Cable festoon systems for reliable power and control cable management on travelling cranes, hoists, and material handling equipment. Protect your cables, ensure uninterrupted power supply, and extend cable life with properly designed festoon systems.
What Are Festoon Systems?
Festoon systems are cable management solutions that carry power and control cables along the travel path of moving equipment such as overhead cranes, hoists, and trolleys. The cables are suspended from a series of trolleys that move along a track, allowing the cables to extend and retract smoothly as the equipment travels.
Without proper cable management, trailing cables can become tangled, damaged, or create safety hazards. Festoon systems keep cables organised, protected, and out of the way while ensuring reliable power and signal transmission.
Reliable Power
Continuous, uninterrupted power supply to moving cranes and hoists throughout their travel.
Cable Protection
Prevents cable damage from dragging, tangling, abrasion, and environmental factors.
Extended Life
Properly supported cables last significantly longer than unsupported trailing cables.
Improved Safety
Eliminates trip hazards and keeps cables clear of personnel and equipment.
Types of Load Limiter
We supply and install load limiting systems to suit different crane types, capacities, and requirements.
C-Track Festoon Systems
The most common type of festoon system, using an enclosed C-shaped track that protects cables and trolleys from dust, debris, and the environment.
- Enclosed track protects cables
- Smooth, quiet operation
- Suitable for indoor and outdoor use
- Available in steel or plastic
- Multiple cable capacity
I-Beam Festoon Systems
Heavy-duty systems using standard I-beam as the track. Ideal for demanding industrial environments and heavy cable loads.
- Heavy-duty construction
- High cable capacity
- Long travel distances
- Uses standard I-beam sections
- Robust trolley designs
Wire Rope Festoon Systems
Economical solution using a tensioned wire rope as the support. Suitable for lighter cable loads and shorter travel distances.
- Cost-effective option
- Quick and easy installation
- Lightweight construction
- Ideal for lighter applications
- Adjustable rope tension
Motorised Festoon Systems
Power-driven systems that actively manage cable position for very long travel distances or complex multi-axis movement.
- Powered cable tensioning
- Very long travel distances
- Prevents cable slack
- Controlled cable payout
- For specialist applications
What We Provide
Track
The rail or support along which the cable trolleys travel. Available in C-track, I-beam, or wire rope configurations depending on application.
Cable Trolleys
Rolling carriers that support the cables and travel along the track. Available in various sizes for different cable capacities.
Tow Arms & Brackets
Connect the cable trolleys together and to the moving equipment, ensuring they travel in sync with the crane or hoist.
End Stops & Tensioners
Prevent trolleys from leaving the track and maintain proper cable tension throughout the system.
Cable Saddles & Clamps
Secure the cables to the trolleys while allowing for thermal expansion and minor movement.
Mounting Hardware
Brackets, hangers, and fixings to secure the track to the building structure or crane runway.
Applications
Festoon systems are used wherever electrical power or control signals need to be delivered to moving equipment.
Overhead travelling cranes
Gantry cranes
Monorail systems
Electric hoists
Transfer cars
Stacker cranes
Automated systems
Theatre & stage equipment
Power vs Control Cables
Festoon systems can carry:
Power cables – Main electrical supply to crane motors
Control cables – Signals for pendant or remote control
Data cables – For sensors, PLCs, and automation
Pneumatic hoses – Compressed air for tools or actuators
Festoon vs Conductor Bar Systems
Festoon systems are one of two main methods for delivering power to travelling cranes. The alternative is a conductor bar (busbar) system. Both have their place depending on the application.
| Factor | Festoon System | Conductor Bar |
|---|---|---|
| Initial Cost | Lower upfront cost | Higher upfront cost |
| Maintenance | Cable replacement over time | Lower ongoing maintenance |
| Duty Cycle | Better for lower duty cycles | Better for high duty / continuous use |
| Travel Speed | Moderate speeds | Higher speeds possible |
| Travel Distance | Short to medium runs | Long runs |
| Data/Control | Easy to include data cables | Separate system needed |
| Environment | Good in dusty/dirty areas (enclosed track) | Sensitive to contamination |
Not Sure Which You Need?
We can assess your application and recommend the most suitable power delivery method. For conductor bar systems, see our Busbar Systems page.
What We Provide
System Design
We design festoon systems to suit your crane, travel distance, cable requirements, and environment.
Supply
Complete festoon systems or individual components from quality manufacturers.
Installation
Professional installation by our experienced engineers, whether new build or retrofit.
Replacement
Upgrade or replace worn festoon systems to restore reliable cable management.
Repairs
Repair and maintenance of existing festoon systems, including cable replacement.
Spare Parts
Trolleys, saddles, end stops, and other components for system maintenance.
Need a Festoon System?
Whether you need a new festoon system designed and installed, or replacement parts for an existing system, we can help.
Or call us: 0800 376 27 27
