Fabrication of cable tray external bend

Fabricating an external bend in a cable tray involves marking, cutting, bending, and reinforcing the tray to create a smooth directional change while maintaining structural integrity.

Tools and Materials Required

Galvanized sheet or pre-fabricated tray (thickness per design, e.g., 1. 6 mm)Measuring tape or scaleMarker or scriberAngle grinder or metal shearDrill machineRivets, nuts & bolts, or welding equipmentManual or hydraulic press brake for bendingReinforcement strips or brackets for side wallsStep-by-Step Fabrication Process1. Marking the Bend Angle Decide the required bend angle (commonly 45° or 90°).

On the flat tray, mark the centerline and sides. Divide the curve into equal segments (3–5 sections) to ensure a smooth radius. 2.

Cutting the Side Walls Cut triangular or rectangular sections along the side walls where the bend will occur. These cuts allow the tray to fold without deforming the cable support surface. 3.

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 the tray's integrity and proper cable support. 4.

Rejoining and Reinforcing After bending, rejoin the cut sections using welding or bolting/riveting with metal strips. For ladder or wire mesh trays, use splice plates, TX brackets, or riser links to reinforce the bend and maintain structural stability. 5.

Securing the Tray Install the bent tray onto strut supports using hold-down units, ensuring at least two secure points along the length. Smooth-head bolts or rivets should face inward to prevent cable damage.

Additional Tips

For wire mesh trays, bends can be made live on-site using bolt cutters, with protective zinc layers or rubber caps to prevent cable damage. Always measure and mark accurately to avoid misalignment. Gradual bending in small increments reduces the risk of tray deformation.

Use reinforcement brackets for larger bends or heavy cable loads to maintain safety and durability. By following these steps, an external bend can be fabricated efficiently, ensuring a professional and safe cable tray installation suitable for industrial or commercial projects.