How to manufacture large bends in cable trays

Cable tray bends are essential for routing cables efficiently, and they can be fabricated using cutting, bending, and reinforcement techniques tailored to horizontal, vertical, and specialized configurations.Types of Bends in Cable Trays1. Horizontal Bend: A horizontal bend changes the tray direction along a horizontal plane, typically between 30° and 90°, allowing the tray to navigate around walls or obstacles at the same elevation. The mesh is cut at precise points, and reinforcement is added at sharp angles to maintain structural integrity ( ). 2. Vertical Inside Bend: This bend allows the tray to transition upward from a lower to a higher level. It is commonly used to move cables from floor-mounted trays to ceiling-mounted systems ( ). 3. Vertical Outside Bend: Used to route trays downward or around external corners, this bend ensures smooth cable transitions while maintaining support ( ). 4. Tees, Crosses, and Reducers: These configurations allow branching, intersecting, or changing tray widths. They can be fabricated on-site using bolt cutters and protective caps to maintain safety and corrosion resistance ( ).Fabrication MethodsMaterials and Tools:Galvanized sheet metal (commonly 1.6 mm thick)Measuring tape, marker, or scriberAngle grinder or metal shearDrill machine, rivets, nuts & boltsManual or hydraulic press brakeWelding machine (optional) ( ) Step-by-Step Fabrication:Marking the Bend Angle: Determine the required angle (e.g., 45° or 90°) and divide the curve into equal segments for smooth bending.Cutting Side Walls: Cut triangular or rectangular sections to allow the tray to bend without deforming.Forming the Bend: Use a press brake or manual bender to gradually shape the tray.Rejoining Side Walls: Reinforce the cut sections using welding or bolting/riveting with metal strips.Finishing: Ensure smooth edges and protective coatings to prevent cable damage ( ). Live Bending: Wire mesh cable trays can be bent directly on-site using bolt cutters. The process drags a layer of zinc across the cut, forming a protective layer, and rubber caps can be applied to protect cut ends ( ).Best PracticesFollow standards such as BS EN 61537 for manufacturing and installation ( ).Minimize sharp angles to reduce cable stress.Reinforce bends to maintain load-bearing capacity.Ensure all cuts and bends maintain protective coatings to prevent corrosion.Only trained personnel should perform fabrication and installation to ensure safety and compliance ( ). By understanding these types of bends and fabrication methods, installers can efficiently route cables, optimize space, and maintain the integrity and safety of cable tray systems.