How to make arbitrary bends in cable trays

Arbitrary bends in cable trays can be fabricated using cutting, segmental bending, and reinforcement techniques, tailored to the tray type and desired angle.

General Fabrication Steps

1. Marking the Bend: Determine the desired bend angle (e.g., 30°, 45°, 90°) and mark the centerline and edges of the tray. For smooth curves, divide the bend into equal segments to guide the bending process .
2. Cutting Side Walls: For solid or ladder trays, cut triangular or rectangular sections along the side walls at the bend location. This allows the tray to fold without deforming the structure .
3. Forming the Bend: Use a manual bender, hydraulic press brake, or bolt cutter (for wire mesh trays) to gradually bend each segment. Ensure uniform bending to maintain cable support and structural integrity .
4. Rejoining and Reinforcement: After bending, rejoin cut sections using welding, bolting, or riveting. For wire mesh trays, protective rubber caps or zinc-coated edges can prevent damage to cables .

Techniques by Tray Type

• Wire Mesh Cable Trays: Bends, tees, and offsets can be made live on-site using bolt cutters. The cutting action forms a protective zinc layer, and rubber caps can be applied to exposed ends .
• Ladder Cable Trays: Professional fabrication involves precise segmental bending using press brakes or specialized bending tools. This ensures clean, uniform curves suitable for industrial installations .
• Solid-Bottom or Perforated Trays: Segmental cuts and gradual bending with a press brake or manual bender allow for smooth directional changes. Reinforcement strips or welding maintain structural strength .

Practical Tips

• Always measure and mark accurately to avoid misalignment.
• Divide bends into multiple small segments for smoother curves.
• Use appropriate personal protective equipment (PPE) when cutting or welding.
• For on-site adjustments, wire mesh trays are easier to bend live, while solid trays may require pre-fabrication in a workshop.
• Ensure that the final bend maintains proper cable support and does not create sharp edges that could damage insulation . By following these methods, arbitrary bends of various angles and radii can be fabricated efficiently, ensuring safe and neat cable routing in electrical installations.