Method for cutting cable tray reducing elbows

A reducing elbow in a cable tray can be made by carefully cutting, notching, and bending the tray using appropriate tools like bolt cutters, band saws, or angle grinders while following safety precautions.

Tools and Materials Needed

• Straight section of cable tray (wire mesh or metal)
• Measuring tape, marker, and set square or protractor
• Bolt cutter (for wire mesh) or band saw/circular saw (for metal trays)
• Drill with bits, nuts, bolts, and washers for assembly
• Cold galvanizing spray or protective coating for cut edges
• Personal protective equipment: Kevlar gloves, safety glasses, helmet, and footwear

Step-by-Step Process

1. Measure and Mark Determine the desired position and angle of the reducing elbow. For a 90° elbow, mark the center line and measure out 45° cuts on each side of the tray base. For a reducer, mark the width transition points along the tray edges to match the smaller section . 2. Cut the Tray

• Wire mesh trays: Use an angular bolt cutter to cut the cross wires and side flanges. Position the cutter perpendicular to the wire for a clean cut and minimal burrs .
• Metal trays: Use a band saw or circular saw for precise cuts. Angle grinders can be used if saws are unavailable, but they produce more sparks and require careful handling . Avoid cutting with torches to prevent weakening the material. 3. Notch the Base (V-Notch) Remove V-shaped sections from the tray base where the bend will occur. This allows the sides to close together smoothly when forming the elbow . 4. Bend and Form the Elbow Carefully bend the tray along the notched lines to create the desired angle. For reducers, gradually taper the tray sides to match the smaller width, ensuring a snug fit between sections . 5. Assemble and Fasten Align the cut and bent sections, then drill holes if necessary and secure with bolts, nuts, and washers. Ensure the reducer or elbow is stable and properly aligned with the rest of the tray system . 6. Protect Cut Edges Apply cold galvanizing spray or use rubber caps to protect exposed metal and prevent corrosion or injury .

Safety Tips

• Always wear gloves, eye protection, and other PPE when cutting or bending trays .
• Keep hands clear of cutting blades and sparks.
• Avoid mixing cutting blades between different metals to prevent galvanic corrosion .
• Ensure the work area is clear of flammable materials when using power tools. By following these steps, you can create a clean, functional reducing elbow in a cable tray that maintains structural integrity and safety while accommodating changes in direction or width.