How to make a 200mm cable tray bend

A 200mm cable tray can be bent by marking, cutting, and gradually forming the bend using a manual or hydraulic bender, then reinforcing and connecting the ends.Tools and Materials NeededGalvanized sheet cable tray (200mm width, typically 1.6mm thick)Measuring tape or scale and marker/scriberAngle grinder or metal shearDrill machineRivets, nuts, and boltsBending tools (manual bender, press brake, or metal bar for field bending)Welding machine (optional for reinforcement)Step-by-Step Fabrication ProcessMark the Bend Angle: Decide the required angle (commonly 45° or 90°). Mark the centerline and sides of the tray, then divide the curve into equal segments to form a smooth radius .Cut Side Walls: Make triangular or rectangular cuts on the side walls where the bend will occur. These cuts allow the tray to fold without deforming the structure .Form the Bend: Gradually bend each segment using a manual bender, press brake, or a sturdy metal bar. Ensure uniform bending to maintain cable support and tray integrity .Rejoin Side Walls: After bending, reconnect the cut sections using welding or bolting/riveting with metal strips for reinforcement .Drill Connection Holes: Drill holes at each end of the bend to attach it to straight tray sections using nuts and bolts .Field Bending ConsiderationsFor wire mesh or basket-type trays, bends can be made on-site using bolt cutters and crimping techniques without specialized machines .Ensure the bend radius is sufficient to prevent cable damage. While NEC 392.18 allows field bends, manufacturers may specify minimum radii for smooth cable pulling .Always inspect the tray for dents or defects before bending and clean it to remove debris or moisture for accurate shaping .Safety TipsWear protective gloves and eye protection when cutting or bending metal.Avoid sharp edges by deburring cuts and using rubber caps if necessary.Ensure the tray remains level and structurally sound to support cables after bending. By following these steps, a 200mm cable tray can be bent safely and effectively, whether in a workshop or on-site, while maintaining proper cable support and alignment.