How to make reducers for mesh cable trays

Reducers for mesh cable trays can be made on-site by cutting and shaping straight tray sections or by using software families for automatic placement between different tray widths.

Field Fabrication of Reducers

Select the Tray Section: Use a straight section of wire mesh cable tray that matches the larger width of the two trays you want to connect. Cut the Tray: Use a bolt cutter, preferably an angular blade offset cutter with long handles, to cut the side and bottom wires of the tray. Position the blades perpendicular to the wire for a clean cut.

The cut edges can be protected with rubber caps to prevent injury and maintain corrosion protection. Shape the Reducer: Gradually bend the cut section to taper from the larger width to the smaller width. This can be done manually by forming the wires to the desired angle.

Assemble the Reducer: Connect the shaped reducer to the existing tray sections using splice bars, connectors, and clamps recommended for your mesh tray system. Ensure the reducer is securely fastened and aligned with the cable path. Check for Safety and Protection: Ensure all cut ends are deburred and capped to prevent damage to cables and reduce the risk of injury.

Software-

Based Reducers (Design Approach)For projects using Revit or similar CAD software, you can create a custom cable tray family that includes a reducer. This allows the reducer to be automatically placed when connecting trays of different widths: Create or Modify a Family: Set up a ladder or mesh cable tray family with multiple width options and define the reducer as a part type (e.g., "Ladder Multi Port"),. Automatic Placement: When two trays of different widths are connected in the project, the software will automatically insert the reducer between them, ensuring proper alignment and reducing manual adjustments.

Load and Test: Load the family into your project and verify that the reducer functions correctly when connecting trays of varying widths.

Tips for Efficient Reducer Fabrication

Always measure the required width reduction before cutting. Use protective gloves and eye protection when cutting and bending mesh trays. For complex angles or large reductions, consider pre-fabricating reducers in a workshop for better precision.

Ensure the reducer maintains proper ventilation and load capacity for the cables. By following these steps, you can create custom reducers for mesh cable trays either on-site or digitally, ensuring a safe, efficient, and professional cable management system.