How to make multiple bends in a cable tray

Multiple bends in cable trays can be created on-site using marking, cutting, and bending techniques, allowing horizontal, vertical, offset, and junction configurations without pre-fabricated fittings.

Tools Required

• Bolt cutter or cable cutter
• Pliers or nose pliers
• Measuring tape and marker/chalk
• Hand gloves for safety

General Guidelines

1. Mark the bend area accurately before cutting to ensure precise angles.
2. Avoid cutting all wires completely; leave enough structure to maintain tray integrity.
3. Respect the cable bending radius to prevent damage to installed cables.
4. Support the bend area during and after bending to maintain shape and stability.
5. Smooth sharp edges after cutting to prevent cable abrasion.

Types of Bends

• Horizontal 90° Bend (Flat Bend): Used to turn the tray left or right. Remove a portion of the tray lip (typically 2/3 of the tray width) on either side of the center line, then bend carefully to form the angle.
• Vertical Bend (Up/Down): Allows the tray to rise or descend between levels. Mark the vertical bend line and bend gradually to avoid kinks.
• Tee (T-Junction) Bend: Creates a branching path for cables. Cut and bend the tray to form a perpendicular junction.
• Cross Bend (4-Way Junction): Enables multi-directional routing. Requires careful cutting and alignment to maintain structural integrity.
• Offset Bend (Side Shift): Used to avoid obstacles. Bend the tray in two opposite directions to shift the path laterally.

Step-by-Step Process

1. Measure and mark the desired bend location.
2. Use a bolt cutter to partially cut the tray wires where the bend will occur.
3. Gradually bend the tray to the required angle using pliers or a bending machine if available.
4. Check alignment and adjust as needed.
5. Smooth any sharp edges and support the bend with brackets or clamps if necessary.

Practical Tips

• Wire mesh trays are flexible and allow on-site modifications without expensive fittings.
• For steel or ladder-type trays, a bending machine or a sturdy metal bar can help achieve precise bends.
• Multiple bends can be made sequentially, ensuring each bend maintains the proper radius and structural support.
• Always wear protective gloves and follow safety protocols to prevent injury during cutting and bending. By following these methods, electricians and contractors can create custom cable tray paths efficiently, accommodating complex layouts while maintaining cable safety and tray durability .