How to add a 45-degree angle to a cable tray bend

A 45-degree bend in a cable tray is achieved by making two 22.5-degree cuts on separate tray sections and joining them to form a mitered joint.

Step-by-Step Instructions

1. Measure and Mark the Cuts

• Determine the location of the bend on the cable tray.
• Draw a perpendicular line across the tray width at the bend point.
• Using a protractor or angle finder, mark a 22.5-degree angle from the perpendicular line on each of the two tray sections. The second piece's cut should be in the opposite direction to the first to allow proper joining . 2. Cut the Tray Sections
• Use an appropriate cutting tool, such as an angle grinder with a metal cutting disc or a hacksaw, to make the 22.5-degree cuts along the marked lines.
• Ensure cuts are precise to maintain a smooth 45-degree bend . 3. Deburr and Smooth Edges
• After cutting, remove any sharp edges or burrs using a file or deburring tool.
• This step is crucial to prevent injury and protect cable insulation during installation . 4. Join the Sections
• Align the two cut sections so that the 22.5-degree cuts form a 45-degree mitered joint.
• Test-fit the pieces to ensure proper alignment.
• Secure the joint using cable tray connectors, bolts, or other recommended hardware to maintain structural stability . 5. Optional Formulas for Accuracy
• For a 100 mm wide tray, the cut length on each side can be calculated as half the total offset. For example, a 45-degree bend requires 22.5 mm on each side from the center line .
• Using cardboard or a mock-up is recommended to verify measurements before cutting the actual tray. 6. Safety Considerations
• Always wear safety glasses, gloves, and ear protection during cutting.
• Ensure the tray is securely clamped to prevent movement while cutting .

Tips for Smooth Installation

• Use a measuring tape and square to maintain accuracy.
• For multiple bends, divide the total offset distance to create consistent angles.
• Consider using pre-fabricated 45-degree elbows if available to save time and ensure precision . By following these steps, you can achieve a precise and safe 45-degree bend in a cable tray, suitable for routing cables around corners or obstacles while maintaining structural integrity.