How to make a trapezoidal cable tray

Assembling a trapezoidal cable tray involves careful planning, proper support installation, and precise alignment of tray sections using clips, cross members, and fasteners. Step 1: Plan and PrepareBefore assembly, plan the tray route according to your site layout, considering clearance, load capacity, and cable separation requirements. Ensure the tray type and size match the number and type of cables to be installed, as undersized trays can cause overheating and oversized trays waste space and resources.

Gather all necessary tools, including hex nuts, washers, all-thread rods, and tray clips. Step 2: Offloading and HandlingWhen offloading tray sections, use an overhead crane or forklift with care. Ensure slings are properly placed to avoid crushing the tray siderails.

Only offload single bundles per lift, and avoid using the tray as a lifting point. Store trays on dunnage to prevent contact with moisture or the ground. Step 3: Install SupportsTrapezoidal trays are typically supported using trapeze or swing supports.

Thread a hex nut 25–50 mm above the intended tray bottom, slide on square washers, and position the cross member. Drill or punch holes in the cross member slightly larger than the all-thread diameter to allow easy adjustment. Ensure the cross member is level before tightening the top set of hex nuts.

Step 4: Mount the TrayAttach the tray to the cross member using tray clips, which can be installed inside or outside the tray depending on space and interference. Ensure the tray is level and aligned with adjacent sections. Supports should be spaced according to load requirements, typically 1.

5–3 meters apart. Use the appropriate fasteners, such as 1/4” or 3/8” bolts, and torque them to the recommended specifications to secure the tray firmly. Step 5: Connect SectionsUse splice plates or connectors to join tray sections.

Align the edges flush, feed screws through the holes in the tray flanges, and secure with lock nuts. Check that the tray is straight and level along the entire run. Allow for minor horizontal adjustments to accommodate tray clips and fittings.

Step 6: Final ChecksAfter assembly, verify that all trays are secure, level, and properly supported. Ensure there is sufficient clearance above and to the sides for cable installation and maintenance. Avoid installing trays in hoist ways or areas prone to physical damage.

Once the tray is in place, cables can be laid and secured according to electrical codes. By following these steps, a trapezoidal cable tray system can be safely and efficiently assembled, providing a durable and organized support structure for electrical cables.