When it comes to installing a wire mesh basket tray or a cable tray, mistakes can be costly, not just financially, but also in terms of time, safety, and long-term performance.  

So, what are the most common errors? Simply put poor planning, wrong product choices, neglecting support intervals, lack of accessories like tray bends and risers, and failing to follow standards.  

These slip ups may sound small, but they can cause big problems. 

Let’s take a closer look at how to avoid these cable containment catastrophes. 
 

Poor Planning from the Start 

Think of installing a cable tray like laying track for a train. If you don’t map the route properly, things go off the rails fast. One of the top mistakes is not planning the cable routing in advance. This can lead to awkward bends, uneven load distribution, and interference with other services. 

Quick fix: 

Use site drawings to plot routes early 

Account for future expansion and maintenance 

Coordinate with other trades before installation 

Choosing the Wrong Type of Tray 

Not all trays are created equal. Galvanised wire mesh tray might suit dry environments, but swap that into a damp plant room and you’ll be shopping for stainless steel in no time. And don’t even mention the chaos of using a light duty tray where a heavy-duty cable tray is needed unless you enjoy the sound of cable trays crashing at 2am. 

Get it right by considering: 

Environment (indoor, outdoor, corrosive, cleanroom) 

Load capacity 

Aesthetics (hello, powder coated cable tray in exposed areas) 
 

Skimping on Supports 

Cable trays are not magical floating structures. Failing to install enough supports or spacing them too far apart leads to sagging, instability, or worse. Check manufacturer guidelines for max span lengths and install accordingly. 

Rule of thumb: 

Support every 1.5 to 2 metres for most mesh trays 

Reduce spacing for heavier loads or high-traffic areas 

Ignoring Accessories and Safety 

Skipping out on essentials like tray dividers, tray bends and risers, or cable tray covers can compromise both performance and safety. Dividers prevent signal interference between power and data lines, while bends and risers ensure the route can follow the actual architecture of the site. Covers protect your precious cables from debris, dust or the occasional inquisitive rodent. 

Checklist of accessories worth including: 

Tray dividers for power/data separation 

Covers for hygiene or safety 

Risers, bends, tees for directional changes 

Earthing kits to meet regulations 

Not Following Standards and Best Practices 

The most preventable mistake? Cutting corners. Skipping compliance with cable management regulations or manufacturer instructions may speed up the install, but it’ll catch up to you later in the form of failed inspections or worse, system failures. 

Stay on track by: 

Referring to British Standards like BS EN 61537 

Following manufacturer's install instructions 

Documenting installations for sign-off and service 

 

 

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FAQs 

What’s the difference between a wire mesh basket tray and a solid-bottom cable tray? 

Wire mesh trays are lighter, easier to cut, and ideal for data cabling. Solid-bottom trays are better for heavy power cables or environments needing more protection. 

How do I know what size cable tray I need? 

Calculate the cross-sectional area of all the cables you’ll run, then add around 25–30% extra space for futureproofing. 

Can I mix stainless steel cable trays with galvanised ones? 

Not recommended. Different metals can cause galvanic corrosion when in contact stick to one material throughout your install. 

Are cable tray covers always necessary? 

Not always, but they're highly recommended in environments prone to dust, water ingress, or physical damage. 

Can I cut wire cable basket trays on-site? 

Yes, but always use the correct tools, deburr the edges, and reseal any protective coating if applicable.  

 

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Final Thoughts 

If you take away one thing, it’s this: a tidy looking install is useless if it fails six months later.  

Avoiding these common mistakes when installing cable tray systems or wire mesh baskets ensures your cable support solution is robust, compliant, and easy to maintain.  

And if you're ever tempted to skip a step just remember, even cable trays need a solid support system, just like us.