Fabrication of Irregular Cable Tray Bends

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 RequiredGalvanized sheet or tray sections (thickness per design, e.g., 1.6 mm)Measuring tape, scale, marker, or scriberAngle grinder, metal shear, or hand grinderDrill machine, rivets, nuts & boltsBending tools (manual bender, hydraulic press brake)Welding machine (optional for metallic trays)Rubber caps for wire mesh tray ends ( )Step-by-Step Fabrication Process1. Marking the BendDecide 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 FlexibilityFor 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 BendUse 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 ReinforcementMetallic 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 ConsiderationsMinimum 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 TipsAlways 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.