How to build a cable tray with a 45-degree bend

A 45-degree cable tray bend is typically made by mitering two tray sections with 22.5-degree cuts on each, then joining them to form the desired angle.Step-by-Step Construction

1. Measure and Mark the Tray

• Determine the location of the bend on the cable tray.
• Draw a perpendicular line across the width of the tray at the bend point.
• Using a protractor or angle finder, mark a 22.5-degree angle from the perpendicular line on the first tray section. Repeat for the second tray section, but in the opposite direction to allow proper joining . 2. Cut the Tray
• Use an appropriate cutting tool, such as an angle grinder with a metal cutting disc, to make the 22.5-degree cuts along the marked lines.
• Ensure cuts are precise to maintain a smooth bend. 3. Deburr and Smooth Edges
• After cutting, remove any sharp edges or burrs using a file or deburring tool.
• This step is crucial for safety and to prevent damage to cables during installation . 4. Join the Sections
• Align the two cut sections so that the angled edges meet, forming a 45-degree mitered joint.
• Overlap or gusset the joint if necessary for added strength, depending on the tray type and load requirements . 5. Secure the Bend
• Fasten the sections together using bolts, rivets, or the tray manufacturer's recommended connectors.
• Ensure the joint is stable and can support the intended cable load. 6. Safety Precautions
• Always wear safety glasses, gloves, and ear protection during cutting and assembly.
• Test the fit with a cardboard or scrap piece first if attempting a new bend technique .

Tips for Accuracy

• Practice on a scrap piece of tray to verify measurements and cuts.
• Use a square and measuring tape to maintain alignment.
• For complex installations, consider using pre-fabricated 45-degree elbows if available, which can save time and ensure uniformity . By following these steps, you can construct a precise and safe 45-degree bend in a cable tray, ensuring smooth cable routing and structural integrity.