How to handle bends in wire mesh cable trays

Wire mesh cable trays can be easily bent on-site using adjustable systems or simple hand tools, allowing horizontal, vertical, and T-junction bends without compromising cable protection.

Pre-Engineered Adjustable Systems

Products like Cablobend EZ allow installers to create bends and drops quickly without cutting the tray. These systems feature easy-to-bend flex wires, adjustable vertical and horizontal angles up to 90°, and pre-assembled sections for faster installation. They are available in multiple heights (2”, 4”, 6”) and widths (6” to 24”), and include rigidity clips to maintain structural strength. Using such systems can reduce installation time from hours to minutes per bend, improve safety by eliminating cutting tools, and maintain a clean, professional appearance .

Manual Bending Techniques

For on-site modifications, wire mesh trays can be bent using bolt cutters, pliers, and hand tools. Key steps include:

• Marking the bend area with a measuring tape and marker.
• Creating horizontal bends to navigate around walls or machinery, typically ranging from 30° to 90° .
• Vertical bends for upward or downward transitions, ensuring smooth cable routing without sharp edges .
• T-junctions and offsets for branching or side-shifting cables, maintaining continuous tray integrity .
• Protecting cut ends with rubber caps or allowing the bolt cutter to form a protective zinc layer .

Manual bending preserves the tray's structural integrity, reduces the number of joints, and minimizes sharp turns that could damage cables. It also allows installers to adapt to complex layouts without pre-fabricated fittings .

Advantages of Easy-to-Handle Bends

• Improved installation efficiency: Fewer connectors and less cutting required.
• Better cable protection: Smooth bends reduce pressure points and kinks.
• Aesthetic appeal: Continuous, seamless trays with well-formed bends.
• Safety: Reduced need for cutting tools and less time on elevated areas .

Recommendations

• For large-scale installations like data centers, consider pre-assembled adjustable systems to save time and ensure consistency.
• For smaller or custom layouts, manual bending with proper tools is effective and cost-efficient.
• Always reinforce bends as needed and protect cut ends to maintain tray strength and cable safety.

By combining adjustable systems and proper manual techniques, installers can achieve efficient, safe, and professional wire mesh cable tray bends suitable for any complex installation scenario.