Aluminium Conduit Profile 120×60 mm Cable Duct Extrusion 2 mm Wall for Machine Wiring

OEM / ODM Available Free Sample Available ISO 9001:2015 EN 755-9 RoHS REACH

120 x 60 mm aluminium conduit profile duct in 6063-T5 with a 2 mm wall and about 65 cm2 of internal area. For machine wiring where the fill ratio and the bend radius decide the section.

Wholesale Price $4.20 - $6.80 / m per m

Material	Aluminium
Alloy Grade	6063-T5
Temper	T5
Section Size	120 x 60 mm
Slot	Base slot 10.2 mm groove, 8 mm mouth, 40 series
Length	6 m stock, cut to drawing to +/-0.5 mm
Tolerance	EN 755-9 / GB/T 6892, wall +/-0.15 mm
Surface	Mill finish / clear anodised / black anodised
MOQ	300
Lead Time	18-28 days after deposit for mill finish
Loading Port	Shanghai / Ningbo
Supply Ability	400 t per month
Payment Terms	T/T 30% deposit + 70% before shipment \| L/C at sight
Trade Terms	FOB \| CIF \| EXW
Certifications	ISO 9001:2015 \| EN 755-9 \| RoHS \| REACH

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Cable management · Aluminium duct

A 120 x 60 mm aluminium conduit profile is a rectangular duct with a 2 mm wall and two Ø4 mm holes through one wide face. It is extruded in 6063-T5, weighs about 1.75 kg/m and is supplied cut to length, drilled or machined. The internal cross-section is roughly 116 by 56 mm, which gives about 65 cm2 of free area.

Capacity is the question this section is usually bought to answer, and it is worth being clear about how it is worked out. A duct is almost always specified by its outside dimensions, and the outside dimensions tell you almost nothing, because they say nothing about how much of the inside is usable. What decides whether a bundle fits is the internal area, the fill ratio you are prepared to work to, and whether the cables have to be pulled through the duct or simply laid into it.

120 x 60 section: 2 mm wall, 116 by 56 mm internal, and two Ø4 mm holes through one wide face.

Capacity is a fill ratio, not an outside size

The fill ratio is the proportion of the internal area that the cables are allowed to occupy. A duct filled completely will not accept its own cables, because a bundle of round cables does not pack into a rectangle without gaps, and because a duct that is full cannot be added to or worked on afterwards.

Two figures cover most installations. A fill ratio of 40 per cent is the usual limit for a duct that is loaded once, closed and not revisited. A fill ratio of 25 per cent is the figure to work to where cables have to be pulled through and where more circuits will be added later, because the pull gets much harder as the duct fills.

Fill ratio	Usable area in this duct	8 mm OD cables	When to work to it
25 per cent	About 16 cm2	About 32	Cables pulled in, or future additions
30 per cent	About 20 cm2	About 39	Mixed pull and lay-in
40 per cent	About 26 cm2	About 52	Loaded once and closed
50 per cent	About 33 cm2	About 65	Only where cables are laid in, never pulled
Above 50 per cent	Over 33 cm2	Over 65	Not recommended at any time

Working out the cable count

List the cables and their outside diameters Take the outside diameter from the cable data sheet, not from the conductor size. A 4 mm2 conductor is nowhere near 4 mm across once the insulation and the screen are counted.
Convert each diameter to an area The area of a round cable of diameter d is 0.785 times d squared. An 8 mm cable is about 50 mm2, which is 0.5 cm2. Add the areas rather than counting cables, because a few large cables occupy far more than the same number of small ones.
Add a factor for the gaps between round cables Round cables in a rectangular duct leave gaps, so the bundle occupies more than the sum of the cable areas. A factor of 1.2 on the total is a reasonable allowance for a mixed bundle of round cables.
Apply the fill ratio and compare with the internal area Take the internal area of 65 cm2, multiply by the fill ratio you have chosen, and compare. If the bundle is larger, go up a section rather than adding a second run of the same size.

Bundle	Sum of cable areas	With the 1.2 gap factor	Fill ratio in this duct
20 cables at 8 mm	10 cm2	12 cm2	18 per cent
40 cables at 8 mm	20 cm2	24 cm2	37 per cent
52 cables at 8 mm	26 cm2	31 cm2	48 per cent
12 cables at 12 mm	13.6 cm2	16.3 cm2	25 per cent
12 cables at 12 mm plus 20 at 8 mm	23.6 cm2	28.3 cm2	44 per cent

The 60 mm depth and the bend radius it allows

Depth is the dimension that catches people out, because it is not a capacity limit at all. The internal depth here is about 56 mm, and that caps the radius of any bend a cable can make inside the duct at about 28 mm. A cable cannot bend more tightly than its own minimum bend radius without being damaged, and the minimum is usually stated as a multiple of the cable diameter.

For a flexible control cable the fixed-installation minimum is typically six times the diameter. A 28 mm radius therefore suits a cable up to about 4.7 mm across and no larger. A cable that has to keep moving, such as one on a machine axis, is usually rated at ten to fifteen times the diameter, which brings the limit down to a cable of less than 3 mm.

Cable type	Typical minimum bend radius	Largest cable for a 28 mm radius
Fixed flexible control cable	6 x diameter	About 4.7 mm
Fixed armoured or screened cable	8 x diameter	About 3.5 mm
Continuous flex cable	10 x diameter	About 2.8 mm
High flex cable for a moving axis	15 x diameter	About 1.9 mm

The practical consequence: a 180 degree turn inside this duct is only possible for small signal cables. Larger power and control cables have to enter and leave at the ends of the run, or the duct has to be a size that gives a deeper internal section. Plan the cable entries around this before choosing the section, not after.

Separating power from signal in a duct with no divider

This section has no central partition, so power and signal cables sharing it will couple. The usual guidance is to keep them apart, and the practical options are to run two separate ducts, to fit a partition strip that divides the internal section, or to accept the coupling and use screened signal cable throughout.

Where the two have to share a duct, keep the runs to the two sides and cross them as rarely as possible and at right angles where you do. A screened signal cable with the screen earthed at one end is the usual answer where a second duct is not available, and it is cheaper than a bigger section with a divider.

Two ducts is the cleanest answerRunning power and signal in separate ducts removes the problem rather than managing it. It also makes later additions to either circuit independent of the other.

A partition strip keeps one ductA partition fitted inside the section divides it without changing the outside dimensions. It costs internal area, so recalculate the fill ratio after allowing for it.

Screen the signal cable insteadWhere neither of the above is possible, screened signal cable earthed at one end is the usual compromise, and it is cheaper than moving to a larger section.

Keep spare capacity in the signal sideSignal circuits are the ones that get added to. Keep the signal side of any shared duct at 25 per cent fill or less, so a later circuit does not force a rebuild.

Frequently asked questions

How many cables will this duct take?

The internal area is about 65 cm2. At a 40 per cent fill that is about 26 cm2 of usable area, which is roughly 52 cables of 8 mm outside diameter once the gaps between round cables are allowed for. At a 25 per cent fill for easy pulling, about 32.

What fill ratio should I work to?

40 per cent where the duct is loaded once and closed, and 25 per cent where cables are pulled through or where more circuits will be added later. Above 50 per cent is not recommended at any time.

Can I turn a cable through 180 degrees inside the duct?

Only for small cables. The internal depth is about 56 mm, which caps the radius at about 28 mm, and a flexible control cable needs six times its diameter as a minimum radius. That limits a full turn to a cable of under about 4.7 mm.

How do I keep power and signal apart?

This section has no central divider, so use two separate ducts, fit a partition strip inside the section, or run screened signal cable earthed at one end. Two ducts is the cleanest and makes later additions independent.

Do you supply it with the cable entries cut?

Yes. We cut to length, drill the Ø4 mm holes to pattern, machine the cable entry slots and openings to drawing, and supply the lid with the duct so it arrives ready to fit.

Send the cable schedule and the bend radii

Tell us the cables, their outside diameters and whether they have to bend inside the duct. We will work out the fill ratio, confirm the section and quote the duct, the cable entries, the lids and FOB pricing.

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