How to bend cable trays at right angles

You can bend a cable tray to a 90° angle using either a manual method with simple tools or a cable tray bending machine, following careful measurement and preparation.

Manual Bending Method

1. Mark the Bend Location: Measure and mark the point on the tray where the 90° bend is required. Ensure the mark is centered along the tray width for accuracy ( ).
2. Prepare the Tray Lip: Remove part of the tray lip to allow the bend. Typically, remove half of the lip on each side of the center line using a hand grinder or file, taking care to wear protective equipment ( ).
3. Cut the Center Line: Make a cut along the center line at the bend point. Be careful not to let the tray fall open or deform ( ).
4. Flatten the Tray Lip: Use a blunt object to flatten the tray lip at the bend point. This helps the tray bend smoothly without cracking ( ).
5. Bend the Tray: Carefully bend the tray to 90° by hand or using a lever bar. Ensure the bend is even and maintains the tray's structural integrity ( ).
6. Reinforce with a Gusset: Measure the distance between the internal edges of the bend and cut a gusset piece from another tray section. Remove one lip completely and bolt it to the bend to strengthen the corner ( ).

Using a Cable Tray Bending Machine

• Place the tray in the machine and align it with the desired bend point.
• Adjust the machine to the correct angle (90°) and slowly bend the tray.
• This method is faster and ensures a precise, smooth bend, especially for thicker steel trays ( ).

Tips and Considerations

• Pre-manufactured Bends: If available, you can use pre-made 90° bends to save time and ensure compliance with cable bending radius requirements ( ).
• Cable Radius: Always consider the minimum bending radius of the cables to avoid damage during installation.
• Safety: Wear gloves, eye protection, and ensure the tray is securely supported during bending.
• Offset Planning: For complex layouts, calculate offsets to ensure the tray aligns correctly with other sections ( ). By following these steps, you can create a reliable 90° bend in a cable tray, either manually or with a bending machine, while maintaining proper cable support and structural integrity.