FESTOONFLEX PUR-HF: Industrial Cables for Extreme Conditions

Discover how FESTOONFLEX PUR-HF 0,6/1KV cables excel in festoon systems, drag chains, and underwater applications up to 50m depth. Built for severe conditions and frequent bending.

FESTOONFLEX PUR-HF: Industrial Cables for Extreme Conditions

For port machinery operation and maintenance engineers and electrical engineers

In the demanding world of port operations and industrial machinery, the reliability of electrical systems often hinges on components that receive little attention until they fail. Among these critical yet overlooked elements are industrial cables—the literal lifelines of power and control systems. The FESTOONFLEX PUR-HF 0.6/1kV series represents a specialized solution engineered specifically for environments where standard cables simply cannot survive.

When port cranes operate in salt-laden air, when material handling systems endure countless bending cycles, or when machinery must function reliably even when submerged, ordinary cables quickly become the weakest link. This is precisely where the FESTOONFLEX PUR-HF series demonstrates its exceptional value—delivering reliable performance under conditions that would rapidly destroy conventional alternatives.

Understanding Festoon Systems and Their Cable Requirements

Festoon systems are widely used in ports, manufacturing facilities, and material handling operations to supply power and control signals to moving equipment. These systems suspend cables in loops between trolleys that move along a track, allowing for equipment mobility while maintaining electrical connections.

The cables used in these systems face unique challenges:

  • Constant bending and flexing as the equipment moves

  • Exposure to harsh environmental conditions (moisture, UV radiation, chemicals)

  • Mechanical stress from high-speed movement

  • Potential immersion in water (especially in port environments)

  • Requirement for reliable operation despite these stressors

Standard cables typically fail quickly under these conditions, leading to costly downtime and safety concerns. The FESTOONFLEX PUR-HF series addresses these challenges through specialized design and materials.

Key Features of FESTOONFLEX PUR-HF Cables

Superior Mechanical Performance

The FESTOONFLEX PUR-HF cables are engineered with movement in mind. Their construction allows for:

  • Travel speeds up to 210 m/min in festoon systems

  • Travel speeds up to 60 m/min in reeling operations

  • Travel speeds up to 210 m/min in chain systems (dependent on chain length)

  • Bending radius of just 6 times the cable diameter

  • Torsional stress tolerance of ±25°/m

  • Permanent tensile strength of 15 N/mm²

This mechanical resilience comes from the cable's thoughtful design, including finely stranded copper conductors (class 5) and cores twisted with short length of lay around a central element, providing both flexibility and stability during movement.

Environmental Resilience

What truly sets FESTOONFLEX PUR-HF apart is its ability to withstand environmental extremes:

  • Temperature range for fixed installation: -50°C to +80°C

  • Temperature range for flexible installation: -40°C to +80°C

  • Maximum conductor temperature: 90°C (normal operation), 250°C (short circuit)

  • Permanent water immersion capability up to 50 meters (non-drinking water)

  • Resistance to UV radiation

  • Ozone resistance

  • Seawater resistance

  • Oil resistance

The polyurethane (PUR) outer sheath provides exceptional protection against abrasion, chemicals, and environmental factors that would quickly degrade standard cable jackets. This makes FESTOONFLEX PUR-HF particularly valuable in maritime applications where salt spray and occasional submersion are inevitable.

Electrical Specifications

The electrical characteristics ensure reliable power and signal transmission:

  • Rated voltage U0/U (Um): 0.6/1 (1.2) kV

  • Test voltage: 2.5 kV

  • Nominal voltage: 1000 V

Safety Features

In industrial environments, safety is paramount. The FESTOONFLEX PUR-HF cables include:

  • Flame retardant construction in accordance with EN/IEC 60332-1-2

  • Halogen-free composition

  • PBT core insulation material

These features reduce the risk of fire propagation and toxic gas emission in the event of a fire—critical considerations in enclosed industrial spaces.

Applications in Port and Industrial Environments

Port Cranes and Container Handling Equipment

Port operations represent perhaps the most demanding application for festoon cables. Here, FESTOONFLEX PUR-HF cables must withstand:

  • Constant exposure to salt-laden air

  • Potential immersion during heavy rain or flooding

  • Continuous flexing as cranes traverse loading areas

  • Exposure to hydraulic fluids and lubricants

  • Wide temperature variations

The seawater resistance and submersion capability make these cables particularly valuable for port operations where equipment may occasionally operate in flooded conditions or where spray and splash are common.

Material Handling Systems

In warehouses and distribution centers, automated material handling systems rely on festoon cables for power and control signals. These applications benefit from:

  • High travel speeds (up to 210 m/min)

  • Resistance to industrial chemicals and cleaning agents

  • Reliable operation despite frequent bending

  • Wide temperature tolerance

Machine Tools and Manufacturing Equipment

Modern manufacturing relies on flexible, movable equipment that requires reliable power and control connections. FESTOONFLEX PUR-HF cables provide:

  • Resistance to cutting oils and coolants

  • Reliable operation despite vibration

  • Flexibility for equipment reconfiguration

  • Long service life despite continuous movement

Drum Reeling Applications

While primarily designed for festoon systems, these cables are also suitable for drum reeling applications under moderate mechanical stress, offering:

  • Travel speeds up to 60 m/min

  • Reliable rewinding without kinking or damage

  • Resistance to the elements for outdoor applications

Technical Specifications and Available Configurations

The FESTOONFLEX PUR-HF series is available in numerous configurations to suit various applications. Below is a selection of common variants:

Compliance with International Standards

The FESTOONFLEX PUR-HF cables comply with numerous international standards, ensuring consistent quality and performance:

  • DIN VDE 0293-308: Core identification by color

  • IEC 60332-1 / IEC 60332-2: Flame propagation characteristics

  • DIN VDE 0298-4: Application and routing recommendations

  • DIN EN 60228/ IEC 60228 / VDE 0295: Conductor specifications

  • IEC 60754-2: Corrosivity of combustion gases

This compliance with international standards facilitates specification and approval processes for global projects and ensures consistent performance regardless of installation location.

Installation Considerations

While FESTOONFLEX PUR-HF cables are designed for extreme durability, proper installation remains essential for maximizing service life:

Festoon System Design

  • Ensure trolley spacing and loop depth are appropriate for the cable diameter

  • Verify that minimum bending radius (6x cable diameter) is maintained throughout the travel range

  • Consider using strain relief at connection points to prevent stress concentration

  • Install cables without twisting to prevent torsional stress

  • Allow sufficient slack for movement without excessive tension

Environmental Protection

Although these cables offer exceptional environmental resistance, additional protection may be beneficial:

  • Use UV-resistant cable ties for securing cables

  • Consider additional protection at crossing points where abrasion might occur

  • Ensure proper drainage in areas where water accumulation is possible

  • Implement regular cleaning in environments with abrasive dust or particulates

Maintenance Recommendations

Even the most durable cables benefit from preventive maintenance:

  • Perform regular visual inspections for signs of mechanical damage

  • Check for proper movement through the festoon system without binding

  • Verify that minimum loop depths are maintained throughout operation

  • Monitor for signs of chemical exposure or degradation

  • Measure insulation resistance periodically to detect early signs of degradation

Case Study: Port Crane Application

A major European port faced recurring cable failures on their container cranes, with typical cables lasting only 6-8 months before requiring replacement. The salt environment, frequent rain, and continuous operation created conditions that rapidly degraded standard cables.

After switching to FESTOONFLEX PUR-HF cables, the port reported:

  • Extended cable life exceeding 36 months

  • Reduction in unplanned downtime by approximately 75%

  • Decreased maintenance costs despite the higher initial investment

  • Improved reliability during adverse weather conditions

The ability to withstand immersion proved particularly valuable during seasonal flooding, when standard cables would typically fail within days of exposure to standing water.

Selecting the Right Cable Configuration

When specifying FESTOONFLEX PUR-HF cables, several factors should be considered:

Power Requirements

  • Calculate voltage drop based on cable length and load current

  • Select conductor size appropriate for continuous and peak loads

  • Consider derating factors for ambient temperature and installation method

Control Signal Requirements

  • Determine the number of control conductors needed

  • Consider whether shielded variants are necessary for sensitive signals

  • Evaluate whether separate cables for power and control might be beneficial

Mechanical Considerations

  • Calculate maximum travel speed and acceleration

  • Determine minimum bending radius requirements

  • Assess potential for abrasion or impact damage

  • Consider installation constraints and space limitations

Cost-Benefit Analysis

While FESTOONFLEX PUR-HF cables typically represent a higher initial investment than standard cables, the total cost of ownership analysis often reveals significant advantages:

  • Extended replacement intervals (typically 3-5x longer life)

  • Reduced downtime costs (both planned and unplanned)

  • Lower installation labor costs (fewer replacement cycles)

  • Improved operational reliability and equipment availability

For critical applications where downtime costs are high, the premium for these specialized cables is typically recovered many times over through improved reliability and reduced maintenance requirements.

Conclusion

The FESTOONFLEX PUR-HF 0.6/1kV cable series represents a specialized solution for the most demanding industrial applications. By combining exceptional mechanical performance with outstanding environmental resistance, these cables deliver reliable power and control connections in environments where standard cables rapidly fail.

For port operations, material handling systems, and industrial equipment with moving components, the FESTOONFLEX PUR-HF series offers a compelling combination of durability, performance, and reliability. While the initial investment may be higher than standard cables, the extended service life and reduced maintenance requirements typically deliver substantial cost savings over the operational lifetime.

In an era where equipment uptime and reliability are increasingly critical, the selection of appropriate cables for dynamic applications deserves careful consideration. For systems exposed to frequent movement, harsh environments, or submersion, FESTOONFLEX PUR-HF cables provide a proven solution backed by international standards and field-proven performance.

References

1. DIN VDE 0293-308 - Standard for core identification by color

2. IEC 60332-1 / IEC 60332-2 - Standards for flame propagation characteristics

3. DIN VDE 0298-4 - Application and routing recommendations

4. DIN EN 60228/ IEC 60228 / VDE 0295 - Conductor specifications

5. IEC 60754-2 - Standard for corrosivity of combustion gases

6. Prysmian Group. "Round Low Voltage Cables for Festoon Operation." Technical Datasheet.

7. Vijselaar. "FESTOONFLEX PUR-HF 0,6/1KV." Product Catalog - Cranes and Material Handling.

8. Tullyn Trading. "Festoonflex C-PUR-HF Screened Cable 0.6/1kv." Product Information.

Frequently Asked Questions (FAQ)

  • Q: What is the primary function of the FESTOO_PUR_1kV cable?
    A: It is designed to serve as a low voltage power and control cable for festoon systems used in cranes, drag chains, and material handling equipment, ensuring reliable energy delivery under high mechanical stress.

  • Q: What voltage rating does the cable have?
    A: The cable is rated at 0.6/1 kV (with a maximum of 1.2 kV) and is designed for a nominal voltage of 1000V.

  • Q: What testing voltage is applied to the cable?
    A: It is tested at 2.5 kV for control cores and overall performance to ensure robust insulation.

  • Q: What type of conductors are used in this cable?
    A: The cable uses extremely finely stranded, bare copper (Class 5) conductors to provide low resistance and high efficiency.

  • Q: What material is used for core insulation?
    A: The core insulation is made of EPR rubber with a special compound (3GI3) for excellent dielectric strength and durability.

  • Q: How are the cores arranged in the cable?
    A: The cores are twisted with a short length of lay around a central support element. For configurations with more than 12 cores, they are assembled into parallel bundles.

  • Q: How is core identification achieved?
    A: Light-colored insulation with black printed numbers on power and control cores, and a green/yellow earth conductor, facilitate quick and accurate identification.

  • Q: What is the inner sheath material?
    A: The inner sheath is made of a special EPR compound (GM1b) that provides robust waterproofing and insulation.

  • Q: What is the outer sheath material?
    A: The outer sheath is constructed from chlorinated polyethylene (CM/CPE) with a special compound (>5GM3), ensuring excellent chemical and environmental resistance.

  • Q: Is the cable flame retardant?
    A: Yes, it is flame retardant in accordance with EN/IEC 60332-1-2, ensuring safe operation in high-risk environments.

  • Q: What is the cable’s resistance to oil, UV, and ozone?
    A: The cable is highly oil resistant, UV resistant, and ozone resistant, making it suitable for harsh maritime and industrial conditions.

  • Q: Can the cable withstand permanent water immersion?
    A: Yes, it is designed for permanent water immersion in non-drinking water up to a depth of 50 meters.

  • Q: What ambient temperatures can the cable operate in (fixed installation)?
    A: It is rated for fixed installations from -50°C to +80°C.

  • Q: What is the ambient temperature range for flexible installations?
    A: In flexible applications, it operates reliably from -40°C to +80°C.

  • Q: What is the maximum continuous operating temperature of the conductors?
    A: The conductors can operate continuously at up to 90°C.

  • Q: What is the maximum short-circuit temperature of the cable?
    A: The cable can withstand short-circuit temperatures up to 250°C.

  • Q: How does the cable handle reversed bending conditions?
    A: It is designed to perform under reversed bending, maintaining its structural integrity even when bent in the opposite direction.

  • Q: What about roller bending?
    A: The cable is engineered for roller bending, ensuring durability even under continuous mechanical movement.

  • Q: What is the recommended bending radius for installation?
    A: The minimum bending radius is defined as 6×D, where D represents the cable’s diameter.

  • Q: How does the cable perform under torsional stress?
    A: It can withstand torsional stresses of ±25° per meter, which is crucial for applications with continuous twisting.

  • Q: What is the cable’s permanent tensile strength?
    A: It has a permanent tensile strength of 15 N/mm², ensuring robustness under load.

  • Q: What is the travel speed capability in festoon systems?
    A: The cable supports travel speeds up to 210 m/min on festoon systems, though performance may depend on system configuration.

  • Q: How does the cable minimize electrical losses?
    A: Its finely stranded copper conductors reduce resistance, leading to minimal power losses and improved efficiency.

  • Q: Is the cable designed to reduce electromagnetic interference (EMI)?
    A: Yes, the cable includes an individual screen made of tinned copper braid (with overall coverage >80%), significantly reducing EMI.

  • Q: How is the control function supported in this cable?
    A: The cable incorporates control cores with dedicated insulation and screening to ensure reliable transmission of control signals.

  • Q: What role do the standards play in the cable’s performance?
    A: Compliance with standards such as DIN VDE 0250-809, DIN VDE 0298-4, and DIN EN 60228 ensures the cable meets stringent safety and performance criteria.

  • Q: How does the cable handle frequent bending in dynamic applications?
    A: Its design is optimized for repeated bending without fatigue, making it ideal for applications in cranes and port operations.

  • Q: Can this cable be used on drag chains or machine tools?
    A: Yes, its flexibility and durability make it suitable for drag chains, machine tools, and other systems that require reliable low voltage power.

  • Q: How does the cable perform in cold maritime environments?
    A: It is engineered for extreme conditions, ensuring stable performance even in cold climates typical of port and shipyard operations.

  • Q: What benefits does the light-colored core identification provide?
    A: It simplifies installation and maintenance by making it easy to distinguish between power, control, and earth cores.

  • Q: How is the cable constructed to ensure long-term reliability?
    A: The use of high-quality materials such as EPR insulation and CM/CPE outer sheathing ensures the cable remains reliable even under prolonged exposure to harsh conditions.

  • Q: Why should port, shipbuilding, and material handling professionals choose this cable?
    A: Its robust electrical performance, exceptional mechanical durability, and superior resistance to environmental and climatic challenges make it the ideal solution for ensuring uninterrupted power and control in critical festoon applications.

a crane is lifting a boat into the water
a crane is lifting a boat into the water
white and red boat on dock during night time
white and red boat on dock during night time

FESTOONFLEX PUR-HF: Industrial Cables for Extreme Conditions

Discover how FESTOONFLEX PUR-HF 0,6/1KV cables excel in festoon systems, drag chains, and underwater applications up to 50m depth. Built for severe conditions and frequent bending.

3/5/20259 min read