DIY Up and Down Bends for Cable Trays

Up and down bends in cable trays can be created on-site using proper marking, cutting, and bending techniques with tools like cable tray benders or bolt cutters.

Tools and Safety Equipment

Cable tray bender or metal bar for manual bendingBolt cutter for wire mesh traysPliers or nose pliers for fine adjustmentsMeasuring tape and marker/chalk for accurate bend placementHand gloves and safety gear to protect from sharp edges and pinch points Steps for Making Vertical (Up/Down) BendsInspect and Prepare the Tray Check the tray for dents, cracks, or defects. Clean it to remove dirt or moisture to ensure accurate bending and prevent damage. Mark the Bend Location Measure and mark the exact point where the up or down bend is required.

Accurate marking ensures the bend aligns with your installation path. Cut if Necessary For wire mesh trays, use a bolt cutter to make cuts along the side walls where the bend will occur. This allows the tray to flex without deforming the mesh.

Bend the Tray

Wire Mesh Trays: Lift the marked section and bend it upward or downward manually or with pliers. Ensure the bend is smooth and consistent. Rubber caps can be used to protect cut ends.

Metal Trays: Use a cable tray bender or a sturdy metal bar. Place the tray in the bender, align the marked point, and apply steady pressure to achieve the desired vertical angle. For small adjustments, manual lifting with leverage can work.

Check the Angle and Smooth the Bend Ensure the bend is at the correct angle (commonly 90°) and that the tray edges are smooth to prevent cable damage. Adjust with pliers if necessary. Secure the Tray After bending, fasten the tray to supports using splice plates, bolts, or riser links as required.

Always install riser links in pairs for stability.

Tips

Always bend slowly to avoid cracking or deforming the tray. For complex installations, consider making a mock-up bend on a scrap piece first. Wire mesh trays are more flexible and allow on-site modifications without pre-made fittings, making them ideal for custom up/down bends.

By following these steps, you can safely and efficiently create vertical bends in cable trays, ensuring proper cable routing and structural integrity.