How to make a flat bend in a cable tray

Flat bends in cable trays can be made on-site using proper cutting, measuring, and bending techniques without expensive fittings, ensuring smooth cable routing and structural integrity.

Tools and Safety

To make flat bends, you will need:

• Bolt cutter or cable cutter
• Pliers or nose pliers
• Measuring tape and marker/chalk
• Hand gloves for safety
• Optional: metal bar or bending machine for steel trays Always wear gloves and mark the bend area clearly before cutting. Avoid sharp bends that could damage cables or compromise tray strength .

Step-by-Step Process for Wire Mesh Cable Trays

1. Mark the Bend Area: Measure and mark the center line of the tray where the bend is required.
2. Cutting: For a 90° flat bend, cut the tray partially along the center line, leaving enough material to maintain structural integrity .
3. Remove Lip: File or cut the tray lip that will overlap during bending. For a 45° bend, calculate half the angle (22.5°) and mark the lip accordingly .
4. Bending: Fold the tray along the marked line, ensuring the cuts overlap smoothly. Use a metal bar or bending machine for steel trays to achieve a clean bend .
5. Support and Finish: Support the bend area while bending to prevent deformation. Smooth any sharp edges to avoid cable damage .

Formulas for Flat Bends

For a 45° bend in a 100 mm tray:

• Half the angle = 22.5°
• Measure from the center line to mark the lip removal distance: 41.42 mm on each side in this example .
• Adjust the formula proportionally for different tray widths and angles.

Tips for Steel Cable Trays

• Use a bending machine or a sturdy metal bar for internal or external 90° bends .
• Manufactured 90° bends are available, but on-site bending can save time and cost.
• Ensure the bend radius complies with cable specifications to prevent damage. By following these steps and formulas, you can create precise flat bends in cable trays, whether wire mesh or steel, while maintaining safety and structural integrity .