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TRUNKING
Right-angle internal bend
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Select a short section of trunking between 900 and lOOOmm in length. Using a soft
pencil and a reliable set square, draw a line (called a datum line) around the outside
(periphery) of the trunking. This should be done at the mid point positions as shown.
Check the width of the workpiece and transfer this measurement to either the top left
or right hand side of the central datum line as shown.
Using an adjustable setsquare as a guide, draw a pencil
line from the marked trunking to the bottom of the
centre datum line as shown in diagram (c). Repeat this
guideline on the opposite vertical side.
At this stage there will be a right-angled triangle drawn on each outer side of the
trunking. Remove the two triangles using a hacksaw with a blade fitted with 25-30
teeth per 25mm of blade. Once removed, file smooth all rough or jagged edges as
these may damage the cables.
(d)
Cut a wooden block with a good square edge on one side
able to be fitted comfortably across the internal width
of the trunking. Place the wooden block to the vertically
cut side as shown in the diagram.
Hold the block firmly in place and with the other hand push up the side of the trunking
adjoining the angled cut. Allow the vertical sides to be sandwiched between the angled
trunking sides. The wooden block will help provide a sharper edge at the bending
point. Once completed, dress the bend with a hammer and remove the wood. Check for
squareness and strengthen with pop rivets. Nut and bolt, or spot weld.
(f)
remove
any
return
flange
Heinemann (2005) Electrical Installations. Oxford
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TRUNKING
Right-angle vertical bend
Mark out the position of the bend on all sides of the trunking.
(a)
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Drill small holes in the corners at the point of the bend (b)
to stop the metal from folding. Then place wooden blocks
inside the trunking for support. Cut the sides of the
trunking with an appropriate hacksaw.
The edge of the trunking can be cut (c)
with a file (as shown in (c) opposite)
and the waste broken off.
Cut away the back of the trunking using a suitable hacksaw. Then file all
the rough and jagged edges and bend the trunking to shape as shown.
(d) (e)
Make a fish plate out of some scrap trunking and drill in some fixing holes.
(f) o
Finally mark out the trunking from the holes in the fishplate and drill. Secure
the assembly with nuts and bolts or pop rivets.Alternatively the joint may be
spot-welded.
(g)
Figu 43 a- g Right-angle vertical bend
Heinemann ( 2005) Electrical Installations. Oxford
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Page 289
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TRAY WORK
Fabricating a flat 90 bend
Measure and mark the mid-point of the bend.
Mark off X when X= f2 x W, where W = width of tray.
c A
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B
Cut through the flange with a hacksaw at point A and along line A-B but do not cut
through the opposite flange. Make a similar cut at point C and along line C-D. Bend
the two outer sections of the tray together to form a 90 angle.
(b)
Mark the flange at the points of overlap E, FandEl, Fl. Cut through the flanges at
these points and bend these flanges flat. Cut away the tongues at both slots A and C
as shown.
(c)
E C El F A Fl
C
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Remove all sharp edges and burrs with a file. Make up the assembly as shown and
secure with round-headed bolts. Ensure that the bolt heads are uppermost.
(d)
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Figure 4.52 a- d Flat 90bend
Heinemann ( 2005) Electrical Installat ions. Oxford
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TRAY--WORK
Forming a cable-tray reduction
Overlap the two segments of cable tray by at least lOOmm. Mark the tray
width and reduction angle as shown.
(a)
1 OOmm overlap
reduction angle
Cut with a hacksaw and cold chisel but do not cut through the flange.
(b)
cut with chisel
Bend the cable tray into shape. Remove all sharp edges and burrs with a file.
(c)
Assemble the joint using round-headed bolts.
(d)
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Ensure that the bolt heads are uppermost to
prevent any damage to the cables.
(e)
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Heinemann (2005) Electrical Installations. Oxford
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