Making a horizontal tee for a cable tray

You can fabricate a horizontal tee for cable trays by cutting, bending, and assembling straight tray sections with precise measurements and gussets or splices.

Tools and Materials Needed

Straight cable tray sections (wire mesh or solid)Bolt cutter or metal saw for cuttingScrewdriver or drill for fasteningGussets or splice plates for reinforcementMeasuring tape, marker, and squareRubber caps for cut ends (optional for safety)Step-by-Step Fabrication Process1.

Measure and Mark

Determine the location where the tee will branch off. Measure the width of the main tray and the branch tray. Mark the cut lines for the branch opening on the main tray, ensuring alignment with the branch tray.

2.

Cut the Main Tray

Use a bolt cutter or metal saw to cut the side rails and bottom wires of the main tray where the branch will connect. For wire mesh trays, remove side wires back to the first complete grid to maintain structural integrity. 3.

Prepare the Branch Tray

Cut the branch tray to the required length. If needed, bend the edges slightly to match the contour of the main tray opening. Some tutorials suggest using a 22.

5° or 45° bend for smoother transitions. 4.

Assemble the Tee

Insert the branch tray into the cut opening of the main tray. Use gussets or splice plates to reinforce the connection. Gussets can be calculated and cut to fit perfectly for a strong joint.

Secure the trays together with screws or bolts, ensuring the branch is level and aligned with the main tray. 5.

Finish and Protect

Cover sharp edges with rubber caps to prevent cable damage. Check that the tee is stable and properly supported before running cables.

Tips for Accuracy and Safety

Always double-check measurements before cutting. For wire mesh trays, ensure that the cut edges maintain the protective zinc layer to prevent corrosion. Use clamps or temporary supports to hold trays in place during assembly.

If the tee is part of a larger system, verify that the branch does not interfere with existing supports or bends. By following these steps, you can create a custom horizontal tee on-site without needing pre-fabricated fittings, saving time and allowing flexibility in cable tray routing.