Fabrication of 45-degree angle ends for cable trays

A 45-degree bend in a cable tray is typically achieved by making two 22.5-degree miter cuts on separate tray sections, then joining them to form the desired angle.Step-by-Step Fabrication Process1. Measure and Mark:Draw a perpendicular line across the width of each cable tray section.From this perpendicular, mark a 22.5° angle on each piece using a protractor or angle finder. The second tray piece should have the 22.5° cut in the opposite direction to allow proper joining . 2. Cutting the Tray:Use a band saw with a blade suitable for the tray material and thickness for precise cuts with minimal burrs.If a band saw is unavailable, an angle grinder can be used, but it produces more splatter and requires careful handling with both hands .Avoid cutting with torches as this can damage surface treatments and weaken the material . 3. Deburring and Smoothing:After cutting, remove any burrs and sharp edges to prevent injury and protect cable insulation .Kevlar gloves, safety glasses, and other PPE are recommended during handling . 4. Joining the Pieces:Align the two cut sections so the mitered edges meet, forming a 45-degree angle.Test-fit the pieces before securing with appropriate cable tray connectors and hardware . 5. Optional Formula for Lip Removal (for flat bends):For a 100 mm wide tray, measure half the tangent of the desired angle from the center line to mark the lip to be removed. For a 45° bend, this is approximately 41.42 mm on each side .This ensures the cut edges overlap correctly when bending.Material-Specific NotesMetal Trays: Avoid mixing cutting blades between stainless steel and carbon steel to prevent galvanic corrosion .Fiberglass Trays: Use tools compatible with FRP; angle grinders may not be suitable .Safety ConsiderationsAlways wear gloves, eye protection, and footwear PPE.Protect surrounding materials from sparks and overheating during cutting .Ensure proper handling to avoid personal injury, especially when using angle grinders . By following these steps, you can achieve precise 45-degree bends in cable trays, ensuring both structural integrity and safe installation.