Method for constructing bends in mesh cable trays
Bends in mesh cable trays can be made on-site using cutting and bending techniques, allowing for 90° bends, vertical bends, tees, crosses, and offsets without expensive fittings.
Tools and Safety
To create bends safely, you will need:
- Bolt cutters for cutting tray wires without compromising protective coatings .
- Hand grinder or file for trimming tray lips when constructing flat bends .
- Blunt object to flatten tray lips before bending .
- Protective gear including gloves and eye protection.
Types of Bends and Methods
1. Horizontal 90° Bend (Flat Bend)
- Mark the tray where the bend is required .
- Remove a portion of the tray lip (about 2/3 of the tray width) using a grinder or file .
- Cut down the center line carefully to avoid tray deformation .
- Flatten the tray lip at the bend point with a blunt object .
- Bend the tray to 90° and secure with bolts.
- Add a gusset piece cut from tray material to reinforce the bend .
2. Vertical Bends (Up/Down)
- Cut the upper side wires along the bend line .
- Bend the tray upward or downward to the desired angle.
- For tighter radii, leave only one row of wires between cuts .
3. Tee (T-Junction) and Cross Bends
- Remove intersecting corner blocks from the perpendicular tray section .
- Align the trays and connect using splice kits or bolts.
- Adjust cuts to form radiused corners for smooth cable routing .
4. Offset Bends (Side Shifts)
- Cut and bend sections to shift the tray laterally.
- Ensure the cuts do not compromise structural integrity; use protective caps if needed .
Tips for Professional Results
- Avoid cutting all wires completely; leave some connections to maintain tray strength .
- Work slowly and measure accurately to ensure proper alignment.
- Use rubber caps or protective coatings on cut ends to prevent cable damage .
- Bends can be made live on-site, reducing the need for pre-fabricated fittings and saving cost . By following these steps, you can create custom bends in mesh cable trays efficiently, ensuring safe and professional cable routing for your installation.
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