A 45-degree cable tray bend is typically achieved by mitering two tray sections with 22.5-degree cuts on each, then joining them to form the full angle.

Step-by-Step Process

1. Measure and Mark the Tray

• Draw a perpendicular line across the width of each cable tray section where the bend will occur.
• Using a protractor or angle finder, mark 22.5° from the perpendicular line on each tray section. The second tray piece should have the 22.5° cut in the opposite direction to allow proper joining . 2. Cut the Tray
• Use an appropriate cutting tool, such as an angle grinder with a metal cutting disc, to make the cuts along the marked lines.
• Ensure the cuts are precise to maintain the correct 45-degree angle when joined . 3. Deburr and Smooth Edges
• After cutting, deburr all edges using a file or grinder to remove sharp metal and prevent damage to cables or injury during installation . 4. Test Fit and Join
• Align the two cut sections to form the 45-degree bend.
• Use cable tray connectors or hardware to securely join the sections, ensuring a stable and smooth transition for cables .

Optional: Using Formulas for Accuracy

• For more precise fabrication, you can calculate the lip removal or overlap using trigonometric formulas. For example, take half of the desired bend angle (22.5° for a 45° bend) and measure the corresponding distance from the centerline to mark the cut .
• Practicing on cardboard or scrap metal first can help verify measurements before cutting the actual tray .

Safety Considerations

• Always wear safety glasses, gloves, and ear protection when cutting metal.
• Ensure the work area is clear and stable to prevent accidents.
• Smooth all edges to protect cable insulation and prevent injuries during installation . By following these steps, you can create a precise and safe 45-degree bend in a cable tray, suitable for routing electrical or communication cables efficiently.