Cable tray cover plates can be fabricated from sheet metal, cut to size, drilled for fasteners, and installed to protect and secure cables.

Materials and Tools

• Material: Use sheet metal such as galvanized steel, aluminum, or PVC depending on environmental conditions and load requirements .
• Tools: Metal shears or saw, drill with appropriate bits, deburring tool, measuring tape, marker, bending brake (for flanged edges), and fasteners (bolts, nuts, or self-tapping screws), .

Fabrication Steps

1. Measure the Tray: Determine the width and length of the cable tray to ensure the cover plate fits flush over the tray edges .
2. Cut the Sheet: Cut the sheet metal to the measured dimensions, allowing for flanges on the sides to secure the cover to the tray.
3. Bend Flanges: Use a bending brake to create flanges along the edges of the cover plate. Flanges typically range from 0.5 to 1 inch to provide a secure attachment point .
4. Mark and Drill Holes: Align the cover plate over the tray and mark the locations for fasteners. Drill clearance holes through the flanges to match the tray's side rails. Standard hole sizes are often 3/8” or 1/4” depending on the fasteners used .
5. Deburr Edges: Smooth all cut and drilled edges to prevent injury and avoid damaging cable insulation.

Installation

• Align the Cover: Center the cover plate over the tray, ensuring it is flush with the tray edges .
• Secure Fasteners: Attach the cover using bolts and nuts, or self-tapping screws through the drilled holes. Torque fasteners according to the tray manufacturer's specifications (e.g., 3/8” bolts to 19 ft-lbs), .
• Check Stability: Ensure the cover is firmly attached and does not move under light pressure. Proper installation prevents cable damage, maintains system stability, and allows for easy maintenance .

Additional Considerations

• Ventilation: For ventilated trays, consider perforating the cover to allow airflow while still protecting cables .
• EMI/RFI Shielding: Solid covers can provide electromagnetic interference protection for sensitive circuits .
• Outdoor Use: Drill weep holes in solid covers to prevent water accumulation if installed outdoors or in humid environments .
• Compliance: Follow local electrical codes and NEMA standards for cable tray systems to ensure safety and reliability . By following these steps, you can fabricate and install cable tray cover plates that are durable, safe, and compliant with industry standards.