How to make a downward bend in a mesh cable tray

Up and down bends in wire mesh cable trays can be made on-site by cutting and bending the tray using bolt cutters or pliers, saving on material and labor costs compared to pre-fabricated bends. Making Up and Down Bends1. Vertical Bends (Up/Down): Identify the section of the tray where the vertical bend is required.

Use a bolt cutter or wire cutter to selectively cut some of the cross wires at the bend location, leaving enough wires intact to maintain structural integrity. Gradually bend the tray upward or downward to the desired angle, typically 90° for standard vertical transitions. Ensure the bend is smooth to avoid sharp edges that could damage cables.

Protective rubber caps can be applied to cut ends for safety. 2. Tools and Techniques: Bolt cutters are preferred for live bending on-site as they cut wires efficiently and leave a protective zinc layer on the cut ends.

Pliers or bending jigs can help achieve precise angles without deforming the tray. Avoid cutting all wires completely; partial cuts allow the tray to bend while maintaining strength. 3.

Advantages of On-

Site Bending: Eliminates the need to purchase pre-fabricated bends, tees, or reducers. Allows customization to fit the exact installation requirements. Can save up to 40% in material costs and 30% in labor compared to using pre-made accessories.

Price ConsiderationsDIY Bending: The main cost is the tooling (bolt cutters, pliers, protective caps), which is a one-time investment. Material savings are significant since straight trays are cheaper than pre-fabricated bends.

Pre-

Fabricated Bends: These are more expensive per unit because they are manufactured to specific angles and sizes. Prices vary depending on tray width, material (galvanized steel, stainless steel), and supplier. On average, a pre-fabricated 90° vertical bend can cost $20–$50 per piece, while creating the same bend on-site from a straight tray may reduce this cost substantially.

Labor Costs: On-site bending requires skilled labor but is generally faster than assembling multiple pre-fabricated pieces, further reducing overall project costs.

Summary

Creating up and down bends in mesh cable trays is practical, cost-effective, and flexible when done on-site using proper cutting and bending techniques. Investing in basic tools allows installers to customize tray layouts, reduce material costs, and save labor time, making it a preferred method for many projects.