A 90-degree cable tray bend can be fabricated by marking, cutting, removing tray lips, bending, and reinforcing with gussets or mitered sections.

Step-by-Step Method

1. Mark the Tray: Begin by marking the center line and the area where the bend will occur. This ensures accurate alignment and symmetry during cutting and bending . 2. Remove Tray Lips: For flat bends, remove part of the tray lip equal to 2/3 of the tray width, split evenly on both sides of the center line. Use a hand grinder or file, taking care to wear protective equipment . 3. Cut Along the Center Line: Carefully cut down the center line without letting the tray fall open, which could damage the tray . 4. Flatten the Lip: Use a blunt object to flatten the tray lip at the bend point. This prepares the tray for a smooth 90-degree bend . 5. Bend the Tray: Gradually bend the tray to 90 degrees. For mitered bends, you can alternatively make two 45-degree cuts and join them to form a 90-degree elbow . 6. Reinforce with Gussets or Bolts: Measure the distance between the internal edges of the bend and cut a gusset piece from tray material. Remove one lip completely and bolt it to the bend to strengthen the joint .

Tools and Safety

• Tools: Hand grinder, file, band saw, circular saw, or angle grinder (with proper PPE). Band saws and circular saws are preferred for precision and reduced burrs .
• Safety: Always wear Kevlar gloves, eye protection, and ensure sparks or heat do not damage surrounding materials. Avoid cutting with torches as it can weaken the tray .

Calculating Cut Sizes

For mitered bends, the cut size depends on the tray width and the angle. For example, a 600mm tray can be bent using two 45-degree cuts, each requiring a 300mm cut-out section . For sweeping bends, multiple smaller angles (e.g., 3 x 30°) can be used to reduce stress on the tray.

Summary

Creating a 90-degree bend in a cable tray involves precise marking, lip removal, careful cutting, bending, and reinforcement. Using gussets or mitered sections ensures structural integrity, while proper tools and safety measures prevent injury and material damage .