Cable Drum Size Calculator
Calculate optimal drum dimensions for cable storage and transportation
Cable Drum Size Calculator
Compliant with IEC 60794 Standards
Results:
Core Diameter (mm): 0.00
Flange Diameter (mm): 0.00
Drum Width (mm): 0.00
How to Use the Calculator
Power Cables
- Select "Power Cable" type
- Enter cable outer diameter
- Provide total cable length
- Input minimum bend radius
- Set appropriate safety factor
Control Cables
- Select "Control Cable" type
- Enter cable diameter
- Provide required length
- Input bend radius specification
- Apply safety factor (1.2-1.5)
Fiber Optic
- Select "Fiber Optic" type
- Enter cable diameter
- Provide cable length
- Use manufacturer's bend radius
- Higher safety factor recommended
How to Calculate Cable Drum Size
Practical design checkpoints to size the core, flange, and width for safe cable handling
1. Lock in the Core Diameter
Use the minimum bend radius from the datasheet and add a safety factor so the first wraps never overstress the cable jacket.
D_core = 2 x Min. Bend Radius x Safety Factor
Keep the core diameter rounded up to the nearest 10 mm so fabrication is practical and repeatable.
2. Estimate Build-Up Height
Translate the cable length and diameter into the radial height needed to hold the full run on the drum.
Build-up height approx = √((Cable Length x Cable OD)/(pi x Mean Diameter))
Mean diameter is the average of the core and outer layers, keeping winding tension consistent.
3. Set the Flange Diameter
Size the flanges to contain the build-up height with a clearance margin for transport vibration.
D_flange = D_core + (2 x Build-up Height) + Clearance
Common clearances are 40-75 mm depending on cable weight and expected handling conditions.
4. Define Drum Width
Balance the number of layers and traverse width so the cable packs evenly without ridging or crushing.
Width approx = 1.2 x Build-up Height or 8-12 x Cable OD (minimum)
Choose the larger of the two to keep the drum stable and avoid over-layering thin cables.
5. Check Handling Loads
Confirm lifting lugs, axle diameter, and core strength match the full drum weight with a margin for dynamic loads.
Full drum mass = Empty drum + Cable mass per metre x Length
Use the higher of calculated mass and rated drum limit to set safe handling practices.
6. Validate Storage and Pay-Off
Ensure the flange diameter and width fit available racks, pay-off stands, and transport restraints.
Keep flange edges clear of obstructions; allow 50-75 mm per side for chocks
Align the drum orientation with the planned pulling direction to avoid twist and extra tension.
Cable Drum Size Chart
Indicative drum dimensions for common low-voltage cable diameters
| Cable OD (mm) | Typical Length (m) | Core Diameter (mm) | Flange Diameter (mm) | Drum Width (mm) | Notes |
|---|---|---|---|---|---|
| 8 | 300 | 320 | 620 | 400 | Small site pulls; compact plywood cores. |
| 12 | 500 | 420 | 760 | 520 | General power circuits on light wooden drums. |
| 18 | 350 | 520 | 940 | 560 | Multi-core control cables with moderate build-up. |
| 25 | 250 | 620 | 1100 | 650 | Common for LV power feeders; allows safe lay length. |
| 32 | 200 | 750 | 1250 | 720 | Heavier drums; confirm axle and lifting ratings. |
| 40 | 150 | 880 | 1450 | 780 | Use steel flanges for transport stability. |
Values are indicative. Always check manufacturer drum tables, bend radius limits, and lifting guidance before final selection.
Cable Drum Size FAQs
How to calculate the capacity of a drum?
Work from the core diameter, flange diameter, and drum width to estimate how many wraps and layers the drum can hold, then convert to total length using the cable outer diameter.
Capacity ≈ (Drum width / Cable OD) x (Average circumference across layers)
How many metres of cable on a drum?
Divide the drum width by the cable OD to find wraps per layer, multiply by the average circumference, and sum for each layer until the build-up height meets the flange limit.
Metres ≈ Wraps per layer x Average circumference x Number of layers
What is a standard drum size?
Manufacturers list standard plywood, timber, and steel drums with defined core diameters, flange diameters, widths, and maximum masses; common mid-range drums sit around 600-1100 mm flanges.
Always match drum rating to the cable mass and transport method
What is the 80/20 rule in drumming?
Keep the drum no more than about 80% full of cable build height to maintain flange clearance, reduce spill risk, and keep lifting loads within the safe working limit.
Stop winding when build-up height reaches ~80% of flange depth
How to calculate the length of cable on a drum?
Use the winding formula with the measured cable OD and drum geometry, or reference the manufacturer drum chart for that specific cable family and drum type.
Length = (Flange^2 - Core^2) / (4 x Cable OD x Drum width)
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