Cable tray elbows are fixed by cutting, bending, and fastening sections to form precise 45° or 90° angles, with proper support and alignment according to standards.

Tools and Materials Needed

• Straight cable tray sections
• Cutting tools (angle grinder with cutting disc or hacksaw)
• Measuring tape, marker, set square, or protractor
• Drill and drill bits
• Nuts, bolts, and washers for fastening
• Cold galvanizing spray for rust protection

Step-by-Step Fabrication of a 90° Elbow

1. Mark the Center Line: Determine the desired bend location and draw a straight line across the tray base.
2. Mark 45° Cuts: Measure equal distances on both sides of the center line (typically 45–82 mm depending on tray size) and mark the cuts.
3. Cut Side Channels: Cut the tray flanges at a 45° angle, stopping at the base.
4. V-Notch the Base: Remove V-shaped sections on the base to allow the sides to close together.
5. Bend the Tray: Fold the tray along the notched lines to form two 45° bends, creating a 90° elbow.
6. Fasten the Elbow: Secure the bent sections with bolts and washers, ensuring alignment and structural integrity.
7. Protect Against Corrosion: Apply cold galvanizing spray to exposed metal edges.

Calculating Bend Dimensions

For precise fabrication, use the isosceles triangle method:

• Determine the bottom side length equal to the tray width (100–400 mm typical).
• Draw perpendicular bisectors on the side rails to form two isosceles triangles.
• Calculate the base length using L = 2 × (tray height × sin 22.5°).
• Cut the triangles to achieve accurate 45° bends, which combine to form a 90° elbow.
• This method can also be adapted for 45° elbows or modified lengths .

Support and Installation

• Position supports so that connectors between straight sections fall between the support point and the quarter-point of the span. Avoid placing connectors at the center of spans or directly on supports .
• Ensure all elbows are supported according to NEMA VE 2 or relevant standards.
• Bond all cable trays with jumpers and ground at intervals of 15 m (50 ft) and at both ends to maintain electrical continuity .

Best Practices

• Use components designed and tested together as a system to ensure safety and reliability .
• Avoid using cable trays as walkways or for supporting personnel.
• Follow manufacturer instructions and local electrical codes for installation. By following these steps, cable tray elbows can be fabricated and fixed securely, maintaining proper cable routing, structural support, and compliance with safety standards.