.8): the wording in the tool was revised in plain UK English. The Engineering Toolkit lines and the cable weight tip now say in the tool, and the segregation checks are called checks. The calculations, the printed report and the exports are unchanged. The printed report check on all six presets, the audit checks, the 27 random brackets, the 56 hand-calculated checks and the 2,553-bracket enumeration were re-run on the final build with no difference; verified live after upload. 15/09/2026 (2.7.7): the printed report was rearranged to read as a technical report, after the owner's review of a printed 2.7.6 report. The bracket drawing now prints large enough to read: text on the report is 8 pt or larger and the drawing labels 6.8 pt or larger, where some labels printed at 3 to 4 pt on 2.7.6. One summary line names each run that needs action, the run schedule shows a size check and a load check for every run, the basis of the load check is stated once instead of on every run, and a findings table lists the runs that need action and the fire-resistant cable lines. Columns with no entries are left out, the sections after page 1 no longer start on a new page, and every page shows its page number. A new automated check prints the report to PDF for every preset and measures the text size, nearly empty pages, repeated sentences, empty columns and page numbers; it fails on the 2.7.6 build. A second check compared the wording and the drawing in the tool and the report data on 2.7.6 and 2.7.7 and found no difference; the 2,553-bracket enumeration, the 27 random brackets, the 56 hand-calculated checks and the audit checks were re-run on the final build with no difference; no width, load, reaction or rod value changed; verified live after upload. 15/09/2026 (2.7.6): the notes written inside the program code were rewritten in plain UK English. The calculations, the wording shown in the tool, the printed report and the exports are unchanged. The 2,553-bracket enumeration and the 27 random brackets were re-run on 2.7.6 with no difference; verified live after upload. 15/09/2026 (2.7.5): the emergency lighting lines were read back against BS 5266-1:2025, which replaced the 2016 edition. Its clause 8.2 applies to emergency lighting fed from a central power supply system, so the segregation note and the fire-resistant cable line now say so, the cable line cites 8.2.2, and supply cables to self-contained luminaires are named as needing no fire protection (8.1). The wording in the tool and the notes written inside the program code were revised in plain UK English. A new automated check reads every BS 5266-1 citation and the wording of every program file, in the tool, the printed report and the report data, and fails on the 2.7.4 build; the 2,553-bracket enumeration, the 27 random brackets, the 56 hand-calculated checks and the audit checks were re-run on the final build with no difference; no width, load, reaction or rod value changed; verified live after upload. 15/09/2026 (2.7.4): the wording of one line was revised. On a BS 8519 fire route the fire alarm and emergency lighting cable lines now state that the category applies to the supports only, with the drop rods and the containment load checked for the fire survival time; the previous sentence did not say what was checked. The automated check reads the sentence in the tool, the printed report and the report data and fails on the 2.7.3 build; the 2,553-bracket enumeration and the audit checks were re-run on the final build with no difference; no width, load, reaction or rod value changed; verified live after upload. 15/09/2026 (2.7.3): changes from the owner's review of a printed 2.7.2 report. On a BS 8519 fire route the fire-resistant cables on each run are now checked in the tool, in the printed report and in the exports alike; before, the only note sat in the design notes shown in the tool. The check was corrected to the standards at the same time: BS 8519:2020 clause 1 excludes the installations covered by BS 5839-1 and BS 5266-1, so fire alarm cables are referred to BS 5839-1:2025 clause 25 and emergency lighting cables to BS 5266-1, and FP200 Gold is treated as the Category 1 control cable its datasheet declares. The segregation reference now cites BS 5839-1:2025 35.5 (26.2 was the 2017 numbering). BS 8519 is switched on from the Standards applied strip, the tier spacing is asked only on a bracket with more than one tier, and the report headline is coloured by the worst verdict. A new automated check reads the fire cable lines in the tool, the printed report and the exports against the scope of the standard and fails on the 2.7.2 build; the 2,553-bracket enumeration, the 27 random brackets and the audit checks were re-run on the final build with no difference; no width, load, reaction or rod value changed; verified live after upload. 10/09/2026 (2.7.2): the tier spacing, the BS 8519 fire route and the cable category, read only by a fire-rated or multi-tier bracket, moved into a route options section on the add-a-run panel, closed until opened, so the common run needs only its cables, spare and support spacing. Three wording defects found by the owner on the live tool the same evening are corrected: the over-table bracket advice offered a third rod, which a two-rod trapeze cannot take, and now reads reduce the bracket spacing or split the route; the worst rod tile read over table and now names the rod exceeded; and the indicative load check offered a heavier duty to a heavy-duty tray and a shorter span where no tabulated span was rated for the load, and now names only a remedy that passes on the benchmark rows, or says that none does. An automated check tests all four against the benchmark rows and the live page and fails on the 2.7.1 build; the 2,553-bracket enumeration, the 27 random brackets and the audit checks were re-run on the final build with no difference; no width, load, reaction or rod value changed; verified live after upload. 04/09/2026: a full enumeration drove 2,553 brackets through the live engine, every containment type with single-core, multicore and mixed cable sets in flat and trefoil formation, spaced and touching, with and without spare, at two spans and on unrated and fire-rated routes of every category, plus bunched data runs at four depths, trunking by reference at fifteen sizes, three-run brackets across tier layouts and over-width splits. Every width, load, bracket reaction, rod size and tier count matched an independent calculation. 04/09/2026 (2.7.1): every numeric input was checked for the figure a reader could enter in its place. The custom cable diameter is now defined as the overall diameter over the sheath, not the conductor size; the weight as kilograms per kilometre, with a figure that reads like kilograms per metre flagged in the tool; the support spacing in metres, not the cleat spacing, limited to 12 m and flagged above 6 m; the tier spacing as the clear distance between tray surfaces that Tables 4C4 and 4C5 Note 3 tabulate at 300 mm. No width, load, factor or rod value changed: the 27 random brackets and the audit checks were re-run and all passed, and the script on the live site was confirmed identical to the tested build. 03/09/2026 (2.7.0): a check across every PD tool that every printed value is reached through the input the standard derives it from. The grouping factor was found to count every tier on the bracket as a tray of grouped circuits, including data and AV tiers; it now counts only the tiers with loaded circuits and says which, and asks the vertical spacing between tiers that Tables 4C4 and 4C5 Note 3 assume. The loading verdict now names the duty chosen and is an indicative check against the manufacturer's declared SWL, which can be entered. Single-core cables over 40 mm diameter, which Table D1 does not cover, take the tested cleat centres of the basis product or ask for the manufacturer's figure. A perforated or unperforated tray is now a choice, unperforated reading Reference Method C (Table 4A2). Blank spare, blank custom diameter and blank weight ask for the value. The 56 offline checks and the 27 random brackets were re-run and all passed; verified live after upload. 02/09/2026 (2.6.1): the revised wording was checked in the tool against the house style, using the multi-service bracket preset; no size, load or factor changed. Claims audit 14/07/2026: every cited clause was checked against the standard itself (BS 7671:2018+A4:2026 Tables 4A2, 4C1, 4C4, 4C5; OSG Appendix D Table D1; BS 8519:2020 Annex I and Table E.2; BS EN 61439-1 Table 7; BS EN 61537; BS 5839-1:2017 26.2, now BS 5839-1:2025 35.5; BS 5266-1:2025 8.2.6; BEAMA guide); one grouping factor was corrected to the standard as a result. The 56 hand-calculated checks are re-run offline before every release, and the 03/07/2026 audit figures were reproduced on the live v2 engine on 13/07/2026. Randomised cross-check 15/07/2026: 27 random brackets, including a 12-run, 4-tier case, matched independently calculated results exactly. Grouping Cg reproduces the Trimble ProDesign worked example. Cable data audit 11/08/2026: all 23 BS 5467 SWA rows were checked row by row against the Eland Cables dimensions tables (Issue 04.0913), and the 3-core 25 mm² was cross-checked against the Doncaster and Cleveland datasheets. Three figures were corrected: the 5-core 10 mm² diameter, 22.09 to 22.9 mm, and the 5-core 70 and 95 mm² rows, which had no published source and now follow the Cleveland Cable BS 5467 datasheet, the only one of the five checked that publishes 5-core above 50 mm². The offline checks were re-run on 12/08/2026 after the interface update and all passed.
- Tray, ladder and basket runs arranged by tier on one support bracket.
- Power runs are sized single-layer, not by the 45% space factor; data, AV, specialist lighting and ELV runs are sized as a bunched fill (EN 50174-2:2018 basis).
- A trunking on the bracket by reference with an indicative 45% fill check on its nominal W x D; the trunking itself is sized in the Trunking Size Calculator.
- Grouping factors count the tiers with loaded circuits at the vertical tier spacing you enter; below the 300 mm of Tables 4C4/4C5 Note 3 the manufacturer's figure is asked for.
- Perforated tray, ladder and basket read Reference Methods E and F; an unperforated tray reads Method C.
- The load check is indicative against a representative SWL for the duty chosen, or against the manufacturer's SWL where you enter it (BS EN 61537).
What's changed
- September 2026 · v2.8.1A sample arrangement was added to the list of typical arrangements: a dedicated life safety bracket for the primary supply, with FP600 power cables on a ladder and FP500 control cables on a tray above it. BS 8519 is applied when the sample is chosen, and the secondary supply is left for a separate route (BS 8519:2020 7.1). The calculations, the wording shown in the tool, the printed report and the exports are unchanged
- September 2026 · v2.8.0The Service list on a run now includes Life safety, primary supply and Life safety, secondary supply, for the supplies to life safety and fire-fighting equipment. BS 8519 is applied to the bracket when either is chosen, and it stays applied while a run serves life safety. The tool now states when the primary and the secondary supplies share one bracket (BS 8519:2020 7.1), when life safety cables share a bracket with other services (7.3) and, for Engineering Toolkit users, when a cable on a life safety run is not a fire-resistant type (clause 11). The calculations and the results for every other service are unchanged
- September 2026 · v2.7.8The wording in the tool was revised in plain UK English: the Engineering Toolkit lines and the cable weight tip now say in the tool, and the segregation checks are called checks. The calculations, the printed report and the exports are unchanged
- September 2026 · v2.7.7The printed report was rearranged to read as a technical report. The bracket drawing prints large enough to read: text on the report is 8 pt or larger and the drawing labels 6.8 pt or larger. A one-line summary names each run that needs action and why, in the words of the run schedule, which now shows a size check and a load check for every run. The basis of the load check is stated once below the table instead of on every run, and a findings table lists the runs that need action and the fire-resistant cable lines. The cable schedule leaves out columns with no entries, the sections after page 1 follow on without starting a new page, and every page shows its page number. The calculations, the wording and the drawing in the tool, the report data and the exports are unchanged
- September 2026 · v2.7.6The notes written inside the program code were rewritten in plain UK English. The calculations, the wording shown in the tool, the printed report and the exports are unchanged
- September 2026 · v2.7.5The emergency lighting lines now cite BS 5266-1:2025 and say which wiring they apply to: the partition in shared containment (8.2.6) and the fire-resistant cable selection (8.2.2) apply to luminaires fed from a central power supply system; supply cables to self-contained emergency luminaires need not be fire-protected (8.1). No width, load, factor or rod value changed.
- September 2026 · v2.7.4On a BS 8519 fire route, the fire-resistant cable lines now say plainly what the category applies to on the bracket: the supports only, with the drop rods and the containment load checked for the fire survival time (120 min at Category 3). No width, load, factor or rod value changed
- September 2026 · v2.7.3The standards strip reads Standards applied, and BS 8519 is the switch for the fire-rated route (red applied, green not applied), with the cable category beside it; the tier spacing shows only on a bracket with more than one tier. On a BS 8519 route the fire-resistant cables on every run are checked in the tool, in the report and on the printed report: fire alarm and emergency lighting cables are selected to BS 5839-1 and BS 5266-1, which BS 8519 does not cover, and FP200 Gold is declared a Category 1 control cable. The report headline is coloured by the worst verdict, trunking runs read ref. Trunking Calculator once, short schedules print in one piece, the design notes in the editable exports are marked for the designer, and the segregation references cite BS 5839-1:2025 35.5. No width, load, factor or rod value changed
- September 2026 · v2.7.2The tier spacing and the BS 8519 fire route, which only a multi-tier or fire-rated route reads, sit under a Route options disclosure on the add-a-run panel instead of in front of every user. Where the worst rod exceeds the largest tabulated rod, the advice reads reduce the bracket spacing or split the route: a trapeze bracket has two rods and the rod centres are the span between them, so a third rod was never the remedy. No load, width or factor changed
- September 2026 · v2.7.1Every numeric input now names the figure a reader could enter by mistake: the custom cable OD is the overall diameter over the sheath, not the conductor csa; the weight is kg per kilometre, not kg/m, and a weight that reads like kg/m is flagged in the tool; the support spacing is in metres, not the cleat spacing in mm, with an entry above 6 m flagged and the field limited to 12 m; the tier spacing is the clear vertical distance between tray surfaces, the spacing Tables 4C4 and 4C5 tabulate at 300 mm (Note 3); spare is future capacity, not the 45% space factor. No width, load, factor or rod value changed
- September 2026 · v2.7.0Grouping counts only the tiers with loaded circuits and names them, with a vertical tier spacing input that asks for the manufacturer's figure below 300 mm (Tables 4C4 / 4C5 Note 3); the load check is an indicative check that names the duty chosen, or the manufacturer SWL when entered, never a compliance verdict; a perforated or unperforated choice on tray runs, unperforated printing Reference Method C; single-core cables over 40 mm OD take the basis product's tested cleat centres or ask for the manufacturer's spacing, never a 300 mm stand-in; a blank spare, custom OD or weight is asked for rather than taken as 0; the fire alarm segregation note keys on the cables; the free emailed report no longer includes the rod size or the Toolkit sentences; the print filename reads the plugin version; the legacy project store routes, its CSV and PDF engine and its purge are retired, its two tables left in place for a later uninstall step
- September 2026 · v2.6.1The wording was revised in plain UK English: limited to replaces capped at, the manufacturer recommendation applies, the grouping factor line names the factor, and the cable picker labels use plain hyphens and the on-screen text has no dashes. No size or factor changed
- August 2026 · v2.6.0The recommended containment sizes stay in view in a bar that follows you down the page while you edit the runs. Drawing labels have a white background so they read clearly over the cables, and a review flag on a run reads as plain text rather than a dash
- August 2026 · v2.5.0Free use is now measured in sessions: three days of anonymous use, then your email continues free use with no password and no account. The applied grouping factor Cg per run is now free in the tool with its table reference; the per-method derivation, the touching versus spaced comparison, the fixing spacings, the fault forces and the drop-rod sizing stay with the Engineering Toolkit and are named in the tool before a single cable is entered. The report goes by email for free users with print as part of the Toolkit
- August 2026 · v2.4.3Subscriber-facing copy states what the Engineering Toolkit adds rather than what the free preview lacks
- August 2026 · v2.4.23-core 10 mm² SWA is now in the cable list, so the 3-core series runs 1.5 to 400 mm²; the 5-core 10, 70 and 95 mm² diameters and weights were corrected to the published dimensions tables
- August 2026 · v2.4.13-core 25 mm² SWA is now in the cable list, from the Eland Cables BS 5467 dimensions table
- July 2026 · v2.4.06491X PVC and 6491B LSZH singles are now in the cable list, 2.5 to 300 mm², for the CPC that runs with the distribution cables (Reg 521.10.1)
- July 2026 · v2.3.6Bunched runs state their usable depth in the run schedule, in the tool and in the report
- July 2026 · v2.3.5Trunking runs explain where they are included by reference
- July 2026 · v2.3.4The include-drawing tick now controls the printed PDF too, and every printed page gets 12 mm top and bottom margins
- July 2026 · v2.3.3Subscriber PDF prints at one font size and paginates naturally; the one-page squeeze stays on the free preview
- July 2026 · v2.3.2Report wording: BS 8519 reads N/A off a fire route, the stacked-tier note appears only on a stacked split, and a new tick marks the BS EN 61537 verification
- July 2026 · v2.3.1My Projects report picker widened to use its row
- July 2026 · v2.3.0Trunking runs can load a saved Trunking Size Calculator report: the W x D, the cable schedule and the verdict come across (Engineering Toolkit)
- July 2026 · v2.2.0Trunking runs have a 45% space factor fill check (OSG Appendix E), with a fill gauge and an OVER FILL verdict
- July 2026 · v2.1.5Claims audit against the standards: the Table 4C5 factor for 3 spaced trays of 3 circuits corrected from 0.89 to 0.86 (BS 7671 p.474)
- July 2026 · v2.1.4Bracket elevation draws a parallel split as separate trays with the 50 mm gap, matching the cross-section
- July 2026 · v2.1.3Default drop-rod centres now the widest tier plus 50 mm (25 mm clearance each side), so a 50 mm tray defaults to 100 mm centres
- July 2026 · v2.1.2A stacked split counts as real tiers: a bearer under every stacked tray, and both drawings show the stack
- July 2026 · v2.1.1Cross-section tier spacing measured from the drawn runs, so bunched piles and deep upstands never overlap the tier above
- July 2026 · v2.1.0Bunched lay for data, AV, specialist lighting and ELV runs (Excel Networking calculator method, EN 50174-2:2018 basis), with a depth input and pile drawing
- July 2026 · v2.0.26491B LSZH singles are now in the cable list for trunking runs; non-sheathed singles are not offered on open tray (Reg 521.10.1)
- July 2026 · v2.0.1The Lighting & power and Other services categories were added; the trunking self-weight is optional, with a built-in estimate when blank
- July 2026 · v2.0.0Multi-service redesign: runs arranged on the bracket by tier, with a bracket-wide support check
- July 2026 · v1.11.2Cleat design note covers mixed trays and updates as the fault current is typed
- July 2026 · v1.11.1A cleat-centres elevation was added to the fixing check
- July 2026 · v1.11.0The cable fixing spacings (OSG Table D1) and the BS EN 61914 fault-restraint check were added
- June 2026 · v1.10.3Free PDF fixed so the branding no longer shrinks the page
- June 2026 · v1.10.0BS 7671 grouping (derating) guidance and editable saved reports were added
- June 2026 · v1.9.0A BS 8519 fire-rated cable category advisory was added (FP200 to FP600)
- June 2026 · v1.1.0Rebuilt to BS 7671:2018+A4:2026 with a dynamic reference-method diagram
