Cable tray cut right angle bend

A 90° right-angle bend in a cable tray can be achieved by marking, cutting, and folding the tray carefully, using either a bending machine, crimping tool, or manual methods with a metal bar.

Tools and Safety

To safely cut and bend a cable tray, use appropriate tools such as a band saw, circular saw, or angle grinder for cutting, and a bending machine or metal bar for shaping. Always wear Kevlar gloves, eye protection, and other PPE to prevent injuries from sharp edges or sparks. Avoid using torches, as they can damage the tray's surface and weaken the metal.

Cutting the Tray

Measure and mark the centerline where the bend will occur. For a 90° bend, you may need to cut the tray along the centerline and remove a portion of the lip to allow the edges to overlap when folded. Use a saw or bolt cutter to make clean cuts.

Bolt cutters are suitable for wire mesh trays and create a protective zinc layer on the cut ends. File or smooth any sharp edges to prevent cable damage and ensure safety.

Bending the Tray

Line up the tray and fold along the marked line. For steel trays, you can use a crimping tool or a metal bar to gradually bend the tray to 90°. Ensure the bend is smooth to maintain the cable bending radius and avoid kinking cables.

For wire mesh trays, bends can often be made live on-site without pre-fabricated fittings.

Tips for Accuracy

Test the bend on cardboard or scrap material first to verify measurements. Use formulas for flat bends if precise angles are required: for a 45° bend, measure half the angle on each side of the centerline; for 90°, adjust accordingly. Consider the available installation space and cable radius to avoid sharp transitions that make cable pulling difficult.

By following these steps, you can create a clean, safe, and accurate 90° bend in a cable tray, whether using pre-fabricated bends or modifying straight sections on-site.