Every overhead crane needs a way to deliver electrical power from a fixed supply to the moving crane or hoist. The two main options are festoon systems and conductor bar (busbar) systems – each with distinct advantages depending on your application, duty cycle, and environment. This guide compares both to help you make the right choice. Two Ways to Power a Travelling Crane When a crane travels along a runway, it needs continuous electrical power for the hoist, trolley, and bridge motors. Unlike stationary equipment, you can’t just plug it in – you need a system that moves with the crane while maintaining a reliable connection. Festoon System Cables suspended from trolleys that travel along a track. The cables extend and retract as the crane moves, carrying power and control signals through flexible conductors. Conductor Bar (Busbar) Rigid copper or steel bars mounted along the runway. Collector shoes attached to the crane slide along the bars, picking up power through continuous contact. Both systems do the same job – but they work very differently and suit different applications. How They Work Festoon System ══════════════ ◯ ─ ◯ ─ ◯ ─ ◯ ┃ ┃ ┃ ┃ CABLES Cables hang from moving trolleys Extends/retracts with crane travel Flexible cable conductors Conductor Bar ══════════════ ━━━━━━━━━━━━━━ ▼ COLLECTOR Rigid bars run full runway length Collector slides along bars Continuous sliding contact Festoon vs Conductor Bar: Quick Comparison Factor Festoon System Conductor Bar Initial cost Lower upfront cost Higher upfront cost Maintenance Cable replacement over time Lower ongoing maintenance Duty cycle Light to moderate duty High duty / continuous use Travel speed Moderate speeds (up to ~60m/min) Higher speeds possible (100m/min+) Travel distance Short to medium runs Long runs (virtually unlimited) Data/control signals Easy – cables carry power and data Separate system often needed Environment Good in dusty/dirty areas (enclosed track) Sensitive to contamination Safety Cables fully enclosed Finger-proof designs available Installation Quicker, simpler More complex alignment When to Use a Festoon System A festoon system is often the right choice when: Budget is a concern – festoon systems typically cost less to purchase and install than conductor bar systems. Travel distances are short to medium – festoon works well for runs up to around 50-80 metres, though longer is possible. Duty cycle is light to moderate – occasional use or intermittent operation, rather than continuous high-speed travel. You need to carry data and control cables – festoon can carry power, control signals, and data cables in one system. The environment is dusty or dirty – enclosed C-track festoon protects cables and trolleys from contamination. Quick installation is required – festoon is generally faster to install than conductor bar. Retrofit situations – easier to add to existing cranes without major modifications. Typical Festoon Applications Light to medium duty overhead cranes Monorail systems and hoists Gantry cranes with moderate travel Workshop and fabrication cranes Applications requiring data/network cables alongside power When to Use a Conductor Bar System A conductor bar (busbar) system is the better choice when: High duty cycle or continuous operation – conductor bars handle frequent, intensive use better than cables. Long travel distances – busbars can run the full length of a building with no practical limit. High travel speeds – conductor bars support faster crane travel without cable wear concerns. Multiple cranes on one runway – several cranes can draw power from the same conductor bar system. Minimising long-term maintenance – once installed, conductor bars require less ongoing attention than cables. High current requirements – conductor bars can carry higher amperages more efficiently. Clean, controlled environments – where contamination is minimal and bars can be kept clean. Typical Conductor Bar Applications High-duty production cranes Automated and semi-automated cranes Long runway installations Steel mills and heavy industry Multi-crane runways Process cranes with continuous operation Which System Do You Need? A Quick Decision Guide 1. What’s the travel distance? Under 50m → Either system works; Festoon often more economical Over 50m or very long → Conductor Bar usually preferred 2. What’s the duty cycle? Light / intermittent use → Festoon is well-suited High duty / continuous → Conductor Bar will last longer 3. Do you need to carry data/control cables? Yes – PLC, network, sensors → Festoon carries all cables together No – power only → Either system works 4. What’s the environment like? Dusty, dirty, outdoor → Festoon (enclosed C-track) protects better Clean, indoor, controlled → Conductor Bar performs well 5. What’s the budget priority? Lower upfront cost → Festoon is typically cheaper initially Lower lifetime cost → Conductor Bar may save on maintenance Safety Considerations Both systems can be designed for safe operation, but they have different safety characteristics: Festoon System Safety Cables are typically enclosed within the C-track or festoon housing, keeping them away from personnel. There’s no exposed live conductor – the power is contained within the cable insulation. Conductor Bar Safety Traditional open conductor bars have exposed live surfaces, which presents a risk of accidental contact. However, modern finger-proof (shrouded) conductor bar designs enclose the live conductors within a protective housing, allowing only the collector shoe to make contact. Colton Safe-T-Bar – Granada Cranes supplies the Colton Safe-T-Bar system, one of the oldest and safest finger-proof conductor systems on the market with over 40 years of proven performance. The shrouded design prevents accidental contact while maintaining reliable power delivery. The Colton Conductor Bar System When a conductor bar system is the right choice, Granada Cranes is the exclusive UK supplier of the Colton Downshop Conductor System – a proven, finger-proof busbar solution. Why Choose Colton? 40+ years of proven performance – one of the longest-established finger-proof systems Finger-proof safety design – shrouded bars prevent accidental contact Multiple configurations – available in 100A and 200A galvanised steel, plus 250A copper bar Cost-effective installation – 4.5m sections with supports every 2.25m (wider spacing than many competitors) Fast availability – complete systems within 2-3 days, spare parts same-day UK stock and support – parts held at our Oldbury depot for immediate collection or dispatch Learn more about the Colton Busbar System → Crane Electrification from Granada Cranes We supply and install both festoon and conductor bar systems – and can advise on which is right for your application: Festoon Systems C-track, I-beam, and wire rope festoon systems for cable management on travelling cranes. View Festoon Systems → Colton Conductor Bar Finger-proof busbar systems – exclusive to Granada Cranes. Fast UK supply and installation. View Colton System → Not sure which system suits your crane? Contact us with your application details – runway length, duty cycle, environment, and any special requirements – and we’ll recommend the right solution. Summary Choose Festoon if: Travel distance is under 50m Duty cycle is light to moderate You need to carry data cables Environment is dusty or dirty Budget is constrained Quick installation is needed Choose Conductor Bar if: Travel distance is long Duty cycle is high/continuous High travel speeds required Multiple cranes share runway Lower long-term maintenance preferred Environment is clean Need Help Choosing? Tell us about your crane and application. We’ll recommend the right power delivery system and provide a competitive quote for supply and installation. Get Expert Advice Or call: 0800 376 27 27
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