How to cut the corner of a cable tray

Proper cable tray corner cutting ensures precise fit, maintains structural integrity, and prevents sharp edges that could damage cables or cause injury.

Planning and Preparation

Before cutting a cable tray corner, measure and mark the cut line accurately using a tape measure and marker or chalk. Consider the tray material (metal, fiberglass, or composite) and the required angle for the corner. Ensure the cut will not compromise the tray's load-bearing capacity or violate installation standards such as BS EN 61537 for cable trays.

Tools and Equipment

Saws: Use a hacksaw for small metal cuts or a power cut-off saw for larger or thicker trays. For fiberglass trays, a fine-toothed saw or band saw is recommended. Clamps or Vise: Secure the tray firmly to prevent movement during cutting, which reduces chipping and ensures accuracy.

Deburring Tools or Files: Smooth sharp edges after cutting to prevent cable damage and injury. Protective Gear: Always wear gloves, safety glasses, and hearing protection to handle sharp edges and metal shavings safely. Lubricant or Cutting Oil: Optional for metal trays to prolong blade life and achieve smoother cuts.

Cutting Technique

Mark the corner cut clearly on the tray. Support the tray on a stable surface to prevent bending or chipping. Cut slowly and steadily, avoiding excessive pressure to prevent heat buildup, which can warp metal or soften fiberglass resin.

Cut in steps for FRP or composite trays if needed, typically in 300 mm increments for optimal strength. Deburr the edges using a file or deburring tool to remove sharp edges and maintain safety.

Installation Considerations

Ensure the cut corner aligns with the tray support system and maintains proper cable routing. For irregular cuts, place the open end inside a starter bracket if possible to maintain torsional strength. Avoid using the tray as a walkway or support for personnel, as this can compromise safety and tray integrity.

Safety and Compliance

Always follow local health and safety regulations and manufacturer-specific guidelines. Cutting operations should be performed by trained personnel familiar with electrical installation practices.

Proper PP

E and careful handling prevent injuries from sharp edges or flying debris. By following these steps, cable tray corners can be cut accurately, safely, and in a way that preserves the tray's structural and functional integrity.