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Bending Aluminum I-Beam and C Channel Cable Trays

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Cable Tray Bending Machine: How to Bending The Aluminum Cable Trays

Bending the I Beam Cable Tray

The I-Beam cable tray design is another side rail style offered besides C-Channel side rail styles for customers that prefer this style. One advantage of I-Beam ladder cable trays is that hold-down clips and expansion guides can be located inside or outside the I-Beam cable tray.

  • I-Beam cable tray is available in all NEMA load classes and CSA load classes. Some
  • I-Beam trays can carry over 100 pounds per foot on spans up to 30′.
  • A full complement of fittings accessories and support material is available.
  • Straights and fittings include splice connectors and hardware (except the basket tray)
  • The material is 6063 T6 Aluminum for side rails, rungs, and splice connectors.
  • Width: 6″, 9″, 12″, 18″, 24″, 30″, 36″, 42″ and 48″
  • Ladder Rung Spacing: 6″, 9″, 12″ and 18″
  • Trough Bottoms: Corrugated Ventilated, Solid Corrugated Non-Ventilated, 4″ Rung Spacing Ventilated Trough
  • Depths: 4-1/2″, 6″, 7″and 8″
  • Lengths: 10′, 12′, 20′, 24′ and 30″
  • Fitting Radius: 12″, 24″, 36″, 48″, mitered and Square Cornered

Bending Aluminum I-Beam and C Channel Cable Trays

radius bend cable trays
radius bend cable trays

Cable Ladder Horizontal E-Bend

Creates a 90° gradual sweep in the horizontal plane for Cable Runway runs. Designed for cabling in conformance with minimum bend radius requirements (typically 4 times the cable diameter). Made of lightweight 1-1/2″ x 3/8″ tubular steel to fit standard Cable Runways. Cross members welded at approximately 23° increments.

  • Conforms to cable bend radius requirements
  • Easy installation using CPI Butt-Splices (P/N 11301-001, not included)
inside radius bend cable trays
inside radius bend cable trays

Ladder Radius Bend – 90° Inside Bend

Creates a 90° gradual bend for cascading cable runs.

  • Made of lightweight 1-1/2″ x 3/8″ (38.1 mm x 9.53 mm) tubular steel
  • Three cross members welded at approximately 23° increments
  • Outside/Inside is determined by welding cross members closer to the cable side
outside radius bend cable trays
outside radius bend cable trays

Ladder Radius Bend – 90° Outside Bend

Creates a 90° gradual bend for cascading cable runs.

  • Made of lightweight 1-1/2″ x 3/8″ (38.1 mm x 9.53 mm) tubular steel
  • Three cross members welded at approximately 23° increments
  • Outside/Inside is determined by welding cross members closer to the cable side


Since the most economical cable tray system utilizes heat-treated aluminum alloys, or high-strength steels with long spans, any limitation on deflection which will not permit the best utilization of material and design will increase the cost. By limiting the maximum fiber and shear stress used in the design the adequacy and safety of the structure is assured.

Why Limit Deflection?

The primary reason to limit deflection in cable tray systems is the appearance of their installations. So rigid restrictions on the deflection of cable trays installed at eye level or in prominent locations are common. However, it is neither economical nor good engineering practice to restrict the deflection of a cable tray system in less prominent areas.

Methods of Decreasing Deflection

There are various ways to limit the deflection of a cable tray. If the objective is minimum installed cost, they should be considered in this order:

Decreasing the Stress by Decreasing the Bending Moment

This can be accomplished by introducing restraining moments at the end of a span in the form of rigid support. The deflection in a continuous beam, with negative bending moments at the intermediate support points, is only a fraction of the deflection in a simple beam.

Increasing the Depth of the Cable Tray

Deflection in any location can be reduced by increasing the depth of the load-carrying side members and/or by adding to their cross-sectional area. Adding to the depth generally utilizes the material most economically.

Increasing the Modulus of Elasticity

Since the modulus of elasticity of steel is 29 x 106 psi, and that of aluminum alloys is only 10 x 106 psi, greater deformation of aluminum alloy trays is to be expected at any given stress level. Under its own weight, an aluminum beam will deflect the same amount as an identical steel beam, since not only the weight but also the modulus of elasticity is only one-third that of steel. However, under the same applied load (disregarding the beam’s own weight), aluminum will deflect almost three times as much as steel. Therefore consideration must be given to the choice of material for any one location. For an isolated run or for an entire installation.

Deflection Criteria Applied to Cable Tray

Design rules and specifications developed for steel should not be applied to aluminum alloys since this would not permit the most economical use of these materials. Deflection criteria which apply only to steel and should not be used when the most economical system is desired, include:

Span-Deflection Ratio

For example the deflection is limited to 1/300 of the span by the National Electrical Manufactures Association specifications for structures supporting air switches. While very important in that instance as even slight deflection could cause misalignment in the operating mechanism and result in binding and difficult switch operation, the application of this specification to a cable tray system is uneconomic and not recommended.

Depth-to-span ratio

Example: The American Institute of Steel Construction, in their specifications for buildings, specifies the depths of beams and girders in floors to be not less than 1/24 of the span, or not less than 1/20 of the span where shock or vibration may be encountered. This specification ensures a certain rigidity and levelness of the structure which is important in that instance but cannot be justified for cable tray systems because of the higher cost involved.

Deflection Constants

Example: Deflection is limited to a certain amount by an engineering company for a tray system. While such a specification might make a system using 8-foot spans look better, it prohibits the use of more economical designs with longer spans which can have much greater deflections and still look acceptable. Such a specification increases the cost of the tray system unnecessarily, especially if the trays are to be installed well above eye level.

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