Proper cable tray corner cutting ensures precise fit, maintains structural integrity, and prevents sharp edges that could damage cables or cause injury.

Planning and Preparation

Before cutting a cable tray corner, measure and mark the cut line accurately using a tape measure and marker or chalk. Consider the tray material (metal, fiberglass, or composite) and the required angle for the corner. Ensure the cut will not compromise the tray's load-bearing capacity or violate installation standards such as BS EN 61537 for cable trays .

Tools and Equipment

• Saws: Use a hacksaw for small metal cuts or a power cut-off saw for larger or thicker trays. For fiberglass trays, a fine-toothed saw or band saw is recommended .
• Clamps or Vise: Secure the tray firmly to prevent movement during cutting, which reduces chipping and ensures accuracy .
• Deburring Tools or Files: Smooth sharp edges after cutting to prevent cable damage and injury .
• Protective Gear: Always wear gloves, safety glasses, and hearing protection to handle sharp edges and metal shavings safely .
• Lubricant or Cutting Oil: Optional for metal trays to prolong blade life and achieve smoother cuts .

Cutting Technique

1. Mark the corner cut clearly on the tray.
2. Support the tray on a stable surface to prevent bending or chipping.
3. Cut slowly and steadily, avoiding excessive pressure to prevent heat buildup, which can warp metal or soften fiberglass resin .
4. Cut in steps for FRP or composite trays if needed, typically in 300 mm increments for optimal strength .
5. Deburr the edges using a file or deburring tool to remove sharp edges and maintain safety .

Installation Considerations

• Ensure the cut corner aligns with the tray support system and maintains proper cable routing.
• For irregular cuts, place the open end inside a starter bracket if possible to maintain torsional strength .
• Avoid using the tray as a walkway or support for personnel, as this can compromise safety and tray integrity .

Safety and Compliance

Always follow local health and safety regulations and manufacturer-specific guidelines. Cutting operations should be performed by trained personnel familiar with electrical installation practices . Proper PPE and careful handling prevent injuries from sharp edges or flying debris. By following these steps, cable tray corners can be cut accurately, safely, and in a way that preserves the tray's structural and functional integrity.