How to cut a 110-degree bend in a cable tray

To create a 110-degree bend in a cable tray, calculate the cut-out size based on the tray width and angle, then use appropriate cutting tools like a band saw, circular saw, or bolt cutter while following safety precautions.

Step 1: Calculate the Cut-Out Section

To bend a cable tray to a specific angle, you first need to determine the size of the section to remove from the tray's side rails. Use the formula: Cut-out length (D) = Tray width (A) ÷ (90 ÷ Desired angle) For a 110-degree bend, you can break it into smaller incremental bends (e.g., 2 x 55° or 3 x ~36.7°) to make the bend manageable. For example, if your tray width is 600 mm and you choose 2 x 55° bends:

1. Calculate C = 90 ÷ 55 ≈ 1.636
2. Cut-out section D = 600 ÷ 1.636 ≈ 367 mm This ensures the tray bends smoothly without kinking or damaging the cables inside .

Step 2: Mark and Prepare the Tray

• Measure and mark the cut-out sections along the side rails according to your calculations.
• Ensure the marks are precise to maintain the correct bend angle.
• For wire mesh trays, you may also need to cut individual wires along the bend line .

Step 3: Select the Cutting Tool

• Band saw: Ideal for precise cuts on metal trays; reduces burrs and debris. Use a blade suitable for the tray material and thickness .
• Circular saw: Good for light channels; ensure the blade is guarded and equipped with a chip collector .
• Bolt cutter: Effective for wire mesh trays; it also forms a protective layer on the cut ends .
• Angle grinder: Can be used if other tools are unavailable, but requires careful handling to avoid sparks and sharp edges .

Step 4: Make the Bend

• After cutting, bend the tray gradually along the cut-out sections.
• For wire mesh trays, bend by hand or with pliers, ensuring the wires do not break excessively .
• For solid metal trays, use a bending brake or carefully apply force to achieve the desired angle.

Step 5: Safety Precautions

• Wear Kevlar gloves, eye protection, and appropriate footwear to prevent injuries from sharp edges .
• Avoid mixing cutting blades between different metals to prevent galvanic corrosion .
• Ensure surrounding materials are protected from sparks or debris during cutting .

Step 6: Final Assembly

• Check the bend angle with a protractor or angle gauge.
• Use rubber caps or protective covers on cut ends to prevent cable damage .
• Secure the tray in place and verify that cables can pass through without obstruction. By following these steps, you can safely and accurately create a 110-degree bend in a cable tray while maintaining structural integrity and cable protection.