Cable tray bends are fabricated by marking, cutting, forming, and rejoining tray sections to create smooth directional changes for cable routing.

Materials and Tools Required

• Materials: Galvanized steel sheets (typically 0.6–3.0 mm thick depending on design), metal strips for reinforcement, rivets or bolts, optional welding materials.
• Tools: Measuring tape, marker or scriber, angle grinder or metal shear, drill machine, bending tools (manual bender or hydraulic/CNC press brake), rivets/nuts & bolts, welding machine (optional) .

Step-by-Step Fabrication Process

1. Marking the Bend

• Determine the angle of the bend (commonly 45° or 90°).
• On a flat tray sheet, mark the centerline and side edges.
• Divide the curve into equal segments to ensure a smooth radius .

2. Cutting the Side Walls

• Cut triangular or rectangular sections on the tray side walls where the bend will occur.
• These cuts allow the tray to fold without deforming the structure .

3. Forming the Bend

• Use a manual bender, press brake, or hydraulic press to bend each segment slightly.
• Ensure uniform bending to maintain structural integrity and proper cable support .
• For wire mesh trays, bends can be made on-site using a bolt cutter, which preserves the protective zinc layer .

4. Rejoining and Reinforcement

• After bending, rejoin the cut sections using welding or bolting/riveting with metal strips for reinforcement.
• For flat 90° bends, gussets may be added by cutting a piece of tray to size and bolting it to the bend for additional strength .

5. Finishing

• Inspect the bend for smoothness and alignment.
• Apply any corrosion protection if required, such as zinc plating, powder coating, or hot-dip galvanizing .
• Ensure all edges are safe for cable installation, using rubber caps if necessary for wire mesh trays .

Machine-Assisted Fabrication

• Roll forming machines produce standard tray sections continuously.
• CNC press brakes are used for bends, elbows, tees, and crosses that cannot be formed on a roll line.
• Punch presses create mounting holes, ventilation slots, and connection points before or after bending .

Key Considerations

• Maintain uniform bend radius to prevent cable damage.
• Choose the appropriate tray type and thickness for the load and installation environment.
• Ensure safety and protective measures during cutting and bending operations. By following these steps, cable tray bends can be fabricated efficiently, ensuring smooth cable routing and structural integrity for electrical installations.