What to cut at the elbow of an electrical cable tray

To create a 90-degree elbow in a cable tray, cut the side flanges at 45-degree angles and remove V-shaped sections from the base to allow the tray to bend.Tools and Materials NeededStraight section of cable trayCutting tools (angle grinder with cutting disc or hacksaw)Measuring tape and markerSet square or protractorDrill and drill bitsNuts, bolts, and washers for fasteningCold galvanizing spray for rust protection Steps to Cut at the ElbowMark the Center Line: Determine where the bend will occur and draw a straight line across the center of the tray base. This line serves as a reference for your cuts .Mark the 45-Degree Cuts: From the center line, measure outward on both sides by a distance equal to the tray width or use a standard range of 45mm to 82mm depending on tray size. Draw the 45-degree lines on the side flanges .Cut the Side Channels: Using your cutting tool, cut the tray flanges along the 45-degree lines, stopping at the base of the tray. This allows the sides to meet cleanly when bent .V-Notch the Base: Remove V-shaped sections from the base where the bend will occur. This step ensures the tray can close properly at the elbow without deforming the sides .Bend and Fasten: Carefully bend the tray along the prepared cuts to form the 90-degree angle. Drill holes if necessary and secure the joint with nuts, bolts, and washers.Protect the Cut Edges: Apply cold galvanizing spray or another rust-preventive coating to the cut edges to prevent corrosion .Additional TipsEnsure accurate measurements to maintain proper alignment and fit.Use appropriate personal protective equipment (PPE) when cutting metal.For larger or heavier trays, consider additional support during bending to avoid deformation.Verify that the bend radius meets cable specifications to prevent damage to installed cables . By following these steps, you can safely and effectively cut a cable tray at an elbow, creating a clean, functional 90-degree bend suitable for installation.