IMPORTANT: Failure to follow these 10 instructions can result in permanent cable damage, project delays, or serious physical injury. --- 1. Keep Drums Upright Drums must be handled and stored only in the upright position, resting on their flanges. Never lay a drum flat on its side, as this causes cable wraps to shift and tangle. On unstable ground, or as local requirements dictate, "chock" drums with wedges to prevent unwanted or dangerous movement.
2. Use Proper Lifting Gear When unloading or moving drums, use only mechanical lifting gear such as a forklift or crane. Ensure the equipment's load capacity exceeds the weight of the drum.
The forklift tynes must be longer than the total width of the drum to ensure they pass fully under both flanges. Approach the drum from the flange side (at 90° to the flanges). Never attempt to lift a drum by the "laggings" (the wood between the flanges) or by only one flange, as this can cause the drum to collapse or break away from the barrel.Once lifted, tilt the mast back slightly so the drum remains secure in the forks. Keep the load 15–20 cm above the ground to avoid dragging the flanges on uneven surfaces. 3. Rolling Direction Drums are permitted to be rolled for short distances only, provided the ground is smooth and free of impediments. Rolling must occur only in the direction of the arrow painted on the flanges to maintain the tension of the cable winding.
Note: The arrow indicates the drum rolling direction for transport and storage; it is not the cable pulling direction.
4. Fastening for Transport Drums must be transported only in the upright position. They must be secured firmly with wedges to prevent rolling during transit; these wedges must be positioned at the flanges' edges and never between the flanges. The use of stones or irregular debris as chocks is strictly forbidden.
For heavy or specialized loads, binding must be made with ropes or straps passing through the central spindle hole and, where necessary, over the drum flanges. Binding with ropes that only cross the drum's laggings is strictly forbidden. Drums should be supported by wedges.
5. Never Drop Drums When unloading from vehicles (trucks, ships, rail cars or other transport), correct lifting gear such as a forklift or crane must always be used. Never drop drums, even from a small height.
The impact from dropping can cause immediate structural damage to the drum flanges and internal displacement of the cable wraps. This leads to defects that may not be visible until the cable is installed, potentially resulting in optical failure or performance issues. Always ensure that any lifting device used is operated only by authorized personnel and never exceeds its permitted weight capacity.
6. Hardware Safety On some cables, lagging (wood between the flanges) is nailed or strapped to the drum flange for protection during transport. Exercise extreme caution regarding the nails and steel strapping used on lagging, as these can cause significant injury to personnel or cause deep gouges in the cable jacket during the paying-off process. Always inspect the drum surface for any protruding hardware before handling, including the inside of the flanges to ensure that no nails are present.
7. Release the Inner-End Before beginning any pulling operation, inner end of the cable—which is typically secured through a hole in the drum flange—must be released so it is completely free. You must remove any steel protection covers, ropes, or nails located near the exit point to ensure there are no obstructions that could snag the cable as the drum rotates.
As the cable is paid out and the drum diameter decreases, the inner end may move due to shifting tension; it should be monitored and re-secured at intervals during the pull to prevent it from flapping or catching on the drum stand. More cable will be released as the pull continues, and failure to free this end can cause the cable to kink or result in a "cable make" defect where the cable is crushed against the drum barrel, which can jam the cable and prevent further de-reeling.
8. Coiling Technique When it is necessary to lay cable slack on the ground during installation or for temporary storage, always utilize a Figure-8 coiling pattern. This specific technique is essential because it neutralizes the mechanical stresses within the cable; for every loop made in one direction, the next loop is made in the opposite direction, effectively preventing the accumulation of torsional forces.
You must never use direct circular loops. Simple circular coiling introduces a full 360° twist into the cable for every single turn, which inevitably leads to severe kinking, twisting of the cable, and permanent damage to the internal elements as the cable is pulled straight again. Proper Figure-8 coiling ensures the cable remains in its original manufactured state, allowing it to be pulled effortlessly and without defect during the final installation phase.
9. Moisture Protection All cable ends must be fully sealed with waterproof end caps at all times to prevent the ingress of water, as moisture can lead to premature cable failure. If a cable is cut during installation, the exposed end should be resealed immediately to maintain the integrity of the cable.
Drums should not be stored in areas liable to flooding; it is preferable to store reels off the ground on timbers or other supports to avoid direct contact with damp surfaces. In humid or damp locations, it is advisable to allow at least 3 inches of space between reels to permit the circulation of air, which helps prevent condensation and rot on wooden flanges. For long-term storage, drums must be moved to an indoor area with a climate control system to protect the cable from environmental degradation.
10. Technical Limits Adhering to the physical limits of the cable is mandatory to ensure it functions with full performance and the longest possible duration. You must never exceed the minimum bending radius or the maximum allowed pulling tension specified for the specific cable type.
The minimum bending radius during installation should typically be equal to or greater than 15 times the outer diameter of the cable, or as otherwise noted on the datasheet. Bending a cable more sharply than this limit can cause permanent structural damage to the internal cable elements. Similarly, exceeding the maximum allowed pulling force can stretch the internal components beyond their elastic limit, leading to defects that may cause the cable to fail immediately or shortly after being installed.