Making cable trays with 45-degree bends

A 45-degree bend in a cable tray is typically achieved by making two 22.5-degree miter cuts on separate tray sections and joining them, or by segmenting and bending the tray using a press brake or manual bender.

Step-by-Step Fabrication Method

1. Planning and Measurement

• Determine the exact location and angle of the bend. For a 45-degree turn, each section contributes half the angle (22.5°) if using a mitered joint approach .
• Measure the width of the tray and mark the centerline and sides for accurate cutting or bending . 2. Cutting for a Mitered Joint (Optional)
• Use a protractor to mark 22.5° from a perpendicular line on two separate tray pieces .
• Cut the tray using an angle grinder, metal shear, or suitable cutting tool.
• Deburr and smooth all edges to prevent cable damage and ensure safety . 3. Segmenting and Bending (Alternative Method)
• Divide the bend area into 3–5 equal segments along the tray width to form a smooth curve .
• Cut triangular or rectangular sections on the side walls to allow bending.
• Use a manual or hydraulic press brake to bend each segment slightly, ensuring uniform curvature . 4. Rejoining and Reinforcement
• After bending, rejoin the cut sections using rivets, nuts and bolts, or welding for structural integrity .
• Drill holes at the ends of the bend for connecting to straight tray sections. 5. Finishing
• Remove sharp edges with a file or grinder.
• Apply anti-rust paint or zinc spray on cut or welded edges if the tray is not pre-galvanized . 6. Safety Considerations
• Always wear safety goggles, gloves, and ear protection during cutting and bending .
• Ensure the tray is clean and free of defects before starting to prevent damage during bending .

Tips for Accuracy and Efficiency

• Test the bend with cardboard or scrap material before working on the actual tray .
• Use precise measuring tools like a tape measure, square, and protractor to maintain correct angles .
• For larger trays, consider hydraulic benders to reduce manual effort and maintain uniformity . By following these steps, you can create a smooth, structurally sound 45-degree bend in a cable tray, ensuring safe and efficient cable routing.