How to make bends in the mesh cable trays of a low-voltage electrical room

Mesh cable trays can be safely bent on-site using bolt cutters and pliers, allowing horizontal, vertical, and offset bends without factory fittings.

Tools and Safety Equipment

• Bolt cutter or cable cutter for cutting cross wires
• Pliers or nose pliers for adjusting wire ends
• Measuring tape and marker/chalk to mark bend locations
• Hand gloves to protect hands during cutting and bending
• Optional rubber caps to cover cut wire ends for safety and protection

Step-by-Step Bending Process

1. Mark the Bend Area

• Measure and mark the exact location where the bend is required.
• Ensure the bend radius is suitable for low-voltage cables like Ethernet or fiber to avoid damage .

2. Cutting Wires (if needed)

• Use a bolt cutter to cut selected cross wires at the bend location.
• Position the cutter perpendicular to the wire for a clean cut. Avoid center-cut blades; offset blades produce smoother edges .
• The cut wires can be bent without compromising the tray's structural integrity, and zinc coating remains protective .

3. Forming the Bend

• Horizontal 90° bend (flat bend): Lift the tray side and bend along the marked line to form a right angle.
• Vertical bend (up/down): Bend the tray upward or downward to navigate ceilings or floor transitions.
• Offset bend (side shift): Bend one side slightly to shift the tray laterally around obstacles.
• Use pliers to adjust individual wires for a smooth curve and maintain structural stability .

4. Finishing and Safety

• Cover exposed wire ends with rubber caps to prevent injury.
• Verify that the bend does not overfill the tray and maintains proper cable spacing.
• Check grounding and bonding continuity after modification .

Tips for Professional Installation

• Work slowly and carefully to maintain a clean, professional appearance.
• Avoid sharp bends that could damage low-voltage cables.
• Use 10-foot mesh trays when possible for easier on-site modifications and reduced labor .
• Plan bends in advance to minimize unnecessary cuts and adjustments.

By following these steps, you can create custom bends, tees, and offsets in mesh cable trays efficiently, ensuring safe and organized cable routing in a low-voltage electrical room .