Cable tray cutting at 90 degrees

A 90-degree bend in a cable tray is typically achieved using two 45-degree cuts, careful measurement, and proper fastening to form a precise elbow.

Tools and Materials Needed

• Straight cable tray section
• Cutting tools: angle grinder with cutting disc, hacksaw, or band saw for precision
• Measuring tape, marker, set square or protractor
• Drill with bits, nuts, bolts, and washers for fastening
• Cold galvanizing spray for rust protection
• Personal protective equipment: Kevlar gloves, eye protection, and appropriate footwear

Step-by-Step Cutting Method

1. Mark the Center Line: Determine the desired bend location and draw a straight line across the tray base.
2. Mark 45-Degree Cuts: From the center line, measure out on both sides by a distance equal to the tray width or use a standard formula (typically 45–82 mm depending on tray size) to mark the cuts .
3. Cut the Side Channels: Cut the tray flanges at a 45-degree angle, stopping at the base.
4. V-Notch the Base: Remove V-shaped sections on the base where the bend will occur to allow the sides to close together.
5. Bend and Fasten: Carefully bend the tray to form a 90-degree elbow and secure with bolts and washers. Apply cold galvanizing spray to protect cut edges from corrosion .

Safety Considerations

• Always wear gloves, eye protection, and other PPE when cutting or grinding metal .
• Use a band saw or circular saw for thin metal trays to reduce burrs and debris. Angle grinders can be used but require careful handling to avoid sparks and overheating .
• Avoid cutting with torches as it can weaken the material and damage surface treatments .

Additional Tips

• Measurements can be scaled for different tray lengths; formulas for a 1000 mm tray can be proportionally adjusted for 2000 mm or 3000 mm trays .
• Ensure accurate alignment using a set square or protractor to maintain a precise 90-degree angle.
• After cutting, deburr edges to prevent injury and ensure smooth installation . By following these steps and safety guidelines, you can create precise 90-degree bends in cable trays suitable for electrical installations, ensuring both functionality and durability.