How to make a 45-degree cable tray elbow

A 45-degree elbow in a cable tray is made by cutting two tray sections at 22.5° each and joining them to form the desired angle.

Step-by-Step Process

1. Measure and Mark the Cuts

• Draw a perpendicular line across the width of each cable tray section.
• Using a protractor, mark a 22.5° angle from the perpendicular line on each piece. 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 angle grinder, jigsaw, or suitable metal cutting tool to make the cuts along the marked lines .
• Ensure all edges are deburr and smoothed to prevent injury and protect cable insulation . 3. Prepare the Tray for Assembly
• If the tray has flanged edges, file or trim the lip that will overlap to allow the two sections to fit together smoothly .
• Test-fit the two pieces to ensure the 45-degree angle is correct before final assembly. 4. Join the Sections
• Align the cut edges and secure them using appropriate cable tray connectors, bolts, or hardware.
• Ensure the joint is stable and the angle is precise. For wire mesh trays, a bolt cutter can be used to make live bends on-site . 5. Safety Considerations
• Always wear safety glasses, gloves, and ear protection during cutting.
• Double-check measurements and angles to avoid misalignment.

Tips and Formulas

• Each tray section contributes half of the total bend angle (22.5° each for a 45° elbow).
• For different tray widths, measure from the centerline and calculate the cut length using the formula: cut length = tray width × tan(22.5°) for precise mitering .
• Practicing on cardboard or scrap metal first can help ensure accuracy before cutting the actual tray. By following these steps, you can create a smooth, secure 45-degree elbow in a cable tray suitable for routing cables safely and efficiently .