Making a cable tray tee

A cable tray tee is fabricated by cutting, bending, and joining sections of cable tray to form a T-shaped junction, using appropriate brackets, fasteners, and protective measures.

Overview

A cable tray tee allows a main cable tray run to branch into two directions, forming a T-junction. Tees are essential in cable management systems for routing power, data, or communication cables efficiently while maintaining structural integrity and safety.

Materials and Tools

Tray materials: Galvanized steel, stainless steel, aluminum, or FRP (fiberglass-reinforced plastic),. Tools: Bolt cutters, metal shears, bending tools, and standard hand tools for fastening. Fittings: TX brackets, splice plates, bolts, nuts, and protective end caps.

Fabrication Steps

Measure and Mark: Determine the location of the tee and mark the main tray and branch tray sections. Cut the Tray: Use a bolt cutter or metal shear to cut the main tray where the branch will join. For wire mesh trays, the cut edges can be protected with rubber caps or zinc drag protection.

Bend Side Walls: Bend down the side walls of the main tray at the cut section to create a slot for the branch tray. Attach Brackets: Install TX brackets or similar tee connectors on both sides of the branch tray to secure it to the main tray. Ensure brackets are fastened with bolts and nuts, using smooth-head bolts on the inside to prevent cable damage.

Install Splice Plates: Use splice plates along the tray lengths to reinforce the connection and maintain structural integrity. Check Alignment: Ensure the branch tray is level and aligned with the main tray. Adjust as necessary before final tightening.

Protect Edges: Apply protective caps or covers to exposed edges to prevent cable abrasion.

Additional Considerations

Risers and reducers: If the tee involves height changes or tray size adjustments, install riser links or reducers in pairs for stability. Support: Secure the tray at multiple points along its length using hold-down units or suspension rods to prevent sagging. Customization: Some projects may require custom-fabricated tees to accommodate specific angles or cable loads.

References and Resources

For visual guidance, instructional videos demonstrate bending and joining techniques for tees in various tray types, including ladder and wire mesh trays. Manufacturers like EzyStrut and JLH Electric provide product-specific instructions and accessories to simplify tee fabrication. By following these steps and using the correct fittings, a durable and safe cable tray tee can be fabricated on-site or in a workshop, ensuring efficient cable routing and system reliability.