How to bend wire mesh cable trays

Bends in wire mesh cable trays can be safely created on-site using proper cutting, bending techniques, and protective measures without compromising tray integrity.

Types of Bends

1. Horizontal 90° Bend (Flat Bend) – Used to change the tray direction along the same plane.
2. Vertical Bend (Up/Down Bend) – Allows the tray to rise or drop between levels.
3. Offset Bend (Side Shift) – Shifts the tray laterally to avoid obstacles.
4. Tee or Cross Bend – Creates junctions for branching or intersecting trays .

Tools and Techniques

• Bolt Cutters: Ideal for cutting individual wires to form bends. The cutting action drags a layer of zinc across the cut ends, maintaining corrosion protection .
• Hand Bending: After selective wire cutting, the tray can be bent manually to the desired angle. Avoid cutting all wires completely to maintain structural strength .
• Protective Caps: Use rubber or plastic caps on cut wire ends to prevent cable damage and ensure safety .
• Step-by-Step Guides: Manufacturers like Pemsa and Siltec provide illustrated instructions and videos showing how to bend trays accurately on-site, including creating 90° bends and junctions .

Best Practices

• Plan the Route: Identify where bends, offsets, and junctions are needed before cutting.
• Cut Selectively: Only cut the wires necessary to achieve the bend; this preserves tray strength.
• Maintain Radius: Avoid sharp bends that could stress cables; follow recommended bend radii.
• Secure After Bending: Use fasteners or connectors to stabilize the bent section and maintain alignment.
• Minimize Waste: On-site bending reduces the need for pre-fabricated accessories, saving material and labor .

Summary

Creating bends in wire mesh cable trays is straightforward when using selective wire cutting, proper bending techniques, and protective measures. Following manufacturer guides and using appropriate tools ensures professional, safe, and efficient installation while maintaining tray integrity and cable protection .