Flat Crane Cable

A flat crane cable supplies power and control to moving machinery where round cable would tangle or occupy too much headroom: crane trolleys, hoist systems, rail mounted gantry cranes, dock levelers and automated storage equipment. The flat geometry keeps multiple conductors side by side in a single compact strip that flexes in one plane, travels smoothly over sheaves and rollers, and stacks neatly on reels. This page explains the construction, the duty requirements and how to match a flat cable to your crane system.

Product Overview

Flat crane cable, also called traveling flat cable or flat festoon cable, is the standard energy supply for crane festoon systems and trolley-mounted equipment. Instead of hanging in loops like round festoon cable, the flat version runs over a series of small sheaves or rides in C-track, taking bending in one direction only — which is exactly what its construction is optimized for.

Typical constructions use flexible class 5 stranded copper conductors (tinned options), EPR or high grade PVC insulation in colored cores with a yellow-green earth core, cores laid parallel under a common extruded sheath, and an outer jacket of oil resistant, weather resistant compound. Standard configurations range from 4 to 24 cores in sizes from 1.0mm2 to 16mm2, for example 4x6, 4x10, 5x4, 7x2.5, 12x1.5 and 16x1.0, with integrated steel or fiber support elements available for vertical hanging duty. Voltage ratings commonly specified are 300/500V and 450/750V, with 0.6/1kV on request. Exact configurations are confirmed per project against the crane manual.

Key Features / Construction

• Flexible class 5 stranded copper conductor, IEC 60228 class 5, tinned options for humid environments

• Insulation: EPR for heat and flexibility, or heat resistant PVC for economical duty, colored cores with yellow-green earth

• Parallel core layout in flat geometry for single-plane bending over sheaves and in C-track

• Optional integrated steel wire or aramid support element for vertical hanging applications

• Outer sheath: oil resistant, weather resistant compound, black or grey, low temperature flexibility options

• Optional individual screens for control and signal pairs where interference must be controlled

• Small bending radius relative to round cable of equivalent capacity, typically 10 times cable height for repeated flexing

• Flame retardant constructions available for indoor electrical rooms and galleries

Electrical and mechanical data reflect commonly specified values for this family. Your project's exact core layout, voltage and support requirements are confirmed on the type TDS before order.

Standards & Certifications

• Conductors per IEC 60228 (class 5 flexible)

• Design practice aligned with IEC 60245 and VDE 0298 for flexible rubber cables, adapted to flat traveling duty

• Flame retardant options per IEC 60332 family where the zone requires

• Project-specific tests: repeated bending over sheaves, torsion, low temperature flexing and oil immersion per specification

Where the flat cable feeds shipboard or offshore equipment, class society documentation applies — confirm the requirement per project. Refer to the Certifications page or contact us with your crane and class details.

Applications

• Overhead crane and gantry crane trolley power and control supply

• Hoists, winches and lifting equipment with C-track or roller festoon systems

• RTG and RMG yard cranes on flat festoon trolleys

• Automated warehouses, stacker cranes and material handling systems

• Dock levelers, scissor lifts and stage equipment

• Vertical hanging supply for ports and workshops using reinforced versions

Why Choose Anhui Tiankang

• Flat-duty engineering. Core spacing, sheath hardness and support elements are tuned for one-plane bending over sheaves — not a round cable pressed flat.

• System-matched selection. Send the C-track or sheave dimensions and we confirm cable width, thickness and minimum bend radius before quoting.

• Compound options. Oil resistant PVC for workshops, EPR sheath for outdoor port duty, cold-flexible versions for unheated yards — recommended per your environment.

• Complete festoon range. Flat crane cable, round festoon cable and spreader cable from one manufacturer, so mixed systems match mechanically.

• Documented supply. TDS, routine test reports and cut-length or reel packing plans accompany each shipment.

Selection Guide / Buying Considerations

1. Confirm the movement system: C-track with rollers, free hanging with support element, or reel winding — each sets different mechanical requirements.
2. State voltage and function — 300/500V or 450/750V — plus core layout, e.g. 4x10, 5x4, 7x2.5, 12x1.5, or power plus control pairs in one flat.
3. Measure the sheave diameter and C-track width: the cable height and minimum bend radius must fit the smallest roller.
4. Describe the environment: oil splash, outdoor UV, temperature range, and vertical hanging length if applicable.
5. Confirm support requirement: free hanging spans generally need an integrated steel or aramid element.
6. Provide quantity, preferred cut lengths and destination port.

Photos of the existing installation and the C-track cross-section are enough for a first accurate quotation.

FAQ

Q1: Flat cable or round festoon cable — which do I need?
C-track and roller systems use flat cable; free-loop festoon systems traditionally use round cable, though flat versions also run in loops. The deciding factor is your trolley hardware — send a photo and we confirm.

Q2: What bending radius should I design for?
For repeated flexing over sheaves, plan around 10 times the cable height for this family, subject to construction. Sheave diameter and roller spacing define the real limit — share the dimensions and we verify fit.

Q3: Can flat crane cable hang vertically?
Yes, with an integrated support element carrying the weight — specify free hanging length and we include steel or aramid reinforcement rated for the load.

Q4: What is the difference between flat crane cable and spreader cable?
Spreader cable is a heavier duty flat type built for container spreader reeling with higher mechanical stress and often fiber integration. For standard crane trolleys, flat crane cable is the right choice — we flag the upgrade path if your duty demands it.

Q5: What information do you need to quote?
Crane type, voltage and core layout, C-track or sheave dimensions, hanging length if vertical, environmental conditions and quantity. Use the contact page to send photos of the existing installation.

Contact / Request a Quote

Send your crane data, C-track drawings or photos of the existing cable through the contact page. We will confirm the flat construction, support element and bend radius for your system, and return a quotation with delivery plans. For system level selection see our port crane and bulk handling cable solutions and the Flat & Festoon Cables range.