How to make rounded corners on cable trays

Rounded corners in cable trays are created by bending or forming the tray material using specialized tools or on-site techniques to ensure smooth curves that protect cables and maintain structural integrity.Methods for Creating Rounded Corners1. Pre-fabricated Bends and Fittings Many cable tray systems come with pre-formed bends, elbows, and radius fittings. These components are manufactured in a factory using press brakes, rollers, or stamping machines to create precise curves in metal trays, ensuring consistent radius and smooth edges for cable protection . 2. On-site Bending for Wire Mesh Trays For wire mesh or basket-type cable trays, rounded corners can be made directly at the installation site. Installers often use bolt cutters or hand tools to bend the mesh into the desired shape. The cutting and bending process slightly drags the zinc coating over the edges, forming a protective layer that prevents corrosion. Rubber caps or edge protectors can also be applied to safeguard cables from sharp ends . 3. Sheet Metal Forming For solid or ventilated metal trays, rounded corners are achieved by bending the sheet metal along a curved die or using a roller. This process gradually forms the tray edges into a smooth radius. After bending, edges are often smoothed or deburred to remove sharp points and ensure safety during cable installation .Material ConsiderationsThe ability to form rounded corners depends on the tray material. Aluminum, stainless steel, and pre-galvanized steel are commonly used because they are ductile and corrosion-resistant, allowing smooth bends without cracking or compromising structural strength . Wire mesh trays are flexible and easier to shape on-site, while solid trays require precise tooling.Practical TipsAlways maintain the recommended bend radius to prevent cable damage.Use protective coatings or caps on cut or bent edges to prevent corrosion and protect cable insulation.For long runs, consider modular fittings to reduce the need for on-site bending and ensure uniformity . By combining pre-fabricated fittings, careful on-site bending, and proper material selection, installers can create rounded corners that are safe, durable, and compliant with cable management standards.