top of page
Search

How to Create Bends in Wire Mesh Cable Trays (Step-by-Step Guide)

  • Sandeep Singh
  • May 2
  • 2 min read

Wire mesh cable trays are widely used because of their flexibility and easy on-site modification. Unlike perforated trays, bends can be created directly at site without expensive fittings.

This guide explains how to make 90° bends, vertical bends, tees, and offsets in wire mesh cable trays safely and professionally.

Tools Required

  • Bolt cutter / cable cutter

  • Plier / nose plier

  • Measuring tape

  • Marker or chalk

  • Hand gloves (safety)

General Rule Before Cutting

  • Always mark the bend area properly

  • Do not cut all wires completely (retain structural strength)

  • Maintain smooth edges to avoid cable damage

  • Bend gradually, do not apply sudden force

1. Horizontal 90° Bend (Flat Bend)

Steps:

  1. Mark the bending section on both sides of the tray

  2. Cut the bottom longitudinal wires (keep side wires intact)

  3. Make small cuts on side wires where required

  4. Gently bend the tray to 90° angle

  5. Adjust alignment using plier

  6. Secure with coupler or tie wire if needed

👉 Use case: Turning tray left or right

2. Vertical Bend (Up / Down Bend)

Steps:

  1. Mark the bending area

  2. Cut the side wires partially

  3. Keep bottom wires continuous

  4. Bend tray upward or downward

  5. Ensure smooth curve (avoid sharp bend)

  6. Fix with support

👉 Use case: Going up or down between levels

3. Tee (T-Junction) Bend

Steps:

  1. Mark center point where branch is required

  2. Cut mesh area in rectangular shape

  3. Insert branch tray

  4. Bend wires around the joint

  5. Secure using couplers or binding wire

👉 Use case: Creating cable branching

4. Cross Bend (4-Way Junction)

Steps:

  1. Cut cross opening in main tray

  2. Insert crossing tray

  3. Bend and lock wires

  4. Secure properly

👉 Use case: Multi-direction cable routing

5. Offset Bend (Side Shift)

Steps:

  1. Mark two bend points

  2. Cut alternate wires

  3. Bend tray in two directions

  4. Create required offset

  5. Fix alignment

👉 Use case: Avoiding obstacles

Important Tips for Strong Bending

  • Keep minimum 2–3 wires intact for strength

  • Avoid over-cutting

  • Use SS or GI couplers for heavy load areas

  • Maintain proper bend radius for cable safety

  • Smooth sharp edges after cutting

Common Mistakes to Avoid

❌ Cutting all wires completely

❌ Creating very sharp bends

❌ Not supporting the bend area

❌ Ignoring cable bending radius

❌ Leaving sharp edges


Advantages of On-Site Bending

  • No need for pre-fabricated fittings

  • Faster installation

  • Cost saving

  • Flexible layout design

  • Easy modifications

Conclusion

Creating bends in wire mesh cable trays is simple, fast, and cost-effective when done correctly. With proper cutting and bending techniques, you can achieve professional cable routing without additional accessories.

 
 
 

Comments

bottom of page