How to cut the corners of a cable tray

Cutting corners on cable trays involves precise measurement, strategic cuts, and proper bending to maintain system integrity and safety.

Choosing the Right Tray and Tools

Mesh cable trays are highly flexible and can be cut and bent on-site to navigate corners, columns, and tight spaces, reducing the need for factory-made fittings and saving installation time. Cable ladders and solid trays require careful cutting to avoid structural weaknesses. Recommended tools include band saws, circular saws, angle grinders, or specialized cable cutters depending on material thickness.

Always wear personal protective equipment such as gloves, safety glasses, and hearing protection to prevent injury from sharp edges or sparks.

Measuring and Marking

Accurately measure the corner angle and mark the cut line on the tray using a marker or chalk. For 90-degree turns, plan strategic side cuts to allow smooth bending without over-stressing the tray. Maintain the proper bend radius to prevent damage to Ethernet or fiber cables running through the tray.

Cutting Techniques

Band saws are ideal for thin metal trays, providing clean cuts with minimal burrs and debris. Circular saws with metal-appropriate blades are suitable for light channels and ladders, often equipped with chip collectors for cleaner work. Angle grinders offer flexibility for irregular cuts but require careful handling to avoid overheating or damaging the tray.

Avoid using torches, as they can weaken the material and damage surface treatments.

Bending and Installation

After cutting, bend the tray carefully along the marked lines to form the corner. Mesh trays can often be bent by hand or with simple tools, while solid trays may require a bending brake or press. Check grounding and bonding after modifications to ensure electrical safety.

Avoid overfilling trays at corners to maintain airflow and prevent cable damage.

Finishing Touches

Deburr edges using a file or deburring tool to prevent injury and cable abrasion. Verify that the modified tray maintains structural integrity and aligns properly with adjacent sections. For modular systems, follow manufacturer guidelines for cutting intervals and post-cut treatment to ensure optimal performance.

By following these steps, you can efficiently cut and bend cable trays to navigate corners while maintaining safety, functionality, and compliance with installation standards.