Cable tray bends can be fabricated on-site using cutting, bending, and fastening techniques, with specific methods for solid and wire mesh trays.

Fabricating 90° Elbows in Solid Cable Trays

To create a 90° elbow, often called a mitered bend, follow these steps:

1. Mark the Center Line: Determine the bend location and draw a line across the tray base.
2. Measure and Mark 45° Cuts: From the center line, measure the tray width or use a standard distance (e.g., 45–82mm depending on tray size) to mark the cuts.
3. Cut the Side Channels: Use an angle grinder or hacksaw to cut the tray flanges at 45° angles.
4. V-Notch the Base: Remove V-shaped sections from the base to allow the sides to close together.
5. Bend and Fasten: Fold the tray along the cuts to form two 45° bends, creating a 90° elbow, and secure with bolts, nuts, and washers. Apply cold galvanizing spray to protect against rust . For precise fabrication, the base of the isosceles triangles used in the cut can be calculated using the formula L = 2 × (tray height × sin 22.5°), ensuring accurate angles and proportions for different tray heights .

Fabricating Bends in Wire Mesh Cable Trays

Wire mesh trays are more flexible and can be modified directly on-site:

1. Tools Required: Bolt cutter, pliers, measuring tape, marker, and safety gloves.
2. Mark the Bend Area: Clearly mark the location for horizontal, vertical, or offset bends.
3. Cut and Bend: Use a bolt cutter to cut the mesh where needed. The cut edges remain protected due to the zinc layer, and rubber caps can be applied for additional safety.
4. Form the Bend: Manually bend the tray to the desired angle (90°, vertical, tee, or offset) without additional fittings . Wire mesh trays allow for quick, cost-effective on-site modifications, eliminating the need for pre-fabricated fittings.

General Tips

• Always measure and mark accurately before cutting.
• Use appropriate personal protective equipment (PPE) such as gloves and eye protection.
• Ensure bends do not compromise the tray's structural integrity or cable support.
• For solid trays, consider rust protection after cutting and bending.
• For complex layouts, pre-fabricate bends in a workshop if possible to save time on-site. By following these methods, both solid and wire mesh cable trays can be efficiently bent to fit installation requirements while maintaining safety and durability .