Cable tray external bend fabrication

An external 90-degree bend in a cable tray can be fabricated on-site by marking, cutting, flattening, and bolting the tray sections together, using basic tools like a hand grinder, file, and bolts.Step-by-Step ProcessMark the Tray Begin by marking the tray where the bend will occur. Measure carefully to ensure the bend aligns with your installation path and the tray width is accounted for .Remove Tray Lips For a flat 90° external bend, remove part of the tray lip. Typically, 2 3/4 of the tray width is removed, split evenly on either side of the center line. Use a hand grinder or file for this step, ensuring proper protective equipment is worn .Cut the Center Line Make a cut along the center line of the tray at the bend point. Take care not to let the tray fall open, as this can damage the tray .Flatten the Tray Lip Use a blunt object to flatten the tray lip at the bend point. This prepares the tray for a smooth bend without cracking or deforming the metal .Bend the Tray Carefully bend the tray to the desired 90° angle. This can be done manually or with a bending machine if available. Ensure the bend is even and the tray maintains structural integrity .Add a Gusset Measure the distance between the internal edges of the bend. Cut a piece of tray to this size, remove one lip completely, and bolt it to the bend to reinforce the structure .Secure and Finish Bolt the bent sections together securely. For wire mesh trays, a bolt cutter can be used to make bends live on-site, and rubber caps can protect cut ends . Check that the bend is smooth and free of sharp edges to prevent cable damage.Tools and SafetyHand grinder or file for cutting and shapingBlunt object for flattening tray lipsBolts and nuts for securing gussetsProtective equipment: gloves, goggles, and hearing protectionOptional: Cable tray bending machine for faster, precise bends TipsPre-fabricated bends are available if on-site fabrication is not feasible.Always measure twice before cutting to avoid errors.For wire mesh trays, the zinc coating remains protective even after cutting, and rubber caps can prevent injury or cable damage . By following these steps, you can create a durable and precise external bend in a cable tray suitable for industrial or commercial wiring installations.