Is your cable management system holding you back?
On utility-scale solar projects, time is money, and where millions of dollars of investment are concerned, systems that drive project efficiencies are invaluable. When seemingly small issues can result in major damage and thousands of dollars worth of lost energy, managing cables correctly can make a big difference to a project’s bottom line.
Moving cable management above ground offers numerous benefits and has become the preferred method in many global markets. While many of these benefits are well-documented — from opening up previously impractical or impossible sites to reducing project timelines — there are still some important factors to consider to really get the most out of this approach.
Key considerations when choosing an aboveground system
One of the most cited reasons for managing cables above ground is efficiency, allowing contractors to lower costs and speed up installation. However, not all cable management solutions are created equal and some methods, while still faster than trenching, could be made more efficient.
One area where a lack of innovation has held contractors back concerns the catenary support system. Traditional turnbuckles or dead-end wraps are time-consuming to install, with great care and attention required to ensure the correct tension is maintained along the run. Alternatively, the new CableSmart Messenger Kit from Gripple, built on decades of wire joining and tensioning expertise, features a dynamic wire joiner and tensioner. This innovation allows a single installer to tension an entire run in one easy step, offering significant time-savings compared to traditional methods.
Damage to wires can be so costly; so, it’s crucial cable management systems also prioritize protection. Many solar cable hangers are narrow and when you have string and home-run cables competing for space, pinch points can quickly appear. If not corrected, these pinch points can accelerate wear and tear, leading to rising O&M costs over time. With its CableSmart Hangers, Gripple has favored a large surface area design, ensuring both string and home-run wires can be accommodated with no pinch points. This minimizes abrasion and mechanical damage, resulting in fewer replacements over time. This may also mitigate de-rating concerns.
Safety and compliance are of course other important considerations for contractors. CableSmart was designed to allow installers access to the hangers from all sides, meaning cables can be routed more quickly, easily and safely. Furthermore, the hangers can slide along the messenger wire, making it easy to target any areas that need additional support. This is important for NEC compliance, which states that cables must be secure and free from hazards to prevent accidental fires.
Best-in-class cable management in action
As with any new innovation, the measure of success is how it actually performs out in the real world. Naumai Solar Farm in Northland, New Zealand, presented some unique challenges for routing cables. Built on a historic flood plain, trenching was not an option, and so the developer, Infratec, chose Gripple CableSmart as the above-ground cable management solution.
During construction, record rainfall meant installation was even more difficult, but with CableSmart, the cable management was completed quickly and efficiently with over 3,000 hangers being installed. Involved from the very early stages of the project, the dedicated Gripple technical services team was able to understand the unique challenges of the site, enabling Infratec to mitigate the risks, costs, and time pressures of the project. The support provided through design and installation also meant Infratec could maximize installation efficiency while ensuring correct specification to minimize material and logistics costs.
Claudio Bessone, Program Manager for Infratec said: “With easy and efficient installation and reliable and consistent support from Gripple, the CableSmart system was the obvious choice. It allowed us to easily manage cables above ground and avoid the risks and cost of excavation work. The Gripple solar technical team was on hand every step of the way to offer support and assistance. CableSmart is definitely a product we will be using again.”
Available to exact specifications in simple, plug-and-play kits, CableSmart can be installed by hand with minimal training, helping reduce costs and speed up solar installations.
Try CableSmart for yourself, inquire today at: https://www.gripple.com/en-us/solar-solutions/solar-cable-management-solutions/.
Or discover the full Gripple Solar range here: https://www.gripple.com/en-us/solar-solutions/.
Watch more on the Naumai Farm project here:Transforming challenges into a success with Gripple CableSmart at Naumai Solar Farm (youtube.com)
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