Chapter 10

Trunking Systems
10.1 AN OVERVIEW OF TRUNKING INSTALLATION
A number of reputable manufacturers can supply trunking ranging from 25mm 
25mm to 300mm  300mm or even larger, with two or more compartments.
They also provide all necessary accessories such as bends, tees, crossovers and
bridges to segregate cables of different systems at junctions.
Trunking systems are more flexible than conduit systems. Extensions can
readily be made during the life of the installation by making a new hole in the
trunking and running a conduit to a new point. Naturally, care is needed with
the design of such an alteration as grouping of additional circuits may require
the de-rating of cables to be re-assessed. However, it may be possible to
implement the alteration without disturbing the existing wiring.
Trunking can be easily and quickly erected, and can be fitted to walls or
suspended across trusses; where it should be supported at each joint. As
with conduit, guidance on the spacing of supports for conduit is given in the
IEE On-site Guide. IEE Table 4D covers both steel and plastic trunking
types.
Where there are vertical runs of trunking, pin racks should be fitted inside the
trunking to support the weight of the cables and to enable the cables to be secured
during installation. These pin racks consist of steel pins, sheathed by an insu-
lating material, mounted on a backplate; they should be fitted at intervals of 5m.
Where vertical trunking passes through floors it must be provided with
internal fire barriers, which must consist of non-flammable materials, cut away to
enable cables to pass through and made good after the installation of the cables.
When large cables are installed in trunking, care must be taken to ensure that
all bends are of sufficient radius to avoid damaging the cable (IEE Regulation
522.8.3). The IEE On-site Guide gives useful advice on this subject. This states,
for example, that non-armoured PVC-insulated cables of an overall diameter
greater than 25mm shall not be so bent that the radius of the inside of the bend
is less than six times the diameter of the cable. Trunking manufacturers provide
bends and tees that enable this requirement to be satisfied.
Trunking can be used to accommodate PVC insulated cables that are too
large to be drawn into conduit. Unless there are special reasons for using
conduit, it will generally be found more economical to use trunking rather than
conduit larger than 32mm diameter.

241
242 PART j II Practical Work

Regulations
The regulations governing wiring in conduit also apply to wiring in trunking, as
far as applicable. All sections of trunking, bends, and other accessories must be
effectively earthed in order to ensure that the conductivity of the trunking is
such as to enable earth-fault current to flow to operate the fuse or earth-leakage
circuit breaker protecting the circuit.
Trunking is usually supplied in 3 m lengths, although in some cases longer
lengths are obtainable. If copper links are fitted these will generally ensure
satisfactory earth continuity, but if tests prove otherwise an insulated protective
conductor should be installed inside the trunking. It is in any case common
practice to provide separate circuit protective conductors to ensure earth
continuity throughout the life of the installation. As with conduit the cable
capacities of trunking can be calculated. To ensure that cables can be readily
installed, a space factor of 45% should be used.
When a large number of cables are installed in trunking, due regard must
be paid to temperature rise due to grouping of cables. IEE Tables 4C1–4C5 give
details of the factors to be taken into account when cables are bunched in trunking
or conduits, and in some circumstances this could result in a very considerable
reduction in the current ratings of the cables installed in the trunking.
For example, if eight circuits are enclosed in trunking the correction factor,
according to IEE Table 4C1, could be as much as 0.52 to the rating values for 16
single-core cables.
The ratings of cables installed in trunking are also affected by ambient
temperatures, and a de-rating of PVC insulated cables will be necessary if the
ambient temperature exceeds 30  C, as will be seen by referring to the rating
factors in IEE Tables 4B1–4B3.
Details of the application of correction factors for grouping and ambient
temperature are given in Chapter 4.

10.2 METALLIC TRUNKING

Metallic trunking for industrial and commercial installations is often used in
place of the larger sizes of conduit. It can be used with advantage in conjunction
with 16mm–32mm conduits, the trunking forming the background of frame-
work of the system with conduits running from the trunking to lighting or
socket outlet points. For example, in a large office building, trunking can be run
above the suspended ceiling along the corridors to feed corridor points, and
rooms on either side can be fed from this trunking by conduits.
In multi-storey buildings trunking of suitable capacity, and with the
necessary number of compartments, can be provided and run vertically in the
riser ducts and connected to distribution boards; it can also accommodate
circuit wiring, control wiring, also cables feeding fire alarms, telephones,
emergency lighting and other services associated with buildings.
Chapter j 10 Trunking Systems 243

a b
(a) 100  100mm steel trunking and lids laid out ready for erection. (b) Components for vertical
and horizontal bends are available pre-formed and ready for assembly. The short straight length is
cut to suit and is drilled with clearance holes for the fixing screws.

c d
(c) Fitting the components of the offset together using set screws inserted into the pre-tapped holes
in the angle pieces. (d) Having fitted the long runs of 100100mm conduit to the wall, the offset is
assembled in position.

e f
(e) Using a magnetic spirit level to check the alignment of the vertical section before tightening the
fixing screws. Note the washers used under the heads of the fixing screws to spread the load. (f) The
completed trunking assembly, with the offset, ready for wiring. Following which the lids will be fitted.
FIGURE 10.1 Steel trunking.
244 PART j II Practical Work

As explained in Chapter 8, cables feeding fire alarms and emergency circuits

need to be segregated by fire-resisting barriers from those feeding low-voltage
circuits (i.e. 50V–1000V). It is usual for telecommunications companies to
insist that their cables are completely segregated from all other wiring systems.
It may therefore be necessary to install three- or four-compartment trunking to
ensure that IEE Regulation 528.1 and the requirements for data and telecom-
munications circuits are complied with. Cables feeding emergency lighting and
fire alarms must also be segregated so as to comply with the requirements of BS
5266 and 5389. Additionally, segregation may be required to achieve electro-
magnetic compatibility requirements.

Lighting Trunking System

Steel or alloy lighting trunking was originally designed to span trusses or other
supports in order to provide an easy and economical method of supporting
luminaires in industrial premises at high levels.
The first types of such trunking consisted of extruded aluminium alloys, the
sections of which were designed to support the weight of luminaires between
spans of up to 5m. More recently sheet-steel trunking has become available,
made in sections which achieve the same purpose.
The advantage of this type of trunking is that it can be very easily installed
across trusses, will accommodate all wiring to feed the lighting points, and can
also accommodate power wiring and, if fitted with more than one compartment,
fire alarm and extra low-voltage circuits.

FIGURE 10.2 Shallow sockets can be obtained for fitting to the lid of skirting trunking and
trunking manufacturers will punch suitable apertures for the reception of sockets.
Chapter j 10 Trunking Systems 245

When installed at high levels it can be very usefully employed to accom-

modate wiring for high-level unit heaters, roof fans and similar equipment.
Its main purpose of course is to support luminaires, and when suspended between
trusses, which have a maximum spacing of 5 m, it should be able to support the
weight of the required number of luminaires without intermediate supports.
It is therefore necessary that trunking suspended in this manner is of suffi-
cient size to take the necessary weight without undue deflection. Manufacturers
of trunking provide the relevant data and should be consulted about this.
Lighting trunking is also manufactured in lighter and smaller sections which
can be fixed directly to soffits, either on the surface or mounted flush with the
finished ceiling; as this does not have to support heavy weights between spans it
is similar to ordinary cable trunking.
Like all other trunking, it must be provided with suitable copper links
between sections to ensure adequate earth continuity, but as already explained,
if the earth continuity is found to be unsatisfactory, an insulated protective
conductor should be installed in the trunking.
Some types of lighting trunking are of sufficient dimensions to accommo-
date the fluorescent lamps and control gear within the trunking. Others have the
control gear in the trunking and the lamp fittings fixed beneath.

Steel Floor Trunking

Underfloor trunking made of steel is used extensively in commercial and similar
buildings, and it can be obtained in very shallow sections with depth of only
22mm, which is very useful where the thickness of the floor screed is limited.

FIGURE 10.3 Office lighting fitted in integral trunking which houses the control units as well as
the light fittings, the whole being suspended from the roof structure.
246 PART j II Practical Work

It is supplied with one or more compartments, and with junction boxes that
have cover plates fitted flush with the level of the finished floor surface. Where
there are two or more compartments these boxes are fitted with flyovers to
enable Band I and Band II circuits to be kept segregated as required by IEE
Regulation 528.1.
When floor ducts are covered by floor screed it is necessary to ensure that
there is a sufficient thickness of screed above the top of the ducts to prevent the
screed cracking as a result of the expected traffic on the floors. Another method
is to use floor trunking, the top cover of which is fitted flush with the finished
floor surface. In this case the top cover plate has to be of sufficient thickness to
form a load-bearing surface.
Outlets for sockets and other points can be fitted on top of the cover plates,
and it is usual to fit pedestals to accommodate the sockets.
Trunking is available which has sufficient depth to accommodate the socket
and plugs, together with the necessary wiring. The minimum depth for this type
of trunking is 50mm. Separate short sections of cover plate are provided in all
positions where sockets may be required; these sections are easily removable
and are provided with bushed holes to enable flexible cords to emerge. It is
necessary to provide suitable holes in linoleum or carpets for the flexible cords
to pass through.
Whatever type of floor trunking is employed, it can be connected to distri-
bution board positions, and also to skirting trunking. Special right-angle bends are
available to facilitate connection between floor trunking and skirting trunking.
If there is any doubt as to the continuity between sections of floor trunking it
is advisable to run an insulated protective conductor in the trunking. Protective
conductors must connect from the trunking to earthing terminals of socket
outlets and other accessories. Where socket outlets are required in positions
where there is no floor or skirting trunking, such points can be wired in conduit
connected to the side of the trunking.
Another type of metal floor trunking is the ‘In-slab’ installation method.
This consists of enclosed rectangular steel ducts (usually 75mm  35mm),
together with junction and outlet boxes. A separate duct is provided for each
wiring system, i.e. for low-voltage circuits, fire alarms, telephone lines, etc.
The separate ducts are spaced apart to give a stronger floor slab. The depth of
the trunking and outlet boxes together with their supporting brackets equals that
of the floor structure, so there is no need for a finishing screed, thus affording
a considerable saving in construction costs. The outlet boxes can be fixed in any
position, but a distance of 1.5 m between boxes will usually provide facilities
for most office needs.

10.3 NON-METALLIC TRUNKING

A number of versatile plastic trunking systems have been developed in recent
years and these are often suitable for installation work in domestic or
Chapter j 10 Trunking Systems 247

commercial premises, particularly where rewiring of existing buildings is

required. The trunking can be surface mounted and if care is taken in the
installation, it can be arranged to blend unobtrusively into the decor. Skirting-
mounted trunking is probably the most appropriate for use in domestic
dwellings, but shallow multi-compartment trunking can also be run at higher
levels in, for example, school classrooms or kitchens. Industrial non-metallic
trunking is also available in a range of sizes up to 150mm  150mm. The
manufacturers of plastic trunking generally supply a full range of fittings and
accessories for their systems, and in some cases these are compatible between
one make and another. Generally, however, once one system is chosen, it will be
necessary to stay with it to achieve a neat appearance and the ability to inter-
change fittings.
The IEE Regulations which apply to metal trunking also generally apply to
non-metallic types. Low-voltage insulated or sheathed cables may be installed
in plastic trunking. In any area where there is a risk of mechanical damage
occurring, the trunking must be suitably protected. Being non-conductive, it
will be necessary to run protective conductors for circuits requiring them inside
the trunking, and the size of these protective conductors must be calculated so
as to satisfy the IEE Wiring Regulations.
The advantages of non-metallic trunking are that it is easier to install, is
corrosion resistant and is maintenance free. In addition the flexibility is such
that it is often possible to reposition outlets or make other alterations without
any major disturbance. For those circumstances where it is required, plastic
trunking can be obtained with metal screening between the different
compartments used for low voltage, communication or other cables. There are
limits to the ambient temperature in which the system can be installed.

FIGURE 10.4 Multi-compartment skirting trunking allows the segregation of different types of
circuit. In this example 13 A ring main socket outlets and telecommunications circuits are provided
(W.T. Parker Ltd).
248 PART j II Practical Work

Installation of Non-Metallic Trunking

Care and good workmanship are needed to ensure a successful installation,
and the use of good quality materials is necessary. The installation layout
must be planned before commencing work. If the installation is in a new or
altered building, all internal structural and wall finishes should have been
completed.
As with plastic conduit, it is necessary to allow for expansion of the
trunking. This is done by leaving gaps between trunking sections as they are
installed. A gap of 4–6mm per 3 m length is recommended if high ambient
temperature variations are likely to occur. The gaps are generally covered by
pieces designed for the purpose. The detail will vary according to the particular
system being used and the manufacturer will be able to advise on the recom-
mended method.
The trunking should be cut using a fine tooth saw. Clean off any burrs and
swarf after making the cut. Appearance will be spoiled if the cut angles do not
match exactly so it is advisable to use a mitre box to make the cuts.
The main component of the trunking is generally fitted to the surface of the
wall using dome-headed screws. It is essential to use washers under the screw
heads, and to cater for expansion of the plastic components, oversize holes
should be drilled in the trunking. Trunking should be fixed at intervals of not
more than 500mm, and there should also be fixings within about 100mm of the
end or of any joint. If it is intended to fit any load-bearing components such as
light fittings, extra fixings should be provided. It is best to first drill the
clearance holes in the trunking, and then use the prepared length as a template
to mark the wall for drilling. It is possible to use shot-fired masonry pins to

FIGURE 10.5 A typical office installation where data, telecommunication and power circuits are
required (W.T. Parker Ltd).
 a b
(a) Three-compartment dado trunking ready for fitting. The compartments and one of the lid
sections can be clearly seen. (b) The end caps are screwed into position.

c d
(c) Having checked the length required, cut the trunking using a fine-tooth hacksaw, the complete
section is screwed in position on the wall. In this case the battery powered electric screwdriver is
fitted with a light to aid the work. (d) The flat twin and cpc cable is prepared for use by running it
out to avoid twists and kinks.

e f
(e) After the cable has been placed into the centre compartment, the socket boxes are clipped in
position. (f) The cable feeding the socket outlets is installed behind the outlet boxes.
FIGURE 10.6 Installing multi-compartment dado trunking.

Continued
250 PART j II Practical Work

g h
(g) The lids are cut to length and fitted and butted up to the socket boxes. (h) In a similar way, the
top and bottom lids are cut and fitted. These compartments will be used for data and communi-
cations circuits. The power cabling is complete and ready for the sockets to be wired.

i
(i) After work is complete, the site is left tidy, removing all rubbish and vacuum cleaning the floor
(all M.W. Cripwell Ltd).
FIGURE 10.6 cont’d. Installing multi-compartment dado trunking.

secure the trunking if desired. In this case it is essential to use cushioning

washers under the heads of the pins.
In general, the various components of trunking systems clip together, but it
may be necessary with some systems to employ glued joints. Special solvent
adhesives are available for this purpose and should be applied in the same way
as described in the section on installation of plastic conduit.
Once the trunking has been fixed, the cables can be run. Some makers supply
special cable retaining clips which make it easier to retain cables prior to fitting
the lids. Alternatively, it is a good idea to use short offcut sections of trunking
lid for this purpose. Cable capacities are calculated in the same way as for
conduit using a ‘unit system’. The manufacturer of the trunking should be
consulted for factors for other shapes.
When fitting the trunking compartment lids, increased stability and
improved appearance will be achieved if the lid joints are arranged not to
coincide with the joints in the main carrier.
Chapter j 10 Trunking Systems 251

a b
(a) The mini-trunking is offered up on site and marked to indicate the location of the bend. (b) Using
a fine-tooth hacksaw, the conduit is cut at the back and on one side to suit the angle of bend required.

c d
(c) The bend is tested on the ground prior to being offered up on the wall. (d) After marking and
cutting to length, rough edges and burrs are removed using a file.

e f
(e) Fixing holes are required and these are next drilled at suitable positions. (f) After drilling the
conduit, the wall is correspondingly marked out and drilled for wall plugs.
FIGURE 10.7 Installing plastic mini-trunking.
252 PART j II Practical Work

g h
(g) The trunking lid is marked out for cutting. (h) After screwing the trunking in position, the lid is
cut to suit. In this case a notch needs to be removed to clear an existing trunking run. The lid is
notched using a saw and pliers used to remove the notch.

i
(i) The lid is fitted, the completed trunking gives a neat and workmanlike appearance (all
M.W. Cripwell Ltd).
FIGURE 10.7 cont’d. Installing plastic mini-trunking.

Skirting and Dado Trunking

Skirting and dado trunking is used extensively in commercial buildings, labo-
ratories, hospitals and similar installations. It usually consists of a shallow PVC
trunking, approximately 50mm deep with two or more compartments. One
compartment is used for socket or lighting wiring, one for communications or
telephone wiring, and very often a third compartment is reserved for data cabling
to computers, as these cables must be separated from all other wiring systems.
Trunking can be shaped to form the skirting, and is frequently fitted around
the outer walls of a building where sockets, telephones, etc., are likely to be
required. It is often also fitted on internal walls. In order to cross the thresholds
of doorways, and to interconnect isolated lengths of skirting trunking, conduits
or floor trunking can be installed in the floor screed. Suitable bends and
adaptors are made to connect between skirting and floor trunking.
Shallow flush-type socket-outlets can be obtained for fitting to the lid of
skirting trunking and trunking manufacturers will punch suitable apertures for
the reception of sockets.
Chapter j 10 Trunking Systems 253

a b
FIGURE 10.8 (a) Underfloor three-compartment trunking installed in a commercial office
installation. With the growth of data processing, flexible office wiring systems are a necessity, and
a raised floor provides a viable method of achieving this. This outlet box is fitted with power sockets
and data sockets will be fitted later. (b) The outlet box with the lid in position, providing a flat floor.

It is often an advantage to fit the sockets, data or telephone outlets on short

lengths of lid, which need not be disturbed when the remainder of the lid is
removed for extensions.
Another form of trunking in use is dado trunking incorporating busbars.
These allow socket outlets and spur boxes to be simply plugged in, effecting an
economy in installation times.
Where trunking passes through partitions, short lengths of lids should be
fitted as this enables the remainder of the lid to be removed without difficulty.

Plastic Underfloor Trunking

As with many other types of wiring system available such as conduit or
trunking, plastic materials are often used instead of their metal counterparts for
the enclosures of underfloor systems.
Underfloor trunking systems made with this material can be divided into two
main types, raised floor systems and underfloor ducted systems.
The raised floor installation has the advantage of extreme flexibility as the
load-bearing floor is structurally supported such that there is an unobstructed
space underneath. The wiring ducts can thus be run under the floor in any
desired position. The outlet positions which are incorporated in floor panel
sections are connected to the ducted wiring using flexible conduit and in this
way outlet positions can be rearranged at will by exchanging the floor panel
sections. This type of layout is especially useful in computer rooms where due
to the rapid advance of technology it is necessary to replace obsolete equipment
at intervals.
The other system supplied in plastic materials is the underfloor ducted
system. With this, shallow ducts are installed prior to the final floor surface
being laid. The ducting is subsequently buried in the concrete screed. A variety
of outlet positions can be used. Concealed and raised socket outlets are
254 PART j II Practical Work

available, and as previously mentioned, ‘power poles’ can also be fitted. Some
manufacturers supply fittings whereby connection can readily be made to
skirting trunking.

10.4 CABLE DUCTS

Cable ducting is defined in the IEE Regulations as ‘an enclosure of metal or
insulating material, other than conduit or cable trunking, intended for the
protection of cables which are drawn in after erection of the ducting’.
Cable ducts usually consist of corrugated PVC, sometimes placed inside
earthenware or concrete pipes buried in the slab or ground, with suitable access
chambers to enable cables to be drawn in. IEE Regulation 522.8.3 requires that
every bend formed shall be such that cables will not suffer damage. Cables
installed in underground ducts should have a sheath or armour to resist any
mechanical damage. Unsheathed cables must not therefore be installed in these
ducts. Mineral insulated copper sheathed cables which are installed in ducts
must have an overall covering of PVC sheath.
The space factor of ducts must not exceed 35%, whereas the space factor for
trunking is 45%, and that for conduit is 40%. All of these space factors depend
upon not more than two 90 bends (or the equivalent) being installed between
draw-in points. IEE Regulation 528.1 makes it clear that Band I and Band II
cables must not be installed in the same duct.
One method of forming concrete ducts is by means of a flexible rubber or
plastic tubing of the required diameter. This is inflated and placed in position
before the concrete slab is poured. After the concrete has set, the tube is
deflated and withdrawn, and can be reused to form other ducts. Bends in ducts
can be formed by this method provided the inner radius is not less than four
times the diameter of the duct.

10.5 UNDERFLOOR TRUNKING SYSTEMS

Open plan office and other types of commercial buildings may well need power
and data wiring to outlets at various points in the floor area. The most appro-
priate way of providing this is by one of the underfloor wiring systems avail-
able. Both steel and plastic construction trunkings can be obtained, and if
required ‘power poles’ can be inserted at appropriate locations to bring the
socket outlets to a convenient hand height. With the increasing use being made
of computers and other electronic data transmission systems, the flexibility of
the underfloor wiring can be used to good advantage.