Cable tray reducing bend

Cable trays can be efficiently cut and bent on-site using specialized tools like bolt cutters or band saws, minimizing installation time and maintaining safety and structural integrity.

Cutting Techniques

For wire mesh cable trays, cutting is typically done with bolt cutters positioned perpendicular to the wire to ensure a clean cut. Using an angular or offset blade cutter helps produce smooth edges, reducing the need for grinding and minimizing burrs, which makes subsequent bending easier and safer (Bonet Cable Tray, Eaton Flextray) . Rubber caps can be applied to cut ends to maintain protection and prevent injury . For modular or solid cable trays, a band saw with an appropriate blade is recommended to reduce swarf and burrs. Angle grinders can be used when band saws are impractical, but they increase the risk of sparks, splatter, and personal injury, so proper PPE is essential . Cutting torches are not recommended as they can damage surface treatments and weaken the material .

Reducing Bends

Instead of cutting and bending each tray section manually, pre-assembled adjustable fittings like Cablobend allow vertical and horizontal bends up to 90° without cutting, significantly reducing installation time and improving safety . For wire mesh trays, bends, tees, and reducers can be created live on-site after cutting individual wires, following a proper cutting pattern to maintain tray integrity .

Best Practices

• Always wear Kevlar gloves, eye protection, and appropriate PPE when cutting or bending trays .
• Protect surrounding materials from sparks or debris during cutting .
• Remove any burrs after cutting to prevent cable damage and ensure smooth assembly .
• Use the recommended cutting intervals and lengths from manufacturer guidelines to optimize installation and reduce unnecessary bends .
• For wire mesh trays, turn the tray open-side down to achieve the best cutting angle and easier bending . By following these techniques and using the right tools, installers can reduce the number of bends, save time, and maintain the structural and protective quality of cable trays.