How to make a high-altitude bend in a mesh cable tray

To create a high-altitude (vertical inside) bend in a wire mesh cable tray, carefully cut and bend the tray upward at the required angle, ensuring smooth transitions and proper support to protect cables.

Understanding Vertical Inside Bends

A vertical inside bend allows the cable tray to transition from a lower to a higher level, such as from a floor-mounted tray to a ceiling-mounted system. Typical angles range from 30° to 90°, depending on the elevation change required. This type of bend is essential in multilevel installations to maintain smooth cable routing without sharp turns that could damage cables ( ).

Tools and Materials Needed

• Bolt cutters: For cutting mesh wires at precise points to allow bending ( ).
• Pliers or bending tools: To grip and gradually bend the mesh wires ( ).
• Protractor or angle marker: To measure and mark the desired bend angle ( ).
• Rubber caps or protective covers: To cover cut wire ends and prevent cable damage ( ).
• Support brackets or clamps: To reinforce the bend and maintain structural integrity ( ).

Step-by-Step Bending Process

1. Measure and Mark: Determine the exact location and angle of the bend using a protractor or angle marker. Mark the mesh wires where cuts or bends will occur ( ).
2. Cut the Mesh: Use bolt cutters to cut selected wires at the bend point. This allows the tray to flex upward without deforming the entire structure. The cut edges are protected by the zinc layer or rubber caps ( ).
3. Bend Gradually: Using pliers or a bending tool, slowly bend the tray upward to the desired angle. Ensure the bend is smooth to minimize stress on cables ( ).
4. Reinforce the Bend: Install support brackets or clamps at the bend to maintain strength and prevent sagging, especially for sharper angles or heavier cable loads ( ).
5. Check for Sharp Edges: Inspect the bend for any sharp wire ends and cover them with protective caps to avoid cable damage ( ).
6. Install and Secure: Mount the bent tray in its final position, ensuring it is properly supported along the vertical run.

Tips for High-Altitude Installations

• Work in sections: For long vertical runs, bend the tray in manageable segments to maintain control.
• Use gradual bends: Avoid abrupt angles to reduce cable stress and maintain airflow.
• Ensure proper support: Vertical bends carry the weight of cables; additional brackets or hangers may be required.
• Safety first: Use gloves and eye protection when cutting and bending mesh wires. By following these steps, you can create a high-altitude vertical bend in a mesh cable tray that is structurally sound, safe for cables, and adaptable to complex installation layouts ( ).