Fabrication of various bends in cable trays

Cable tray bends can be fabricated on-site using proper marking, cutting, bending, and joining techniques to achieve horizontal, vertical, tee, cross, and offset configurations.

Tools and Materials Required

Measuring tape, marker, or chalk for accurate layoutBolt cutter, cable cutter, or angle grinder for cuttingPliers or nose pliers for adjustmentsHand gloves and safety equipmentSheet metal (galvanized, typically 1. 6 mm) for solid traysRivets, nuts & bolts, or welding equipment for rejoining cutsManual or hydraulic press brake for bending sections General Fabrication Steps1.

Marking the Bend

Determine the type of bend: horizontal 90°, vertical up/down, tee, cross, or offset. On the tray, mark the centerline and sides of the bend. For smooth curves, divide the bend into equal segments (e.g., 3–5 sections) to guide bending.

2.

Cutting the Tray

For wire mesh trays, use a bolt cutter to cut the mesh at the bend area. Cuts may be triangular or rectangular to allow folding. For sheet metal trays, cut side walls or sections to facilitate bending without deforming the tray.

Ensure edges are smooth to prevent cable damage. 3.

Forming the Bend

Gradually bend each segment using a manual bender or press brake. For wire mesh, fold the mesh carefully to maintain structural integrity. For sheet metal, bend incrementally to achieve the desired angle while keeping the tray uniform.

4.

Rejoining and Reinforcement

After bending, rejoin cut sections using welding, rivets, or bolts with metal strips for reinforcement. For wire mesh, the bolt cutter may leave a protective zinc layer, and rubber caps can protect cut ends. 5.

Special Configurations

Tee (T-junction): Cut and bend a branch section to join the main tray at 90° using the same cutting and bending principles. Cross (4-way junction): Fabricate two perpendicular bends and join at the center. Offset (side shift): Bend the tray in two opposite directions to shift the path laterally while maintaining cable support.

Safety and Best Practices

Always wear gloves and eye protection when cutting or bending. Mark accurately to avoid misalignment. Ensure bends are smooth to prevent cable damage.

Reinforce joints to maintain structural strength and support cable weight. By following these steps, you can fabricate professional, durable bends in cable trays on-site without relying on pre-fabricated fittings, ensuring efficient cable routing and installation.