Volt Cable - Packaging, Transportation, Storage, and Installation Guideline

Introduction

Cable reels require the utmost care and attention during transportation and handling. Incorrect transportation practices can easily cause severe problems, such as breaking the cable reels or inflicting visible and invisible damage to the cable itself.

Invisible cable damage is one of the primary reasons a cable becomes unusable during or after installation. Therefore, the fundamental rules outlined in this document must be strictly followed throughout the shipping, storage, and installation processes.

If a wooden or plywood cable reel is correctly transported and stored as described in this guideline, the durability and usability of the cable shall be under the Volt Cable warranty for following shipment. Our commitment extends to all our export destinations, including the rapidly growing infrastructure markets in Balkan countries such as Bulgaria, Romania, Serbia, and Greece. If a cable reel shows signs of damage resulting from improper transportation, the warranty for both the reel and any subsequent cable failure will become invalid.

For the permissible temperature ranges required for cable transportation and storage, as well as general conditions, please refer to the official Volt Cable product catalogs.

1. Cable Packaging Standards

Protective Wrapping: Each cable reel must be tightly covered with stretch film to protect the cable from external elements.
Securing the Load: Plywood cable reels should be securely tightened with plastic strips (bands) onto the pallets, whereas wooden cable reels require steel strips. If applicable, wooden reel caps may also be nailed for extra cable protection.
Coils and Plastic Reels: A maximum of 5 plastic cable reels should be stacked on top of each other and passed through a shrink machine. Cable coils must be individually bagged and shrink-wrapped.
Water Insulation: To prevent the cable from soaking in water, the cable wound on the reel must be covered with a shrink cover or a water-resistant cap-like material.
Winding Security: Cable ends and shrink wraps must be firmly fixed to prevent the cable winding from loosening during transport and storage.
Pallet Usage: Extra nylon strips can be used to make the loaded cable pallet more stable. Packed cable pallets cannot be loaded on top of each other (except for optimized 2-tier container loading with proper protection).
Wooden Standards: All wooden materials used for cable packaging must be disinfected according to ISPM 15 regulations.
Labeling: At least 2 Volt Cable identification tags are affixed to each reel (one on the side flange, one on the inner belly) to enable quick cable identification. Labels include the cable type, length, and code number.

2. Transportation and Logistics Rules

The cable must be strictly protected during transit. Whether delivering locally or exporting across diverse topographies—from the mountainous routes of Bosnia and Herzegovina, Montenegro, and Albania to the transit highways of North Macedonia and Croatia—incorrect lifting and loading methods will cause permanent cable damage.

Securing: Cable reels must be fixed with sturdy wedges to protect them against sudden bumps, uphill/downhill slopes, and potholes on the roads.
Forklift Handling: * Cable reels must only be lifted by the forklift forks from the flange edges.
- The forklift forks must never touch the cable itself or its protective wrapping.
- Wooden cable reels must never be transported in a horizontal position (laying flat on the flanges).
- Plywood cable reels, however, can be palletized and transported horizontally on their sidewalls.
Crane Handling: If a cable reel is lifted by a crane or an axle, the carrier shaft must be inserted exactly through the center axle hole. Avoid slings or ropes that apply crushing side pressure to the cable reel flanges.
Loading/Unloading: Cable reels must never be dropped from a truck or a loading ramp. Appropriate lowering equipment must be used for all cable deliveries.
Wooden Maintenance: In dry and hot weather, wooden shrinkage may occur. Before moving the cable reels, all loose bolts and screws must be tightened using a torque wrench.

3. Cable Storage Conditions

Whether your cable storage facility is situated in the Mediterranean climate of Slovenia or facing the continental weather variations of Kosovo, the following cable storage conditions are mandatory:

Indoor vs. Outdoor: Cables designed for indoor use must be stored indoors. Outdoor-rated cables can be stored outdoors, provided they remain within the permissible temperature ranges.
Sun and Heat Protection: Unprotected cables (especially those with black outer sheaths) will absorb heat and become much hotter than the ambient temperature if left under direct sunlight. Cable reels must be kept in shaded areas or covered with dark-colored/reflective insulating foils to protect the cable.
Chemical and Fire Risks: Cable storage areas must be far from high temperatures and fire hazards. Precautions must be taken in zones where petroleum derivatives or chemicals might leak onto the cable.
Ground Conditions: The storage ground must be flat, even, solid, and well-drained. To prevent the cable reels from rotting, they must not be in direct contact with humid soil or standing water.
Positioning: * Wooden cable reels must always be stored vertically (like a standing wheel) and secured with wedges against rolling. Storing wooden reels horizontally will damage the cable.
- Plywood cable reels can be stored horizontally; storing them vertically may cause damage.
Periodic Inspection: If cable reels are stored outdoors, periodic inspections are highly recommended at least every 3 months. This interval should be shortened if the cable is exposed to harsh weather conditions.

4. Cable Installation Guideline

All installation and assembly operations must be executed carefully to preserve the cable's mechanical and electrical integrity.

Bending Radius

Bending a cable creates compression on the inside of the curve and tension on the outside. To avoid structural damage to the cable, the minimum bending radius limits listed below must be strictly respected. Avoid excessively tight curves and multiple bends during cable training.

Cable Type	Minimum Bending Radius
Metallic Tape Armoured Cables	15 x D*
Metallic Wire Armoured Cables	12 x D*
Metallic Shielded Cables	10 x D*
Un-armoured & Un-shielded Cables	8 x D*

(D: Overall external diameter of the cable)

Tensile Load (Cable Pulling Force)

During the cable pulling stage, the maximum permissible tensile load must not be exceeded. Armoured cables generally have a higher tensile load capacity than unarmoured cables. While cable socks apply pulling force only to the outer sheath, a pulling eye transfers the force across all cable layers. For the maximum pulling force of a specific cable, please refer to the Volt Cable technical datasheet.

Cable Rollers

To prevent sheath tearing caused by ground friction, the cable must never be dragged directly on the floor. Appropriate cable rollers must be utilized along straight paths and sharp corners during the cable pulling process.

Cable Rewinding (Figure 8 Method)

If the cable is to be unspooled onto the ground before being laid into a trench, the "Figure 8" laying method must be used. This technique ensures the cable is not subjected to extra mechanical torsion.

Halogen-Free (LSZH / HFFR) Cable Installation

For Low Smoke Zero Halogen (LSZH / HFFR) cables, the permissible installation temperature is generally between -5°C and +50°C. Installing halogen-free cable at temperatures above 50°C is highly risky because the sheath becomes less resistant to mechanical stress and more susceptible to cracking. LSZH cable sheaths are inherently less durable against physical tearing compared to standard PVC cable sheaths and require extra care.

Main Causes of Mechanical Stress in Cables:

Applying a bending radius smaller than the permissible limit.
Exposing the cable to high-temperature variations in a short period.
Careless, harsh, or excessively fast cable pulling.
Creating extra torsion on the cable armour by unspooling incorrectly (twisting the cable).
Failing to use cable protection devices (like rollers) around sharp corners.

For further technical support and project-specific cable solutions, please contact the Volt Cable Technical Support Team via our contact page.