Complete Guide to Cutting Bends on Cable Trays

Cable trays can be cut and bent on-site using appropriate tools like band saws, circular saws, or bolt cutters, with specific techniques for T-branches, cross-overs, 90° bends, risers, and reducers.

General Cutting Guidelines

For metal cable trays and ladders:

• Use a band saw with a blade suitable for the material thickness to reduce burrs and swarf.
• Circular saws are effective for light channels and trays; cordless models with chip collectors improve safety and cleanliness.
• Angle grinders can be used when other tools are impractical, but they produce sparks and require careful handling.
• Avoid cutting with torches, as this can damage surface treatments and weaken the material.
• Always wear Kevlar gloves, eye protection, and PPE to prevent injuries from sharp edges or flying debris . For wire mesh cable trays:
• Bolt cutters are recommended for live on-site modifications. The jaws drag a layer of zinc across the cut, forming a protective layer. Rubber caps can be used to cover cut ends for safety .

Cutting and Bending Techniques for Specific Configurations

• T-Branches and Cross-Overs:
  • Mark the cut lines carefully.
  • Use clamps to hold the tray securely.
  • Cut with a bolt cutter or saw, then bend the tray to form the branch or cross-over.
  • Ensure edges are deburred or capped to maintain protection .
• 90° Bends:
  • For ladder or solid trays, use a band saw or circular saw to make precise cuts at the bend points.
  • Gradually bend the tray using a bending tool or manual leverage, ensuring the bend radius matches cable specifications .
• Risers and Falling Bends:
  • Cut the tray to the required length for vertical transitions.
  • Use clamps and bending jigs to achieve smooth vertical bends without deforming the tray structure .
• Reducers:
  • Cut the tray ends to taper the width.
  • Ensure the cut edges are smooth and protected to prevent cable damage.
  • Bolt or clamp the reduced section to the main tray securely .

Safety and Post-Cutting Considerations

• Remove burrs and sharp edges after cutting to prevent injuries and cable damage.
• Protect surrounding materials from sparks and heat when using grinders.
• Follow local and national HSE regulations for PPE and safe handling .
• For mesh trays, rubber caps or zinc layers from bolt cutters provide additional protection . By following these methods, installers can achieve clean, safe, and structurally sound bends in cable trays, ensuring proper cable management and long-term durability.