In commercial buildings, data centers, and industrial facilities, cable tray selection plays a critical role in long-term system reliability, safety, and performance. While galvanized or zinc-plated trays are widely used due to their corrosion resistance and cost-effectiveness, they can present a lesser-known but serious risk: zinc whiskers. These microscopic, hair-like conductive filaments can grow on electroplated zinc surfaces over time. When disturbed by vibration, airflow, or routine maintenance, they may detach and become airborne, potentially migrating into servers, power supplies, network switches, and other sensitive electronic equipment. Once inside, they can cause short circuits, intermittent faults, equipment damage, and costly downtime. 

This risk is particularly concerning in mission-critical environments such as data centers, telecom rooms, healthcare facilities, and smart buildings, where uptime is essential. Even minor contamination can lead to system instability, troubleshooting challenges, and unexpected maintenance expenses. Because zinc whiskers are microscopic, they are difficult to detect until problems occur, making prevention far more effective than remediation. 

For installations focused on safety, NEC compliance, and reducing long-term operational risk, black powder-coated wire mesh cable trays offer a safer and more reliable alternative. Unlike electroplated zinc finishes, powder coating encapsulates the metal surface in a durable, protective layer that eliminates exposed zinc. This significantly reduces the potential for whisker formation while also providing added corrosion resistance and a clean, professional appearance suitable for exposed ceiling applications. 

Key Takeaways 

  • Zinc whiskers can cause short circuits in sensitive equipment. 
  • Electroplated zinc trays carry contamination risks in data centers. 
  • Black powder-coated trays eliminate exposed zinc surfaces. 
  • NEC Article 392 grounding and bonding requirements still apply. 
  • Mesh trays improve airflow and simplify inspection. 
  • Ideal for power, control, Ethernet, and fiber installations. 

What Are Zinc Whiskers? 

Zinc whiskers are tiny crystalline filaments that can develop on electroplated zinc surfaces as the metal ages and undergoes internal stress changes. While they are nearly invisible to the naked eye, their impact can be significant in environments with sensitive electronics. 

  • Microscopic and difficult to detect during routine inspections 
  • Electrically conductive, making them a potential short-circuit risk 
  • Capable of becoming airborne through airflow or vibration 
  • Known to cause short circuits in IT, telecom, and data center equipment 
     

In data centers, smart buildings, and telecom rooms where uptime is critical, even a single conductive filament can migrate into servers, switches, or power supplies and create a failure point. Because modern facilities rely heavily on uninterrupted connectivity and power continuity, mitigating zinc whisker risk is an important consideration when selecting cable tray finishes and infrastructure materials. 

Why Black Powder-Coat Is a Safer Alternative 

Black powder-coated mesh trays eliminate the exposed zinc surface that can generate whiskers. Instead of electroplating, powder coating provides a durable, non-conductive protective layer over the tray. 

Key Benefits: 

Reduced Risk of Conductive Contamination 
No exposed zinc plating means no zinc whisker formation. 

Enhanced Durability 
Powder coating provides corrosion resistance and mechanical protection. 

Improved Aesthetics 
Black finishes blend seamlessly in modern office and data center environments. 

NEC Compliance Support 
Powder-coated trays can still maintain proper grounding and bonding when installed per NEC Article 392 requirements. 

NEC Considerations: Grounding & Bonding Still Apply 

Regardless of coating type whether galvanized, zinc-plated, or black powder-coated—metallic cable trays must comply with NEC Article 392 grounding and bonding requirements. The protective finish does not change the electrical safety obligations of the installation. To remain code-compliant, tray systems must maintain electrical continuity across all sections, ensure that all splice points are properly bonded, use grounding conductors sized according to NEC tables, and connect securely to the building grounding electrode system. 

Proper bonding is essential because it ensures that any fault current has a low-resistance, effective path to ground. This allows overcurrent protective devices to trip quickly, reducing the risk of shock hazards, equipment damage, arc faults, and fire. 

Supporting Power & Control Cable Installations 

Black powder-coated mesh trays are ideal for routing a wide range of cable types in commercial, industrial, and smart building environments. Their open design provides strong mechanical support while maintaining airflow and simplifying NEC-compliant grounding and bonding inspections. 

Power Cables (Primary CTA) 

Higher-voltage power cables require secure support, proper spacing, and reliable bonding to reduce fault risks and ensure safe operation. A properly grounded metallic tray system provides an effective fault current path, helping protective devices trip quickly during a fault condition. 

Control Cables (Primary CTA) 

Tray-rated PLTC control cables are commonly used in industrial automation, manufacturing systems, and building management applications. These cables are designed specifically for tray installations, simplifying NEC compliance and improving installation efficiency. 

Ethernet & Fiber in Modern Infrastructure 

In commercial offices and smart buildings, trays often carry structured cabling systems. 

Ethernet Cables 

PoE lighting and IP camera systems generate additional heat because Ethernet cables are carrying both data and electrical power. In high-density installations, bundled PoE cables can experience elevated temperatures that may impact performance and long-term reliability. Proper cable selection, spacing, and tray fill management are essential to prevent overheating and potential ampacity concerns. 

Fiber Optic Cables 

Fiber backbone links require proper support and strict bend radius protection to maintain signal integrity and long-term performance. Unlike copper cabling, fiber optic cables are sensitive to excessive bending, pulling tension, and compression. Exceeding the manufacturer’s minimum bend radius can cause microbending or macrobending, leading to signal loss, reduced bandwidth performance, or permanent damage to the fiber strands. 

Reducing Installation Time & Risk 

Black powder-coated mesh trays help reduce installation time by: 

  • Allowing easy field modifications 
  • Supporting quick cutting and bending 
  • Simplifying visual inspection of grounding 
  • Reducing contamination risk in clean IT spaces 

Their lightweight yet strong design makes them ideal for: 

  • Data center pathways 
  • Commercial office networks 
  • Industrial automation facilities 
  • Smart building infrastructure 

ShowMeCables provides high-performance cable management solutions engineered for mission-critical environments. Traditional electroplated zinc cable trays can pose contamination risks—particularly in data centers where zinc whiskers may lead to short circuits in sensitive equipment. Our black powder-coated mesh tray systems eliminate exposed zinc surfaces, significantly reducing this risk while maintaining full compliance with NEC Article 392 grounding and bonding requirements. 

Designed to improve airflow, simplify visual inspection, and support efficient heat dissipation, our mesh tray solutions are ideal for power, control, Ethernet, and fiber optic installations. Built for reliability, safety, and performance, our systems deliver the durability and compliance today’s high-demand infrastructure requires. 

 

ShowMeCables offers a full range of network connectivity and infrastructure solutions for small and medium-sized businesses. In addition, our customer-focused approach includes a same-day shipping policy and U.S.-based customer service support.  Questions? Please call us at +1 (866) 545-8420, email us or visit our contact page.   

Frequently Asked Questions 

What Are Zinc Whiskers? 

Microscopic conductive filaments that can grow on zinc-plated surfaces and cause electrical shorts. 

Are Zinc Whiskers Common in Data Centers? 

They have been documented in raised floor systems and electroplated components in sensitive IT environments. 

Does Powder Coating Affect Grounding? 

No. Proper bonding and grounding per NEC requirements must still be maintained.