Method for fabricating and installing side bends on cable trays

Side bends on cable trays are fabricated by cutting, forming, and rejoining tray sections, then installed using bolts or welding to maintain structural integrity and proper cable routing.

Materials and Tools Required

• Materials: Galvanized sheet or perforated cable tray (1.6 mm or as per design), metal strips for reinforcement, nuts, bolts, washers, and optional welding rods.
• Tools: Measuring tape, marker or scriber, angle grinder or metal shear, drill machine, rivets or bolts, bending tools (manual or hydraulic press brake), welding machine (optional), and protective equipment like gloves and eye protection .

Fabrication Steps

1. Marking the Bend Angle: Determine the required bend angle (commonly 45° or 90°). Mark the centerline and sides of the tray, dividing the curve into equal segments to ensure a smooth radius .
2. Cutting the Side Walls: Cut triangular or rectangular sections on the side walls where the bend is needed. These cuts allow the tray to fold without deforming the structure .
3. Forming the Bend: Gradually bend each segment using a manual bender or press brake. Ensure uniform bending to maintain cable support and tray integrity .
4. Rejoining the Side Walls: After bending, rejoin the cut sections using welding or bolting/riveting with metal strips for reinforcement .
5. Drilling Connection Holes: Drill holes at each end of the bend to connect it to straight tray sections using high-tensile bolts and washers .

Installation Guidelines

• Support Structure: Fabricate and install MS support structures (angles or C-channels) at regular intervals (typically 1 meter) to support the tray and bends .
• Mounting the Bend: Position the fabricated bend on the support structure and secure it using bolts or welds, ensuring alignment with the straight tray sections .
• Isolation and Protection: Use insulating sheets (e.g., G-10 or FRP) at supports to prevent electrical contact and protect cables .
• Wire Mesh Tray Bends: For wire mesh trays, bends can be made on-site using bolt cutters, with protective caps applied to cut ends to maintain corrosion protection .

Best Practices

• Maintain the minimum bend radius recommended for the cable type to prevent damage .
• Ensure uniform spacing and alignment to avoid cable sagging or stress.
• Always follow safety standards and use personal protective equipment during cutting, bending, and welding .
• Verify that all bends and joints are secure and properly reinforced before cable installation.

By following these steps, side bends can be fabricated and installed efficiently, ensuring smooth cable routing, structural stability, and compliance with electrical installation standards.