Complete Guide to Cutting Cable Tray Bends at 90° Angles

A 90-degree cable tray bend is typically made by cutting two 45-degree angles, removing V-notches, and fastening the tray to form a precise elbow.

Tools and Materials

• Straight cable tray section
• Measuring tape, marker, set square or protractor
• Cutting tools: angle grinder, circular saw, or hacksaw
• Drill with bits, nuts, bolts, and washers
• Cold galvanizing spray for rust protection
• Personal protective equipment: gloves, eye protection, and PPE for sparks and debris

Step-by-Step Fabrication

1. Mark the Center Line: Determine the desired bend location and draw a straight line across the tray base to serve as a reference . 2. Mark 45-Degree Cuts: Measure from the center line to mark the points for two 45-degree cuts on the tray flanges. For standard trays, the distance can range from 45mm to 82mm depending on tray width . 3. Cut the Side Channels: Using an angle grinder or circular saw, cut the tray flanges at the marked 45-degree angles, stopping at the base . 4. V-Notch the Base: Remove V-shaped sections from the tray base where the bend will occur. This allows the sides to close together without deformation . 5. Flatten and Bend: Use a blunt object or hand tools to flatten the tray lips at the bend point, then carefully bend the tray to 90 degrees . 6. Gusset Installation (Optional): Measure the internal edge distance and cut a gusset from a tray piece. Remove one lip and bolt the gusset to reinforce the bend . 7. Fastening and Finishing: Drill holes as needed and secure the bend with bolts and washers. Apply cold galvanizing spray to exposed metal to prevent rust .

Safety Considerations

• Always wear Kevlar gloves, eye protection, and appropriate PPE when cutting or grinding .
• Avoid mixing cutting blades between stainless steel and carbon steel to prevent galvanic corrosion .
• Angle grinders require two-handed operation and caution to prevent sparks or overheating surrounding materials .

Notes

• The method can be adapted for horizontal or flat bends, and formulas such as L = 2 × (tray height × sin 22.5°) can help calculate precise cut lengths for isosceles triangles in the bend .
• For modular systems, follow manufacturer-specific cutting guidelines to maintain structural integrity and fit within 3D plant designs . This approach ensures a precise, safe, and durable 90-degree cable tray bend suitable for electrical installations.