Fabrication and welding of various bends in cable trays

Bends in cable trays can be fabricated and welded using precise cutting, bending, and joining techniques, tailored to the tray material and project requirements.

Types of Bends and Configurations

Cable trays often require 90° bends, 45° bends, tees, crosses, risers, and reducers to navigate building layouts or equipment installations. These can be fabricated from straight sections of tray either in the workshop or on-site. Wire mesh trays, for example, can be bent live at the project using a bolt cutter, which forms a protective zinc layer on cut ends, and rubber caps can be applied for additional safety .

Fabrication Process

1. Material Selection: Choose the appropriate tray material based on environment and load requirements. Common materials include galvanized steel, stainless steel, aluminum, and pultruded fiberglass. Aluminum offers corrosion resistance and light weight, while stainless steel provides high strength and durability .
2. Cutting and Shaping: Cut the tray to the required length using metal shears, saws, or bolt cutters. For bends, edges are bent using press brakes, bending machines, or manual tools depending on tray type and thickness .
3. Bending: Maintain the minimum bend radius to prevent cable damage. For solid or channel trays, use mechanical bending tools to achieve precise angles. Wire mesh trays can be bent manually with pliers or bolt cutters, ensuring the mesh integrity is preserved .
4. Welding and Joining: For steel or aluminum trays, weld joints to strengthen corners and maintain structural integrity. Ensure proper welding techniques for the material type (e.g., TIG or MIG welding for aluminum, arc welding for steel). Smooth edges after welding to prevent cable abrasion .
5. Finishing and Protection: Apply protective coatings if necessary, such as galvanization or powder coating, to prevent corrosion. Ensure all cut or welded edges are smooth and capped to protect cables and installers .

Best Practices

• Follow standards such as BS EN 61537 for cable tray systems to ensure safety and load compliance .
• Ensure bends do not exceed the minimum bend radius for the cables being installed to avoid insulation damage .
• Use precision tools for consistent bends and welds, especially in high-load or long-span installations .
• For on-site adjustments, wire mesh trays allow quick live bending without specialized equipment, which is useful for retrofits or complex layouts . By following these steps, cable tray bends can be fabricated and welded efficiently while maintaining structural integrity, cable protection, and compliance with safety standards.