How to make a horizontal tee for cable trays yourself

You can fabricate a horizontal tee for cable trays by cutting, bending, and assembling straight tray sections with precise measurements and gussets or splices.

Tools and Materials Needed

• Straight cable tray sections (wire mesh or solid)
• Bolt cutter or metal saw for cutting
• Screwdriver or drill for fastening
• Gussets or splice plates for reinforcement
• Measuring tape, marker, and square
• Rubber caps for cut ends (optional for safety)

Step-by-Step Fabrication Process

1. Measure and Mark

• Determine the location where the tee will branch off.
• Measure the width of the main tray and the branch tray.
• Mark the cut lines for the branch opening on the main tray, ensuring alignment with the branch tray. 2. Cut the Main Tray
• Use a bolt cutter or metal saw to cut the side rails and bottom wires of the main tray where the branch will connect.
• For wire mesh trays, remove side wires back to the first complete grid to maintain structural integrity . 3. Prepare the Branch Tray
• Cut the branch tray to the required length.
• If needed, bend the edges slightly to match the contour of the main tray opening. Some tutorials suggest using a 22.5° or 45° bend for smoother transitions . 4. Assemble the Tee
• Insert the branch tray into the cut opening of the main tray.
• Use gussets or splice plates to reinforce the connection. Gussets can be calculated and cut to fit perfectly for a strong joint .
• Secure the trays together with screws or bolts, ensuring the branch is level and aligned with the main tray. 5. Finish and Protect
• Cover sharp edges with rubber caps to prevent cable damage.
• Check that the tee is stable and properly supported before running cables.

Tips for Accuracy and Safety

• Always double-check measurements before cutting.
• For wire mesh trays, ensure that the cut edges maintain the protective zinc layer to prevent corrosion .
• Use clamps or temporary supports to hold trays in place during assembly.
• If the tee is part of a larger system, verify that the branch does not interfere with existing supports or bends. By following these steps, you can create a custom horizontal tee on-site without needing pre-fabricated fittings, saving time and allowing flexibility in cable tray routing .