Introduction
You should have used an extension cable at your house or office. It is of great use, especially when
you cannot use regular wire lengths to complete the electrical connections. To top it all off, the usual
cables we use at home or for personal use are smaller in size and easier to store. But the same can’t
be said for industrial cables! Be it an oil refinery or a construction zone, the cables used are quite
lengthy and more complex to store if proper equipment is not used. This is where cable reels step in! The
following discussion will shed light on various aspects of ATEX-certified cable reels, including their
types, characteristics, and significant use cases.
What are ATEX cable reels?
In textbook terms, ATEX cable reels are specially designed products to withstand harsh and
hazardous environments. Their construction and material choice adhere to the ATEX standards to
ensure no workplace explosion or any other form of accident. Hence, they can be used in places with
the presence of vapors, flammable gases, and even dust.
Types of industrial extension cable reels
Lift reel
These are mounted vertically to feed the cables vertically as per the requirements. As the reels are
stationary, you will either have to pull the cables by hand or opt for a mechanical system. They are
designed to sustain the combined weight of the cable and a single outlet box. Ratchets are used to
lock the cable in place once extended to the required length.
Drag reel
Although similar in function to that of the lift cable reels, these are mounted either on the ground or
close to it. Cables are extended horizontally through manual mechanisms. You will also find ratchets
here to lock the cables and prevent any further extension.
Stretch reel
Stretch reels are mounted at an elevation or on the ceiling, either on moving objects or at a
stationary position. Cables are extended or rewound horizontally. Cabling should be carefully
measured as the reels allow sag and usually stretch to approximately 10% of the total distance to be
covered.
Retrieve reel
These specialty cable reels are mounted on movable objects, like railcars. Once the machinery
moves away, the cables are paid out and extended. On the other hand, cables wind up on the reel
drum once the object on which it is mounted moves closer.
Characteristics of cable reels
Industrial cable reels have three most important dimensions to be considered.
a. Outside flange diameter
b. Inner core diameter
c. Inside traverse or the length between the reel flanges
ATEX certification explained: What does it mean for a cable reel?
When it comes to industrial cable reels, ATEX certification entails:
1. Explosion-proof build and usage of enclosures to prevent sparks and excessive heat
generation.
2. Compliance with ATEX Zone classifications.
3. Heavy-duty construction that makes the reels suitable for use in different industrial
purposes.
Differences between standard and ATEX-certified cable reels
Features |
Standard cable reels |
ATEX-certified reels |
| Application | General commercial or household use | Special usage in hazardous environments with vapors, dust, and flammable gases |
| Explosion protection | Don’t come with explosive protection | Built to prevent explosions from excessive heat accumulation |
| Electrical safety | Standard safety like insulation and earthing | Explosion-proof electrical components are used |
| Material | Common options include plastic, aluminum, and steel | Special materials are used to prevent sparks and current overdraw |
| Ingress Protection | IP ratings like IP55 and IP44 for water and dust protection respectively | Higher ratings like IP65 and IP68 |
| Temperature rating | Standard range between -10°C and 50°C | Rated for extreme temperature conditions |
ATEX classification and compliance standards
Industrial cable reels are designed and rated as per the ATEX Directive 2014/34/EU standards. These
directives entail to:
a. Equipment to be used in places with potential explosion risks
b. Defining areas into zones based on explosion forming
c. Compliance adherence during manufacturing process
When it comes to ATEX standards, zonal classifications are the most important to be considered.
These are divided into two groups, namely:
1. Gas environments
a. Zone 0: Continuous presence of explosive gases like fuel tanks
b. Zone 1: Flammable gases are likely to appear during standard operations like around
fuel pumps
c. Zone 2: Explosive environment is unlikely to occur during normal times. like near
ventilation exhausts
2. Dust environments
a. Zone 0: Continuous presence of combustible dust like inside grain silos
b. Zone 1: Dust may be present during continuous operations, like surrounding areas of
flour processing machine
c. Zone 2: Sudden and temporary presence of explosive dust like in storage areas near
powdered chemicals
Key features to consider when choosing a cable reel
1. Operational mechanism: Most cable reels come in three different configurations, namely:
a. Manually-operated reels
b. Spring-loaded reels for self-retracting function
c. Motorised reels for automated winding and unwinding of the cables
2. Mounting option: Fixed reels can be mounted permanently on stationary surfaces like walls
or the ceiling. Some products can be mounted on moving objects for automatic winding and
unwinding.
3. Safety and protective reinforcements: Industrial cable reels are reinforced with numerous
safety features, like:
a. Electrical insulation covers
b. Slip rings for continuous power transmission
c. Overload protection from excessive current draw
d. Ratchets to lock the cables in place
4. Material used for construction: Premium-quality materials like steel and aluminum are used
to improve build quality. Sometimes, cable reels are also manufactured with composites to
reduce the overall weight.
Applications of ATEX cable reels
Oil and gas industry
Powering equipment units and tools used at offshore oil rigs and refineries
Safer cable management for maintenance operations at drilling platforms
Setting up a safer electrical transmission system in fuel transfer stations
Zone 0, Zone 1, Zone 2 (Gas)
Chemical processing plants
Power supply circuits connecting mixers and pumps
Prevention of static charge accumulation in fuel-handling zones
Handling cables for ventilation systems
Zone 1, Zone 2 (Gas)/ Zone 21, Zone 22 (Dust)
Mining operations
Providing power to underground mining machinery like conveyors and drills
Supplying power to emergency backup systems
Ensuring safer cable retraction in gas detection and ventilation systems
Zone 0, Zone 1 (Gas)/ Zone 20, Zone 21 (Dust)
Food and beverage industry
Electrical cable handling for automated food processing setups
Managing retractable cables in explosion-risk areas
Supplying power to conveyors, mixers, and grinders in flour mills
Zone 20, Zone 21, Zone 22 (Dust)
Aviation and marine sectors
Fueling and maintenance tasks at aircraft hangers
Safe electrical connections on marine oil platforms, tankers, and ships
Zone 1, Zone 2 (Gas)/ Zone 21, Zone 22 (Dust)
Comparison of top ATEX cable reels in 2025
Brand & model |
Certifications |
Cable length (in meters) |
Rewind type |
IP rating |
Best for |
| Atexor SLAM® Cable Reel 16EX | II 2 G Ex e d IIC T4 Gb
II 2 D Ex tb IIIC 120°C Db |
15 – 80 | Manual | IP66 | Chemical processing, oil and gas, marine, aviation |
| Atex Global CR20 | II 2G h IIC T4 Gb X | Up to 20 | Spring-loaded | IP65 | Chemical processing, mining, oil and gas |
| GIFAS Series 573 STAHL | Ex db ed IIC T6 Gb
Ex II 2G / CE1258 |
20 – 50 | Manual | IP66 | Mining, oil and gas, chemical processing, food and beverage |
| GIFAS Series 518 STAHL/CEAG | Ex II 2 G Ex de IIA T6
PTB Ex 06-16168 |
45 | Manual | IP65 | Chemical processing, mining, and oil and gas |
| Wolf LL-300/110/CEAG | CE marked to 2014/34/EU ATEX Equipment Directive | 30 | Manual | IP54 | Aviation, marine, oil and gas |
Conclusion
Industrial cable reels hold immense significance in both regular and explosion-risk areas. That’s why
investing in the right product is crucial to prevent unwanted disruptions in normal operations. From
checking the retracting mechanism to the safety features, you should consider different factors to
evaluate the feasibility of the reels. After all, workplace safety depends greatly on this specific
equipment unit.
FAQs:
How do I get the right cable needed for my requirements?
You should consider different evaluation factors, like the operational mechanisms, flange and core
diameters, built material and durability, cable length, and ATEX certifications.
How is a fixed cable reel different from a retractable one?
Fixed cable reels have to be manually operated for winding and unwinding. On the contrary,
retractable ones use motorised mechanisms to automate the process.
What cable lengths are available for industrial cable reels?
You can opt for 15 meters to 50 meters of cable length for the industrial reels.
What is the appropriate storage solution for cable reels?
Cable reels need to be cleaned regularly and inspected for any underlying damage. Proper
ventilation will be required for long-term storage plans.
How should I handle the cable reels safely?
Proper grounding, full unwinding of the cables, prevention of current overdraw, and use of
explosion-proof slip rings are a few measures you should take while handling industrial reels.