Large bends in cable trays are fabricated by segmenting, cutting, and gradually bending the tray to achieve a smooth curve while maintaining structural integrity and cable protection.

Materials and Tools

To fabricate a large bend in a cable tray, you typically need:

• Galvanized or stainless steel sheet (thickness per design, e.g., 1.6mm or BS EN 10088-2 Grade 1.4401 for stainless steel)
• Measuring tape, marker, or scriber
• Angle grinder or metal shear
• Drill machine, rivets, or nuts & bolts
• Bending tools (manual bender or hydraulic press brake)
• Welding machine (optional for reinforcement)
• Protective caps for cut ends in wire mesh trays

Fabrication Steps

1. Marking the Bend: Determine the bend angle (commonly 45° or 90°) and mark the centerline and sides of the tray. Divide the curve into equal segments to form a smooth radius .
2. Cutting Side Walls: Cut triangular or rectangular sections along the side walls where the bend will occur. This allows the tray to fold without deforming the structure .
3. Forming the Bend: Gradually bend each segment using a press brake or manual bender. Ensure uniform bending to maintain cable support and tray integrity .
4. Rejoining Side Walls: After bending, rejoin the cut sections using welding or bolting/riveting with metal strips for reinforcement .
5. Finishing: Smooth edges, apply protective coatings if necessary, and install rubber caps for wire mesh trays to prevent cable damage .

Considerations for Large Bends

• Bend Radius: Maintain a radius that prevents cable stress; larger bends reduce sharp turns and improve cable longevity.
• Structural Integrity: Reinforce bends with welding or metal strips to prevent sagging or deformation under load .
• Compliance: Follow relevant standards for materials, thickness, and mounting, such as BS EN 10088-2 for stainless steel trays and proper fixing hardware .
• On-Site Adjustments: Wire mesh trays can be bent live at the project using bolt cutters and protective caps, allowing flexibility during installation .

Summary

Large bends in cable trays require careful planning, precise marking, segmented bending, and proper reinforcement to ensure smooth cable routing, structural stability, and compliance with safety standards. Using the correct tools and materials ensures durability and protects cables from mechanical damage.