Cable Tray Bend Fabrication Guide

Cable tray bends are fabricated by cutting, bending, and rejoining tray sections to create smooth directional changes for cable routing.Materials and Tools RequiredMaterials: Galvanized steel sheets (commonly 1.6 mm thick), aluminum, or wire mesh trays depending on the project environment and corrosion requirements .Tools: Measuring tape, marker or scriber, angle grinder or metal shear, drill machine, rivets or nuts & bolts, bending tools (manual or hydraulic press brake), welding machine (optional for reinforcement), .Fabrication Steps for Sheet Metal Cable Tray BendsMarking the Bend Angle: Determine the required bend (commonly 45° or 90°). Mark the centerline and sides of the tray, dividing the curve into equal segments to ensure a smooth radius .Cutting the Side Walls: Make triangular or rectangular cuts on the side walls where the bend is needed. These cuts allow the tray to fold without deforming the structure .Forming the Bend: Use a manual bender or press brake to bend each segment slightly, gradually forming the desired curve. Ensure uniform bending to maintain cable support .Rejoining the Side Walls: After bending, rejoin the cut sections using welding or bolting/riveting with metal strips for reinforcement .Fabrication for Wire Mesh Cable TraysWire mesh trays can be bent on-site using a bolt cutter to make cuts that allow the tray to curve. Protective zinc layers remain intact, and rubber caps can be used to cover cut ends for safety .For tees, crosses, or risers, make appropriate cuts in the side walls, bend the tray, and secure with brackets or riser links, typically installed in pairs .Installation TipsAlways use splice plates and bolts to join tray sections securely, ensuring smooth cable support .Maintain proper radius and alignment to prevent cable damage and ensure compliance with electrical standards .Select materials based on environmental conditions: galvanized steel for general use, aluminum for lightweight and corrosion resistance, and stainless steel for highly corrosive environments .SummaryFabricating cable tray bends involves careful measurement, cutting, bending, and reinforcement. Both sheet metal and wire mesh trays can be modified on-site or in a workshop, using appropriate tools and materials to ensure structural integrity, cable protection, and compliance with installation standards .