Cable Tray Column Bypass with Width and Clearance

Measure the column in plan view

A horizontal bypass leaves the incoming line, passes alongside a column and returns to the original line with a parallel outgoing run. Measure the obstacle along the incoming route and across it. Use the incoming retained tray edge as the transverse reference for column depth. The tray base stays level throughout this example.

Use a 300 mm column depth, 400 mm obstacle length along the route and 50 mm clearance. The tray is 200 mm wide with 50 mm side walls. Use four 45° folds, a 350 mm lead and a 350 mm tail. The near edge of the straight middle run must reach 300 + 50 = 350 mm from the incoming reference edge.

Include tray width in both diagonal sections

Let D be column depth, c clearance, W tray width and θ the individual fold angle. Set the middle near-edge offset to R = D + c. The retained diagonal length is S = [R + W(1 − cos θ)] / sin θ. Alternating horizontal folds retain opposite tray walls, which introduces the width term into the corner geometry.

With R = 350 mm, W = 200 mm and θ = 45°, S = 577.82 mm. The longitudinal advance to the middle-run reference corner is Q = S cos θ − W sin θ = 267.16 mm. These dimensions refer to their named stock edges and formed corners. Identify those references in the top view before marking.

The straight middle section includes clearance and both fold setbacks. Its axis spacing is P = O + 2[c + W tan(θ/2)], where O is obstacle length. Here P = 400 + 2[50 + 200 tan 22.5°] = 665.69 mm. The 400 mm obstacle therefore fits within the longer middle segment.

Worked example dimensions

Mark four stations and follow the retained walls

Add the five developed segment lengths in route order. The fold stations on the original stock are 350, 927.82, 1593.50 and 2171.32 mm. Total stock length is 2521.32 mm. The turn sequence is +45°, −45°, −45°, +45°. The second and third joints retain the wall opposite to the first and fourth joints.

Each full horizontal V opening is 2W tan(θ/2) = 165.69 mm. Mark each V on the closing side and keep its opposite wall connected. All four horizontal joints close their own wedges as the route forms. Use the Original, Mark, Cut and Form stages to inspect the retained connections and the full tray footprint around the column.

Try changing width and clearance separately in the model. Width affects the diagonal length, middle spacing and notch setbacks. Clearance changes the obstacle envelope. Check the resulting geometry against the actual cable path, product profile and available site space before fabrication.

Review the fabrication detail

The model represents ideal sharp horizontal folds and a rectangular obstacle. Review the actual tray width, rolled lips, kerf, material allowances, joint fastening and cable turning space with the selected product instructions.