How do you cut a cable tray into a 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

1. Measure and mark the centerline where the bend will occur.
2. 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 .
3. 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 .
4. File or smooth any sharp edges to prevent cable damage and ensure safety .

Bending the Tray

1. Line up the tray and fold along the marked line.
2. For steel trays, you can use a crimping tool or a metal bar to gradually bend the tray to 90° .
3. Ensure the bend is smooth to maintain the cable bending radius and avoid kinking cables.
4. 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.