Bends in trapezoidal cable trays are fabricated by marking, cutting, bending, and rejoining tray sections using appropriate tools and safety measures.

Tools and Materials Required

• Galvanized sheet metal (typically 1.6 mm or as per design)
• Measuring tape, marker, or scriber
• Angle grinder, metal shear, or band saw for cutting
• Drill machine for connection holes
• Rivets, nuts, and bolts for assembly
• Manual or hydraulic press brake for bending
• Welding machine (optional for reinforcement)
• Personal protective equipment (Kevlar gloves, eye protection, footwear)

Steps for Fabricating Various Bends

1. Simple Bends (45° or 90°)

• Mark the bend location and angle on the tray.
• Cut triangular or rectangular sections on the side walls to allow smooth bending.
• Use a press brake or manual bender to form the curve gradually, ensuring uniformity.
• Rejoin the cut sections using welding or bolting with metal strips for reinforcement.
• Drill holes at the ends for connecting to straight tray sections . 2. Tee Junctions
• Mark the junction location on the main tray.
• Cut an opening sized for the junction piece.
• Insert the junction and secure it with bolts or rivets . 3. Double Bends and Saddle Sets
• For double bends, mark two bend points and bend sequentially, maintaining correct angles and spacing.
• Saddle sets require four bends; measure distances between bends carefully and form each bend using a bending machine or spring . 4. On-Site Adjustments
• Wire mesh or modular trays can be bent live at the project using bolt cutters or bending tools. Protective zinc layers and rubber caps help maintain corrosion resistance and safety .

Cutting and Safety Considerations

• Use band saws or angle grinders for cutting; avoid torches to prevent material weakening.
• Remove burrs after cutting to prevent injury and ensure smooth cable support .
• Avoid mixing cutting blades between stainless steel and carbon steel to prevent galvanic corrosion.
• Always wear PPE and follow local HSE regulations during fabrication .

Best Practices

• Ensure bends maintain the tray's structural integrity and cable support.
• Follow manufacturer guidelines and standards such as BS EN 61537 for cable trays .
• Verify angles and dimensions before final assembly to ensure proper alignment and fit. By following these steps, various bends in trapezoidal cable trays can be fabricated safely and efficiently, ensuring smooth cable routing and compliance with installation standards.