How to bend cable trays vertically

Vertical bends in cable trays are achieved using pre-fabricated fittings or by carefully forming the tray to change elevation while maintaining cable support and bend radius.

Overview

Vertical bends in cable tray systems allow cables to change elevation, such as moving from a ceiling to a lower level or transitioning between floors. These bends are essential for maintaining proper cable routing, avoiding sharp angles that can damage cables, and ensuring compliance with standards like DIN EN 61537 for cable support systems .

Methods for Vertical Bending

1. Pre-fabricated Vertical Bend Fittings
   • Most cable tray manufacturers provide vertical elbows or bends designed for specific tray types (ladder, solid-bottom, or mesh trays).
   • These fittings maintain a smooth bend radius, preventing cable stress and ensuring mechanical support .
   • They are available in standard angles (e.g., 30°, 45°, 60°, 90°) and can be combined for custom elevation changes.
2. Field Bending (Manual or Mechanical)
   • For certain tray types, especially mesh or wire basket trays, vertical bends can be formed on-site by cutting and reshaping side rails or wires to achieve the desired elevation change .
   • Care must be taken to maintain the minimum bend radius recommended for the cable type to prevent damage.
   • Tools such as bending jigs or mechanical benders are often used to ensure uniformity and reduce installation time.
3. Combination of Horizontal and Vertical Bends
   • In complex installations, vertical bends are often combined with horizontal bends to navigate around obstacles.
   • Proper alignment and support are critical to prevent sagging or uneven load distribution .

Installation Considerations

• Support Spacing: Vertical bends require adequate support at the start, end, and along the bend to prevent tray deformation and cable strain .
• Bend Radius: Always follow the manufacturer's recommended bend radius for the specific cable type to avoid insulation damage or signal interference .
• Material and Finish: Ensure the tray material (steel, stainless steel, or aluminum) and surface finish (galvanized, powder-coated) are suitable for the environment, especially in industrial or corrosive settings .
• Safety: Only trained personnel should perform bending operations, and pre-fabricated fittings are preferred for high-load or critical installations .

Practical Tips

• Use pre-fabricated vertical elbows whenever possible for speed and reliability.
• For wire mesh trays, cut and remove side wires carefully to form the bend without compromising structural integrity .
• Always secure the tray with clamps or brackets after bending to maintain alignment and load-bearing capacity .
• Plan the routing to minimize the number of vertical bends, reducing installation complexity and potential cable stress. By following these methods and considerations, vertical bends in cable trays can be executed safely, efficiently, and in compliance with industry standards, ensuring long-term reliability of cable installations.