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Cable Festoon System vs. Cable Carrier

igus® alternative to a cable festoon system

On cable festoon systems, cables hang free and loose, exposed to the wind and weather. Unprotected, they can swing freely and become tangled, leading to costly maintenance efforts. Cable festoon systems typically require regular maintenance operations to lubricate the cable trolleys, and long travels can require motor and control systems. igus® offers a secure and modular alternative that allows you to save cables and avoid downtime.  e-chain® cable carriers are ideal for industries such as port and terminal cranes, oil and gas and shorepower, as well as various applications for cranes  such as bulkhandling cranes, ASC cranes, STS cranes, RTG/RMG cranes, and indoor cranes. Browse all crane applications.

Advantages of e-chain® systems

  • Essentially maintenance free operation
  • Decreased mechanical stress on cables
  • No additional motors or controls required for long travels
  • Roller chains  allow for a significant reduction in required drive force
  • Approx. 50% less cable length required
  • Cables are guided with a defined bending radius at all times
  • Guide trough secures system from wind effects
  • Easily add or replace cables as needed in the carrier
  • Trolley speeds of up to 32.8ft/s and travel distances of up to 2,600 ft
Contact an igus® expert now

White Paper:
Efficient energy supply systems for cranes in steel plants

Learn the advantages of e-chains® vs. cable festoon systems.

In this white paper, you can find the following topics:
  • Advantages and disadvantages of energy chain systems and cable festoon systems for steelworks cranes
  • The most innovative solution for cranes for steel plants
  • Future technologies: roller energy chains
Download cable festoon systems white paper
news 2022

What are the differences between e-chain® cable carriers and a cable festoon system?

Case Study: of a cable festoon system at a 100m plant

cable festoon system

Energy chain system

In the solution with cable carriers, the cables are fed into the e-chain® in the middle of the travel. The e-chain® is pushed or pulled to halfway.
cable festoon system

Cable festoon system

In a cable festoon system, the cables are attached at the end of the travel and the cable loops are pulled all the way by the cable trolley.

Energy chain system review

Cable lengths/space requirements

  • About 50% less cable
  • Approx. 800mm system height
  • About 10% less structural steel (cable festoon system)

Influencing the crane girder construction
No cable station required
Dynamic parameters
Rolling energy chains can be operated at a speed of over 600m/min and with an acceleration of over 2m/sec .
Secure cable guidance
Cables are safely guided in the energy chain and cannot get caught anywhere.

Cable festoon system review

Cable lengths/space requirements

  • Approx. 115m cable (115% travel length) for 100m travel
  • About 3,500mm length for the "cable loops"
  • System height approx. 5,000mm 

Influence on the crane girder construction
Cable festoon is required

Dynamic parameters
Cable festoon systems reach their limits at speeds of 240m/min. and accelerations of more than 0.8m/sec.2

Secure cable guidance
Cables hang uncontrollably and may get caught in the crane structure (e.g. by wind).
cable festoon system infographic
Cable Festoon System Infographic:

The Challenges of Cable Festoon Systems

Cable festoon systems have been a staple in crane operations for many years, but as demands for faster installation, increased flexibility, and improved technology have grown, the drawbacks of cable festoon systems have become apparent.


Alternative cable festoon system products

e-chain® festoon cable carriers

e-chains festoon cable carrier Recommended products:
  • P4HD - e-chain® with the longest service life
  • P4.1 - The universal e-chain®
  • Guide troughs - Long travel accessories
Shop all e-chains®

chainflex® festoon cables

chainflex® festoon cables Recomended Products
Shop all chainflex® cables

Sensors for crane festoon system

Sensors for crane festoon system Recomended Products
Shop all sensors for cranes

Replacement cable festoon system applications

See all crane applications

8 Common questions when considering a cable festoon system

  • 1) What are the drawbacks of a traditional cable festoon system?

    Traditional cable festoon systems can be prone to entanglement during operation, leading to downtime, and they require huge lengths of cable, taking up a great deal of space and needing protective cladding, which increases the mechanical stress on the cables

  • 2) How does a cable festoon system impact cable replacements?

    Cable festoon systems consume space on the crane rail, limiting the amount of crane travel that can be accomplished, and the structure makes cable replacement or addition a time-consuming process.

  • 3) Do unprotected cables in a festoon system create problems?

    Unprotected cables in festoon systems can swing, become tangled, and get caught in the crane structure, especially during harsh weather, leading to costly repairs and downtime.

  • 4) How does a cable festoon system compare in terms of cable length and space requirements?

    Cable festoon systems require approximately 115% of the travel length in cable, while energy chain systems require about 50% less cable, reducing mechanical stress and system weight.

  • 5) Are there limitations of a cable festoon system in harsh environments?

    Cable festoon systems have to be specially protected in harsh environments, increasing the total weight of the system and the steel structures required to bear the large cable lengths and the cable junction.

  • 6) How does a cable festoon system compare in cost of operation?

    Cable carriers can lead to lower operational costs and increased energy savings due to their energy-efficient design and reduced maintenance requirements. In contrast, cable festoon systems have limits with regard to energy efficiency and service life, requiring higher energy input and maintenance costs..

  • 7) How does a cable festoon system differ in maintenance or downtime?

    The low wear properties of cable carriers ensure a high service life and minimize maintenance requirements and downtime, while cable festoon systems have suboptimal wear behavior, increasing the need for maintenance and potentially causing system downtime in the long term.

  • 8) How does a cable festoon system impact service life of cranes?

    Cable carriers, made from tribologically optimized polymers, ensure a high service life and minimize maintenance requirements and downtime, providing a durable and low-cost solution for industrial crane systems. In contrast, cable festoon systems have proven to have limits with regard to energy efficiency and service life, requiring extensive protective cladding and being relatively heavy.


microflizz vs busbars
System Comparison:

Energy chain systems instead of busbar systems

Deliver data, energy, fluids and air safely in a single energy chain system. For narrow compact spaces and fast lane movement.


More crane technology information

chainflex® Flexible Cables in Stage Technology

10 tips for the crane industry

crane industry Brochure

Crane industry brochure

Orange Service

Engineering Services


Application Assistance

For further questions or product information, please contact:

Photo
Scott Parker

Sales and Product Manager, e-chain®

Email

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Monday to Friday from 8 am - 5 pm

Online:

24h


The terms "igus", "Apiro", "chainflex", "CFRIP", "conprotect", "CTD", "drylin", "dry-tech", "dryspin", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-skin", "e-spool", "flizz", "ibow", "igear", "iglidur", "igubal", "kineKIT", "manus", "motion plastics", "pikchain", "plastics for longer life", "readychain", "readycable", "ReBeL", "speedigus", "triflex", "robolink", "xirodur", and "xiros" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries.

igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsibushi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention in this website. The products offered by igus® are those of igus® GmbH