Method for fabricating vertical bends in cable trays

Vertical bends in cable trays can be fabricated on-site using proper marking, cutting, and bending techniques without the need for pre-made fittings.

Tools Required

• Bolt cutter or cable cutter
• Plier or nose plier
• Measuring tape
• Marker or chalk
• Hand gloves for safety

Step-by-Step Fabrication Process

1. Mark the Bend Area: Measure and mark the exact location where the vertical bend is required. Ensure the bend aligns with the intended cable routing between levels or floors .
2. Prepare the Tray: For wire mesh trays, remove any excess lip or wire strands that may interfere with bending. This ensures a smooth bend and prevents sharp edges .
3. Cutting (if necessary): Use a bolt cutter to partially cut the tray at the bend line. Avoid cutting all wires completely to maintain structural integrity. The cutter may also create a protective zinc layer on the cut edges for corrosion resistance .
4. Bending the Tray: Gradually bend the tray upward or downward to the desired angle. For vertical bends, ensure the bend radius is sufficient to prevent cable damage. Avoid sharp bends that exceed the minimum cable bending radius .
5. Support the Bend: After bending, provide temporary or permanent support to maintain the shape and prevent sagging. This is especially important for heavy cable loads .
6. Check Alignment: Verify that the bend aligns with the next section of the tray and that cables can be routed smoothly without stress or kinks .

Safety and Best Practices

• Always wear gloves and eye protection during cutting and bending.
• Maintain proper bend radius to avoid damaging cables.
• Avoid creating sharp edges; file or smooth any rough areas.
• Vertical bends can be fabricated directly on-site, reducing the need for expensive pre-fabricated fittings .

Additional Tips

• For ladder-type trays, professional fabrication techniques may involve specialized bending machines for precise angles and clean bends .
• Horizontal bends, tees, and offsets can be fabricated using similar marking and bending principles, adjusting for the direction of the bend . By following these steps, vertical bends in cable trays can be fabricated efficiently, safely, and with minimal additional hardware, ensuring professional cable management and installation.