How to make a 90-degree bend in cable trays

A 90-degree bend in a cable tray can be made by marking, cutting, flattening the tray lips, bending carefully, and reinforcing with a gusset or using a bending machine.

Step-by-Step Method

1. Mark the Tray: Begin by measuring and marking the location where the 90-degree bend is required. Ensure the marks are precise to maintain alignment with the rest of the tray system . 2. Prepare the Tray Lips: For a flat 90-degree bend, remove part of the tray lip. Typically, remove 2/3 of the tray width, split evenly on both sides of the center line. Use a hand grinder or file carefully, wearing protective equipment . 3. Cut the Center Line: Make a cut along the center line of the tray at the bend point. Take care to prevent the tray from opening or deforming during this step . 4. Flatten the Tray Lip: Use a blunt object to flatten the tray lip at the bend point. This ensures the bend will be smooth and reduces stress on the metal . 5. Bend the Tray: Carefully bend the tray to 90 degrees. If using a bending machine, follow the machine's instructions to achieve a precise angle. For manual bending, a metal bar or crimping tool can help control the bend without damaging the tray . 6. Reinforce with a Gusset: Measure the distance between the internal edges of the bend. Cut a piece of tray to this size, remove one lip completely, and bolt it to the bend to reinforce the structure . 7. Alternative Method – Isosceles Triangle Technique: For bridge-style bends, draw perpendicular lines on the side rails, create isosceles triangles with a base length calculated as L = 2 × (tray height × sin 22.5°), cut them out, and bend the tray to form two 45-degree bends that combine into a 90-degree elbow . 8. Final Assembly: Bolt the bent sections together securely, ensuring the tray maintains its shape and alignment. Check for smooth edges to prevent cable damage during installation .

Tips

• Always wear protective gear when cutting or grinding metal.
• Use a bending machine for larger trays or frequent bends to ensure accuracy.
• For small or emergency bends, a metal bar or crimping tool can be used effectively .
• Verify measurements before cutting to avoid material waste. By following these steps, you can create a precise, structurally sound 90-degree bend in a cable tray suitable for electrical installations.