Steps for fabricating cable tray installation around bends

Cable tray bends can be fabricated on-site using cutting, marking, and fitting techniques while ensuring structural integrity and safety.Planning and PreparationBefore fabricating bends, review the approved shop drawings to determine the layout, bend angles, and tray sizes required for the installation . Ensure all materials, including straight tray sections, bends, tees, and accessories, are inspected for damage and compliance with standards such as BS EN 61537 for cable trays . Store trays horizontally on flat surfaces with timber supports to prevent deformation .Fabrication TechniquesMarking and Cutting: Measure and mark the tray sections according to the required bend angle. For wire mesh trays, a bolt cutter can be used to cut straight sections, forming bends, tees, or crosses on-site. The cutting process drags a layer of zinc across the cut end, providing a protective layer against corrosion . Rubber caps can be applied to exposed edges for additional safety .Bending Formulas: For solid or perforated trays, bends are typically fabricated using a 90-degree bend formula or other angle calculations based on tray width and radius . This ensures the bend maintains the correct geometry and allows smooth cable routing.Assembly: After cutting and bending, align the tray sections and secure them using bolts, nuts, or manufacturer-recommended fasteners. Ensure that bends are supported adequately to prevent sagging or stress on cables .Installation ConsiderationsSupport Spacing: Maintain proper support intervals, especially around bends, to handle the weight of cables and prevent deformation .Cable Protection: Avoid sharp edges that could damage cables. Use protective caps or edge guards where necessary .Live Adjustments: Wire mesh trays allow on-site adjustments, enabling installers to create bends, risers, or reducers without pre-fabrication .Compliance and Safety: Only trained personnel should perform fabrication and installation. Ensure all work complies with electrical installation standards and safety guidelines .SummaryFabricating cable tray bends involves careful measurement, cutting, and assembly, with attention to support, protection, and compliance. Wire mesh trays offer flexibility for live adjustments, while solid or perforated trays require precise bending formulas. Proper planning, marking, and protective measures ensure a safe and durable installation .