Fabrication of Irregularly Bent Cable Trays

Irregular bends in cable trays can be fabricated on-site using cutting, bending, and reinforcement techniques to ensure smooth cable routing and structural integrity.

Tools and Materials Required

• Galvanized sheet or tray sections (thickness per design, e.g., 1.6 mm)
• Measuring tape, scale, marker, or scriber
• Angle grinder, metal shear, or hand grinder
• Drill machine, rivets, nuts & bolts
• Bending tools (manual bender, hydraulic press brake)
• Welding machine (optional for metallic trays)
• Rubber caps for wire mesh tray ends ( )

Step-by-Step Fabrication Process

1. Marking the Bend

Decide the angle and radius of the bend (commonly 45° or 90°). On a flat tray, mark the centerline and sides. For smooth curves, divide the bend into equal segments to guide incremental bending ( ).

2. Cutting for Flexibility

For metallic trays, cut triangular or rectangular sections along the side walls where the bend is required. This allows the tray to fold without deforming the structure ( ). For wire mesh trays, cuts can be made using a bolt cutter, which preserves the protective zinc layer ( ).

3. Forming the Bend

• Use a manual bender or press brake to bend each segment slightly, gradually forming the desired curve.
• For flat 90° bends, flatten the tray lip at the bend point and bend carefully to avoid damage ( ).
• Ensure uniform bending to maintain cable support and structural integrity.

4. Rejoining and Reinforcement

• Metallic trays: weld or bolt/reinforce the cut sections with metal strips or gussets to restore strength ( ).
• Wire mesh trays: use rubber caps to protect cut ends and maintain safety ( ).

5. Field Considerations

• Minimum bend radius is generally manufacturer-specific; some trays allow bends of 12”, 24”, 36”, or 48” radius ( ).
• Field-fabricated bends can be made by cutting and bolting straight sections, but this may result in angular bends rather than smooth curves.
• For complex or irregular paths, specialized products like SnakeTray can accommodate multiple odd bends ( ).

Safety and Quality Tips

• Always wear protective equipment when cutting or grinding.
• Ensure uniform bending to prevent cable damage.
• Verify that the bend allows smooth cable pulling without sharp edges.
• Reinforce bends to maintain load-bearing capacity and prevent deformation over time. By following these steps, irregular bends can be fabricated efficiently on-site, ensuring both structural integrity and safe cable routing.