Cable festoon systems carry electrical power and control signals to a hoist that travels along a beam. The most common type is the festoon system, in which flat cable hangs from trolleys that run inside a C-rail.
We send the model list and current prices for this category on WhatsApp. Tell us the load and the lifting height and we'll pick the right models with you.
Get a Quote on WhatsAppWhen a monorail hoist or an overhead crane is working, the trolley keeps moving along the beam. The cable that feeds the hoist has to follow this movement without sagging, tangling or getting crushed. A cable festoon system carries power and control signals safely along the whole line. The need is the same on monorail chain hoists and monorail wire rope hoists.
A C-rail is fitted beside or below the hoist beam. The cable hangs from cable trolleys that run on wheels inside this rail. As the towing trolley, which is connected to the hoist trolley, moves forward, the trolleys spread apart, and as it comes back they close up again, so the cable opens out and folds up like an accordion. A fixed end clamp at the start of the line holds the cable and takes the supply. Flat cable is used in most of these systems because it does not tangle when it folds and it stacks neatly. Some systems have a tension rope between the trolleys, so the pulling force is taken by the rope instead of the cable. Our range includes C-rail cable festoon systems and steel cable trolleys. The system is also known as a C-track festoon or a C-rail cable trolley system.
In a conductor bar system, a line of conductor bars runs along the beam. A current collector (carbon brush) on the trolley slides along the bars and picks up the power. In enclosed conductor bar systems, the conductors sit inside an insulating housing and are protected against contact. In open conductor bar systems the conductors are exposed, so they must be installed out of reach of people and in line with electrical safety rules. With conductor bars there is no cable stack at the end of the line. Our range also includes crane conductor bar systems and open conductor bar systems.
| Topic | C-rail festoon | Conductor bar |
|---|---|---|
| Line length | Economical for short and medium lines | Preferred for long lines |
| Curves and switches | Usually used on straight lines | Adapts more easily to curved lines |
| Space at the end of the line | Needs room for the cable stack | No extra space needed |
| Control signals | Several cables can travel in the same package | Needs extra conductors or a radio remote |
| Maintenance | Needs little maintenance | Current collectors wear and are replaced |
In short, on a straight, short monorail line a festoon system is usually enough and practical. As the line gets longer, or as curves and switches are added, a conductor bar system becomes the stronger choice.
Where the power line is fitted in relation to the beam is covered in our article on the monorail beam and installation. If the beam, the hoist and the power line will be planned together, see our monorail crane systems page.
The main factors that set the price are the line length, whether the system is a festoon or a conductor bar, the cable cross-section and number of cores, the number and type of trolleys, and the hangers and fittings. The power line is usually priced together with the beam length. Just send us the beam length, the motor power of the hoist and whether the line is straight or curved on WhatsApp.
A festoon is a system in which the hoist cable hangs from trolleys that run inside a C-rail. As the hoist moves forward the cable opens out in loops, and as it comes back the loops fold up again. It is widely used on short and medium-length straight lines.
The C-rail is fixed beside or below the hoist beam with mounting brackets. The bracket spacing depends on the weight of the C-rail and the cable package. The C-rail must be straight and parallel to the hoist beam, otherwise the trolleys will catch.
On short, straight lines a festoon is usually more economical. As the line gets longer or curves are added, a conductor bar system can be the better option. For an exact comparison, both options need to be calculated for your line length and the power the hoist needs.
The number of trolleys depends on the line length, how far the cable loops hang down and the spacing between trolleys. Send us the line length and the number of cables to be carried, and we will work out how many trolleys you need.
In an open conductor bar the conductors are bare, so there is a risk of contact. These systems must be installed out of reach of people and conductive materials, with earthing and protective devices, in line with electrical safety rules. On lines where people work nearby, an enclosed conductor bar or a festoon system is a better fit.
We explain what a monorail hoist is, how it works, its parts and types, and how to choose the right model, all in one place.
Read more: What Is a Monorail Hoist? Types, Parts and How to Choose One →Why can two monorail hoists with the same capacity have very different prices? We explain the eight factors that set the price and how to get the right quote.
Read more: Monorail Hoist Prices: 8 Factors That Determine the Price →A monorail hoist is only as safe as its beam. We explain how to choose the I-beam, the hanger types, curved beams and the installation steps.
Read more: Monorail Beam Systems: I-Beam Selection, Installation and Beam Length →The load, the lifting height and the beam length. Send them on WhatsApp or give us a call and we'll come back with a model and a price.
