Cable Handling and Wrapping Guide

Ensuring proper cable handling and wrapping is essential in the AV industry. It is crucial to maintain the integrity and performance of various cables. In this comprehensive guide, we will delve into the best practices for managing SDI, XLR, Fiber Optic, Ethernet, DMX, A/C Power, and HDMI cables. Additionally, we will explore advanced wrapping techniques such as over-under and over-over. Rather than just skimming the surface, we have delved deeply into this topic to provide a detailed outline. So, prepare yourself to become a cable wrapping professional!

Here is a quick general rule of thumb for all cables:

1. Respect the Bending Radius: Never coil a cable tighter than its specified bending radius to avoid internal damage.

2. Consistent Coil Size: Maintaining consistent coil size, especially for longer cables, aids in deployment and avoids damage.

3. Use Reels for Long Cables: For lengths over 250 feet, using a spool or cable reel can make handling easier and safer.

4. Gentle Handling: Always coil cables gently, allowing them to maintain their natural curve. Forced or tight coiling can lead to wear and eventual failure, particularly with delicate cables like fiber optics.

If you are new to cable wrapping, remember the saying "Slow is smooth, smooth is fast." This means that by practicing your technique slowly and consistently, you will gain experience and eventually increase your speed over time. Focus on perfecting and repeating the same length of cable wrapping until you become more proficient. With dedication and practice, you will see improvement and efficiency in your work.

Respect the Bending Radius: Avoid coiling tighter than the specified radius.

1. SDI Cables

• Bending Radius: Approximately (10 times the diameter) of the cable.

  Coil Size:

• Short (25-50 feet): Smaller coils, respecting the bending radius.

• Medium (100 feet): Larger coils to prevent signal degradation.

• Long (200-300 feet): Larger coils to maintain signal integrity.

2. XLR Cables

• Bending Radius: At least (5 times the diameter) of the cable.

  Coil Size

• Short (25-50 feet): Medium-sized coils.

• Medium (100 feet): Larger coils to avoid stress.

• Long (200-300 feet): Larger coils for easier deployment.

3. Fiber Optic Cables

• Bending Radius: 15 times the diameter or more

  Coil Size

• Short (25-50 feet): Large diameter coils, avoiding tight loops.

• Medium (100 feet): Large, gentle coils.

• Long (200-300 feet): Use a spool to maintain a safe radius.

4. Ethernet Cables

• Bending Radius: At least (4 times the diameter) of the cable.

  Coil Size

• Short (25-50 feet): Medium-sized coils.

• Medium (100 feet): Larger coils to prevent kinks.

• Long (200-300 feet): Use larger coils or a cable reel.

5. DMX Cables

• Bending Radius: At least (5 times the diameter).

  Coil Size

• Short (25-50 feet): Medium to small coils.

• Medium (100 feet): Larger coils to prevent stress.

• Long (200-300 feet): Use larger coils or a spool.

6. A/C Power Cables (8, 10, 12 Gauge)

• Bending Radius: No more than (4 times the diameter).

  Coil Size

•  Short (25-50 feet): Medium to small coils.

•  Medium (100 feet): Larger coils to prevent kinks.

•  Long (200-300 feet): Use large coils or a heavy-duty reel.

7. HDMI Cables

• Bending Radius: No less than (10 times the diameter).

  Coil Size

• Short (< 10 feet): Coils should respect the bending radius.

• Long (> 10 feet): Larger coils to prevent damage, especially at connectors.

I'm sure you're wondering how to calculate the bending radius. You can use this straightforward formula to determine the bending radius.

Formula for Bending Radius:

Radius = 10 × Cable Diameter. For example, if your cable has a diameter of 0.5 inches, the bending radius would be 10 × 0.5 inches = 5 inches.

Common practice however is to maintain a bending radius of 30 degrees on any cable.

Visual of 30 Degree on a cable 

Consistent Coil Size: Helps with deployment and avoids damage.

From both a business and quality perspective, why do we place so much importance on this matter? Let's provide a different perspective on why this best practice has such a significant impact and importance.

from the Business Perspective:

Cost Reduction: Consistent coiling helps prevent cable damage, reducing the need for frequent replacements. This directly impacts the bottom line by lowering equipment costs and maintenance expenses.

Efficiency: Properly coiled cables are easier to transport, store, and deploy quickly. This saves time during setup and teardown, potentially reducing labor costs and allowing for more efficient use of staff resources.

Reliability: Cables that are consistently coiled are less likely to develop kinks or internal damage. This improves overall system reliability, reducing the risk of technical failures during events that could lead to customer dissatisfaction or lost business opportunities.

From a Show Perspective

Performance Consistency: Proper coiling helps maintain signal integrity, especially for longer cables. This ensures consistent audio and video quality throughout an event, enhancing the overall audience experience.

Visual Appeal: Neatly coiled cables contribute to a cleaner, more professional-looking setup. This is particularly important for visible areas of the stage or event space, as it enhances the overall aesthetic quality of the production. (Clients really care about this)

Quick Troubleshooting: In the event of a technical issue, consistently coiled cables make it easier to trace connections and identify problems quickly, minimizing disruptions to the show. (Show does labeling your cables, yes am talking to you)

Flexibility: Consistent coiling allows for easier last-minute changes or additions to the setup, as cables can be quickly and safely extended or repositioned without risking damage or performance issues.

In short businesses can improve their operational efficiency, reduce costs, and enhance the quality and professionalism of their events. This attention to detail can set a not only a company apart but individual freelancers in the competitive event production industry, leading to increased client satisfaction and potential business growth.

Use Reels for Long Cables: Facilitates handling and safety.

Let's keep this brief and focus on the facts. While it may not always be available, when it is, here are the pros and cons of using cable reels.

Pros of Using Cable Reels

1. Ease of Handling: Cable reels simplify the process of unwinding and rewinding cables, making it easier to manage long lengths without tangling or kinking.

2. Safety: Reels help prevent tripping hazards by keeping cables organized and off the ground, reducing the risk of accidents during setup and operation.

3. Storage Efficiency: Reels allow for compact storage of cables, saving space and making it easier to transport equipment to different locations.

4. Protection: Cables stored on reels are less likely to incur damage from environmental factors or mishandling, prolonging their lifespan.

5. Quick Deployment: Using reels allows for faster setup and teardown times during events, improving overall operational efficiency.

Cons of Using Cable Reels

1. Initial Cost: Investing in quality cable reels can be expensive, especially for large-scale operations requiring multiple reels.

2. Space Requirements: While reels can save space for storage, they do require adequate space for setup and operation, which may be a limitation in smaller venues.

3. Complexity: Some reels, especially powered ones, may require additional training for staff to operate safely and effectively.

4. Weight: Larger reels can be heavy and cumbersome, making them difficult to transport without proper equipment or assistance.

Gentle Handling: Maintain the natural curve of cables to prevent wear.

I would like to begin by explaining why I chose not to title this section "Cable Wrapping Techniques: Over-Under vs. Over-Over." The method you choose for wrapping cables can have a substantial impact on the durability and effectiveness of the cable. There are two commonly used techniques: over-under and over-over wrapping. Both methods are correct, and each has its own specific applications depending on the type of cable being used.

Over-Under Wrapping: Best For: Cables with twisted pairs, such as XLR, Ethernet, and DMX cables.

• Technique: The over-under method involves alternating the direction of each loop. Start with an "over" loop (a normal loop), followed by an "under" loop (a reverse loop). This technique helps to prevent kinks and maintain the natural lay of the cable.

  Advantages

• Reduces Tangles: By alternating the loop direction, the cable is less likely to tangle when uncoiled.

• Maintains Cable Integrity: Helps to preserve the internal structure of twisted pair cables, reducing stress and potential damage.

• Easy Deployment: Cables wrapped using the over-under method tend to deploy smoothly without twists.

Twisted Pair Cables (Over-Under Method):

• Ethernet cables (Cat5e, Cat6, Cat7)

• DMX cables (for lighting control)

• Balanced audio cables (XLR, TRS)

• Digital audio cables (AES/EBU)

• HDMI cables

Over-Over Wrapping: Best For Cables without twisted pairs, such as A/C power cables.

• Technique: The over-over method involves coiling the cable in the same direction for each loop. This is a straightforward approach that works well with cables that are less sensitive to twisting.

• Advantages:

• Simplicity: Easier to learn and execute, making it a quick method for wrapping cables.

• Suitable for Stiffer Cables: Works well with stiffer cables like power cords, where the risk of internal damage from twisting is minimal.

•  Consistent Coil Size: Produces uniform coils, which can be beneficial for storage and transport.

Non-Twisted Pair Cables (Over-Over Method):

• Power cables

• Coaxial cables (for video or RF signals)

• RCA cables (for consumer audio/video)

• Fiber optic cables

• SDI (Some SDI is twisted))

Choosing the Right Method

Twisted Pair Cables: Use the over-under method to protect the integrity of the twisted pairs and ensure smooth deployment.

Non-Twisted Pair Cables: The over-over method is suitable for power cables and other non-sensitive cables where twisting does not pose a risk.

By selecting the appropriate wrapping technique for each type of cable, you can enhance the durability and functionality of your cables, ensuring they remain in good condition and are easy to handle during setup and breakdown.

Examples of Twisted Pair vs Non-twisted Pairs