How to cut notches in cable trays to connect parallel cable trays

Cutting notches in cable trays is possible but must be done carefully to maintain structural integrity and comply with safety standards.

Planning and Safety Considerations

Before cutting, assess the structural impact of removing portions of the side rail, as it provides stiffness and support to the tray system. Notching can weaken the tray, potentially causing sagging or buckling if not properly reinforced. Always consult the manufacturer for approved methods or adapters, and follow NEC 392.

18 guidelines for cable tray modifications ( ). Use personal protective equipment (PPE) including Kevlar gloves, eye protection, and appropriate footwear ( ).

Tools and Cutting Methods

Band saws: Recommended for precise cuts with minimal burrs. Cordless models like Hilti SB 4-A22 are suitable for low-height, thin metal trays ( ). Angle grinders: Can be used when band saws are impractical, but they produce more sparks and debris, and require careful handling with both hands ( ).

Avoid torches: Cutting with torches can damage surface treatments and weaken the metal ( ). Blade selection: Use blades appropriate for the material (stainless steel vs carbon steel) and avoid cross-contamination to prevent galvanic corrosion ( ).

Cutting Procedure

Mark the notch locations accurately on the tray side rail where the parallel tray will connect. Secure the tray to prevent movement during cutting. Cut the notches using a band saw or angle grinder, following the marked lines.

Deburr edges to remove sharp metal fragments and prevent injury or cable damage. Check alignment with the parallel tray and ensure the connection is stable.

Alternatives and Best Practices

Use adapters or pre-fabricated connectors: Many cable tray systems offer components designed to join parallel trays without cutting the side rails ( ). Reinforce cut areas: If notching is necessary, consider adding support brackets or plates to maintain structural integrity. Plan in 3D software: For complex installations, modeling the tray system can help determine optimal notch placement and reduce on-site modifications ( ).

By following these steps and safety precautions, you can cut notches in cable trays effectively while minimizing risks to both personnel and the tray system.