Connecting cable trays and making bends

Cable trays can be connected and bent on-site using simple tools and proper techniques, allowing for 90° bends, vertical bends, tees, and offsets without pre-fabricated fittings.

Types of Bends

Horizontal 90° Bend (Flat Bend): Used to change the direction of the tray along the same plane. Mark the tray, cut along the center line, flatten the tray lip, bend to 90°, and secure with bolts or gussets for reinforcement. Vertical Bend (Up/Down Bend): Allows the tray to rise or drop vertically.

Wire mesh trays can be bent upward or downward by carefully manipulating the wires without cutting all strands. Tee (T-Junction) and Cross Bends: For branching or intersecting trays, cut and bend the tray to form a junction. Gussets or additional tray pieces may be used to reinforce the connection.

Offset Bend (Side Shift): Used to shift the tray laterally to avoid obstacles. Wire mesh trays can be modified on-site by bending individual wires to achieve the offset.

Tools and Techniques

Bolt Cutter: Ideal for wire mesh trays; it cuts wires while forming a protective zinc layer on the cut ends, maintaining corrosion resistance. Hand Grinder or File: Used to remove tray lips or smooth edges before bending steel trays. Crimping Bar or Metal Bar: Can be used to manually bend steel trays when a bending machine is unavailable.

Gussets: Small tray pieces bolted to bends to reinforce structural integrity. Rubber Caps: Protect cut wire ends to prevent injury and maintain safety.

Safety and Best Practices

Always wear protective equipment when cutting or grinding metal. Avoid cutting all wires in wire mesh trays; leave some intact to maintain strength. Measure and mark precisely before bending to ensure proper alignment and fit.

Use bolts and gussets to secure bends and maintain tray stability. By following these methods, cable trays can be customized on-site to navigate complex routes efficiently, ensuring safe and professional cable management without relying solely on pre-fabricated fittings.