How to make a horizontal flared end for a cable tray

A horizontal flared end for a cable tray can be made by cutting, bending, and reinforcing the tray edges to create a smooth, outward-opening transition for cables.

Tools and Materials Needed

Galvanized or stainless steel sheet (matching tray thickness, typically 1. 6 mm)Measuring tape, marker, or scriberMetal shear or angle grinder for cuttingManual or hydraulic press brake for bendingDrill machine, rivets, or nuts & bolts for reinforcementOptional: welding machine for permanent joins Step-by-Step Process1. Mark the Flare Area Measure the width of the tray and mark the area where the flare will start.

Decide the flare angle and length, ensuring it provides enough space for cables to exit without sharp bends. 2. Cut the Side Walls On the marked section, cut triangular or trapezoidal sections along the side walls.

These cuts allow the metal to bend outward smoothly without deforming the tray. 3. Form the Flared Shape Using a manual bender or press brake, gradually bend the cut sections outward to create the flared end.

Make small incremental bends to maintain uniformity and avoid cracking the metal. 4. Reinforce the Flared End After bending, rejoin or reinforce the side walls using rivets, bolts, or welding.

Adding metal strips along the edges increases structural integrity and ensures the tray can support cables safely. 5. Smooth Edges and Finish Deburr all cut edges to prevent cable damage.

Ensure the flare is symmetrical and provides a smooth transition for cable routing.

Additional Tips

Ensure the flare is compatible with the type of cable tray (ladder, perforated, or solid bottom). Maintain proper clearance for cable pulling and future maintenance. For large or heavy trays, consider using hydraulic bending tools to reduce manual effort and improve precision.

Pre-fabricated horizontal bends are available for standard sizes and can save time while ensuring precise angles. By following these steps, you can create a horizontal flared end that allows cables to exit smoothly, maintains system integrity, and reduces stress on the cables.