Making a side bend in a cable tray

Cable tray side bends are fabricated by cutting, forming, and rejoining tray sections to create smooth directional changes while maintaining structural integrity and cable support.

Tools and Materials Required

Galvanized sheet or tray material (typically 1. 6 mm thick or per design)Measuring tape or scale, marker, or scriberAngle grinder or metal shear for cuttingDrill machine, rivets, or nuts & bolts for joiningBending tools (manual bender or hydraulic press brake)Welding machine (optional for reinforcement)Step-by-Step Fabrication ProcessMarking the Bend Angle: Determine the required bend angle (commonly 45° or 90°). On a flat tray, mark the centerline and sides, then divide the curve into equal segments to form a smooth radius ( ).

Cutting the Side Walls: Cut triangular or rectangular sections along the side walls where the bend is needed. These cuts allow the tray to fold into the desired curve without deforming the tray's integrity ( ). Forming the Bend: Gradually bend each segment using a manual bender or press brake.

Ensure uniform bending to maintain a smooth curve and proper cable support ( ). Rejoining the Side Walls: After bending, rejoin the cut sections using welding or bolting/riveting with metal strips for reinforcement. This step restores structural strength and ensures the tray can safely support cables ( ).

Finishing and Protection: For wire mesh trays, use bolt cutters to make live bends on-site, and apply rubber caps or protective coatings to cut ends to maintain corrosion resistance ( ).

Additional Considerations

Bend Radius: Maintain a radius that prevents cable damage and allows easy cable pulling. Sharp bends should be avoided unless specifically required. Tray Type: Ladder, solid-bottom, and wire mesh trays may require slightly different cutting and bending techniques.

Wire mesh trays often allow on-site bending with minimal tools ( ). Load and Support: Ensure the fabricated bend maintains the tray's load capacity and is properly supported according to design specifications ( ). Safety: Always wear protective equipment when cutting, bending, or welding metal trays.

By following these steps, a smooth, structurally sound side bend can be fabricated, ensuring safe and organized cable routing in industrial or commercial installations.