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Method for making a 90-degree right-angle bend in a cable tray

Method for making a 90-degree right-angle bend in a cable tray

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90-degree bends in cable trays can be achieved using pre-manufactured fittings, bending machines, or on-site fabrication with cutting, crimping, and gusseting techniques.

Pre-Manufactured Bends

The simplest method is to use pre-fabricated 90-degree elbows designed for your tray type. These are available for both wire mesh and solid metal trays and ensure consistent angles, proper support, and compliance with industry standards.

On-Site Fabrication Techniques

When pre-manufactured bends are unavailable, you can fabricate bends on-site using the following methods: 1. Cable Tray Bending Machine

  • Place the tray in a bending machine designed for your tray width.
  • Mark the bend location accurately.
  • Apply gradual pressure to form a smooth 90-degree bend without deforming the tray edges.
  • This method is ideal for metal trays and ensures a professional finish with minimal stress on the tray material . 2. Crimping and Gusset Method
  • Mark the bend line on the tray.
  • Use a crimping tool to create small indentations along the bend line.
  • Cut a gusset piece from another tray section, remove one lip, and bolt it to the bend to reinforce the corner.
  • This method allows for internal or external bends and is useful when a bending machine is not available . 3. Manual Bending with a Metal Bar
  • For small adjustments or emergency bends, a metal bar can be used to lever the tray into a 90-degree angle.
  • Ensure the tray is supported and bend gradually to avoid kinks or sharp edges.
  • Smooth the bend with a hammer or mallet if necessary .

Wire Mesh Tray Bends

Wire mesh trays are more flexible and allow on-site bending without specialized machines:

  • Mark the bend area clearly.
  • Use bolt cutters or pliers to adjust wires as needed.
  • Avoid cutting all wires completely; maintain structural integrity.
  • Ensure the bend radius is sufficient to prevent cable damage .

Safety and Best Practices

  • Always wear gloves and eye protection when cutting or bending trays.
  • Maintain a minimum bend radius to prevent cable stress.
  • Support the tray adequately during bending to avoid deformation.
  • Verify measurements before cutting or crimping to ensure proper alignment with the installation path . By combining these techniques, installers can achieve precise, safe, and professional 90-degree bends in both metal and wire mesh cable trays, whether using pre-fabricated fittings or on-site fabrication.
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