Complete Guide to Cutting Cable Tray Elbows and Their Dimensions

Cutting and fabricating cable tray elbows involves precise measurement, angled cuts, and secure fastening to ensure proper routing and structural integrity.Tools and Materials NeededStraight cable tray sections (ladder, solid, or wire mesh type)Cutting tools: angle grinder with cutting disc, hacksaw, or band saw suitable for metal thickness Measuring tape, marker, set square, or protractorDrill and drill bits for fasteningNuts, bolts, washers, and optional connecting platesCold galvanizing spray or protective caps for exposed metal edges Personal protective equipment: gloves, goggles, and appropriate footwear Step-by-Step Fabrication of a 90° ElbowMark the Center Line: Determine the bend location and draw a straight line across the tray base.Mark 45° Cuts: Measure from the center line to the tray width or use standard offsets (typically 45–82 mm depending on tray size) to mark the angled cuts .Cut Side Channels: Cut the tray flanges at the 45° angle, stopping at the base.V-Notch the Base: Remove V-shaped sections on the base to allow the sides to close together.Bend the Tray: Fold the tray at the center point so the cut sides meet perfectly, forming a 90° angle.Secure the Joint: Drill holes through overlapping sides and fasten with bolts; use connecting plates for larger trays .Finish the Surface: Apply cold galvanizing spray to prevent rust on exposed metal .Dimensions and ConsiderationsElbow Radius: Typically, the inside radius of a 90° elbow is equal to the tray width for standard bends, but this may vary depending on manufacturer specifications .Tray Widths: Common widths range from 50 mm to 600 mm; depth and flange height vary by type and load requirements .Material Thickness: Steel trays often range from 1.0 mm to 2.5 mm; wire mesh trays have thinner gauge wires but require careful cutting to maintain structural integrity .Safety: Always remove burrs after cutting to prevent injury and ensure proper fit; Kevlar gloves are recommended when handling sharp edges .Additional TipsFor wire mesh trays, bolt cutters can be used to make bends live on-site, and rubber caps protect cut ends .When using modular systems, follow manufacturer cutting guidelines to maintain proper intervals and avoid compromising structural support .Always verify dimensions in the field, as drawings may not reflect final equipment placement . By following these steps and adhering to safety and dimensional standards, cable tray elbows can be fabricated efficiently, ensuring proper cable routing and long-term durability.