What to do if the cable tray has no bends

If a cable tray has no pre-fabricated bends, you can create field bends by cutting and bolting straight sections together or use manual bending techniques while ensuring proper cable bend radius.

Field Bending of Cable Trays

When pre-fabricated bends are unavailable, straight sections can be cut and bolted together to form a bend. This method is allowed under NEC 392.18(A), which permits field bends of trays. While this approach may result in a bend without a smooth curve, it is acceptable as long as the cables are not excessively stressed during installation and the bend radius is within manufacturer or industry recommendations (Electrical Professionals forum, Mike Holt) .

Using Manual Bending Techniques

For metal cable trays, manual bending using a bar or simple tools is possible if a bending machine is not available. This technique allows you to create internal 90-degree bends or other angles on-site, ensuring the tray follows the required path around obstacles (YouTube, Electrical UK Wiring) . Care must be taken to avoid kinking or damaging the tray.

Importance of Bend Radius

Even when creating bends in the field, it is crucial to maintain the minimum bend radius for cables to prevent damage. The radius depends on the cable type and tray width, and manufacturers often provide guidelines. Smooth transitions reduce stress on cables, prevent pinching, and maintain system reliability (Kiash Electricals) .

Alternative Solutions

• Pre-fabricated bends: If possible, purchase bends of different radii for the tray width to simplify installation and protect cables.
• SnakeTray or flexible tray systems: For installations with many odd angles, flexible or modular tray systems can accommodate complex routing without field bending .
• Proper support and alignment: Ensure all bent or bolted sections are securely attached to the supporting structure to prevent sagging or misalignment. By combining these methods—field bending, manual bending, and proper support—you can safely route cables even when the tray system has no pre-installed bends.