Fabrication of semi-circular bends in cable trays

Semi-circular bends in cable trays can be fabricated on-site using manual bending techniques, specialized accessories, or bending machines while maintaining cable protection and structural integrity.

Methods for Fabricating Semi-Circular Bends

1. On-Site Manual Bending Wire mesh or ladder-type cable trays can be bent directly at the project site using simple tools like bolt cutters or metal bars. For wire mesh trays, a bolt cutter can cut and manipulate the tray to form bends, while the zinc coating remains intact to protect against corrosion. Rubber caps can be used to cover cut ends for additional safety . For steel trays, a metal bar or crimping technique can be used to gradually form a smooth bend without a bending machine . 2. Using Accessories Some cable tray systems, such as EzyTray, provide accessories like radius plates, TX brackets, and riser links that allow installers to fabricate bends, tees, or crosses from straight tray sections. The radius plate helps achieve a consistent bend, and splice plates with SBH or CNH nuts and bolts secure the tray sections. Riser links and brackets should always be installed in pairs to maintain stability . 3. Pre-Fabricated or Machine Bends For larger projects or precise bends, semi-circular bends can be purchased pre-fabricated or made using a cable tray bending machine. This ensures uniform radius and reduces the risk of damaging the tray or cables during installation .

Best Practices

• Maintain Minimum Bend Radius: Ensure the bend radius is sufficient for the type of cables being installed to prevent damage or excessive stress. Typically, a radius of at least 6–9 inches (150–230 mm) is recommended for instrumentation and control cables .
• Secure Tray Properly: Always fasten bent sections with appropriate splice plates and brackets to maintain structural integrity and prevent sagging.
• Protect Cut Ends: Use rubber caps or smooth-head bolts to prevent sharp edges from damaging cables.
• Plan Bends in Advance: Determine the required angles and radius before bending to minimize on-site adjustments and ensure smooth cable routing.

Summary

Semi-circular bends in cable trays can be fabricated using manual bending, accessories, or bending machines, depending on the tray type and project requirements. Following proper bend radius guidelines, securing the tray, and protecting cut edges ensures a safe and durable installation .