Cable tray turning a right angle bend

A right-angle (90°) bend in a cable tray can be achieved using pre-fabricated elbows, bending tools, or on-site fabrication techniques depending on the tray type and project requirements.

Using Pre-Fabricated Elbows

For many cable tray systems, especially steel or modular trays, pre-manufactured 90° elbows are available. These fittings are designed to maintain the tray's structural integrity and provide a smooth path for cables, reducing stress and potential damage during installation . They are the simplest and most reliable method for creating a right-angle turn.

On-Site Fabrication Techniques

If a pre-made elbow is not available, you can fabricate a bend on-site using several methods:

• Bending with a Tool or Bar: For steel trays, a crimping tool or a sturdy metal bar can be used to gradually bend the tray to 90° . This method is useful when a bending machine is not available. The process involves lifting and bending the tray sides incrementally to achieve a smooth curve.
• Cut-and-Bend Method: For wire mesh or basket-type trays, you can cut triangular sections from the side walls and bend the tray to form the desired angle. For example, a 600mm wide tray can be divided into multiple smaller angles (e.g., 2 x 45° or 3 x 30°) to create a sweeping 90° bend . Rubber caps or protective coatings can be applied to cut edges to prevent cable damage .
• Modular Accessories: Some systems, like EzyTray, allow you to assemble bends using accessories such as TX brackets and riser links. This method involves cutting the side walls, bending them down, and securing with bolts, providing flexibility for custom angles and offsets .

Key Considerations

• Support: Always secure the tray at multiple points along the bend to prevent sagging or stress on cables. Pairs of brackets or hold-down units are recommended .
• Cable Protection: Ensure that any cut edges or bends are smooth or capped to avoid damaging cable insulation .
• Gradual Bends: For large trays or heavy cable loads, consider breaking the 90° turn into smaller incremental angles to reduce stress on the tray and cables .

By choosing the appropriate method based on tray type, available tools, and project constraints, you can safely and efficiently create a right-angle bend in a cable tray system.