Right-angle welding of cable tray bends

Right-angle cable tray bends can be welded by carefully marking, cutting, bending, and joining the tray sections, ensuring proper alignment and support for structural integrity.

Tools and Materials Needed

Galvanized sheet metal (typically 1. 6 mm or as per design)Measuring tape, marker, or scriberAngle grinder or metal shearDrill machine for connection holesWelding machine (MIG/TIG or arc welding depending on material)Bending tools (manual bender or hydraulic press brake)Rivets or nuts & bolts for reinforcement if neededStep-by-Step Welding ProcessMarking the Bend: Determine the 90° bend location and mark the centerline and side walls of the tray. Divide the bend into equal segments to form a smooth curve.

Cutting Side Walls: Cut triangular or rectangular sections along the side walls to allow the tray to bend without deforming the structure. Forming the Bend: Gradually bend each segment using a press brake or manual bender to achieve the right-angle curve. Ensure uniform bending to maintain cable support.

Temporary Positioning: Place the bent tray on a flat surface or use temporary supports to hold it in position. Some methods use a synthetic rubber adhesive on the lower plate to stabilize the tray during welding. Welding the Joints: Weld the side cuts or reinforcement strips to rejoin the tray walls.

Ensure continuous welds along the seams for strength and electrical grounding continuity. Drilling Connection Holes: Drill holes at the ends of the bend for bolting to straight tray sections, ensuring proper alignment and secure attachment.

Safety and Quality Considerations

Ensure proper ventilation and personal protective equipment (PPE) during welding. Verify that the welded joints maintain the tray's load-bearing capacity and comply with local electrical codes. For wire mesh trays, consider using bolt cutters and protective caps as an alternative to welding to maintain corrosion protection.

Check alignment and level of the tray after welding to prevent cable sagging or misrouting.

Alternative Methods

Bolting or Riveting: For on-site adjustments, side cuts can be rejoined using metal strips with bolts or rivets instead of welding. Wire Mesh Trays: Live bends can be made using bolt cutters without welding, preserving the protective coating. By following these steps, a right-angle cable tray bend can be fabricated and welded efficiently, ensuring both structural integrity and safe cable routing.