Empty reels for re-spooling

Reels that will carry cable again

Re-spooling means winding cable, wire, rope or hose onto a reel other than the one it came on: cutting a long length into job-sized pieces, consolidating part-reels into one, or storing returned cable. The reel has to be able to take the load and turn smoothly on a stand. That narrows the choice to reels in the best condition grade: flanges flat and parallel, every stave of the drum in place and tight, no soft wood, and an arbor hole that is round, centred and undamaged.

The dimensions that matter

For re-spooling, the reel's numbers are working numbers, not just a description.

• Drum diameter. Cable has a minimum bending radius. Winding a stiff cable onto a drum that is too small can damage it, so the drum has to suit the cable. Ask the cable maker or check the cable data sheet for the minimum drum size.
• Traverse. The inside width between the flanges sets how many wraps fit per layer.
• Flange. The flange diameter, minus clearance at the rim, sets how many layers fit. Cable makers leave a margin between the outer layer and the flange edge so the cable is protected.
• Arbor hole. It has to fit your reel stand or payoff. Most North American wood reels have a 3⅛-inch hole; Southwire's information lists 3.125 inches for its wood reels and 2 inches for its small G series plywood spools. Heavy reels may have a steel arbor plate.

Okonite's Technical News on reel anatomy explains the standard method of describing a reel, Flange x Inside Traverse x Drum, and the parts that matter on a stand: the arbor hole, the drive holes that take the stand's drive pin, and the test hole that gives access to the inner cable end.

Matching sets

Rewinding work usually wants reels of one size, so that lengths are consistent and reels stack evenly on a truck. Say how many of a size you need. Matching sets of up to about ten mid-size reels are often possible from one pickup; larger sets may take a few weeks to build up. If a close size will do, give the acceptable range.

Inspecting a reel before use

Even a reel graded ready to use should be checked on your own stand before loading it with cable:

1. Spin it empty on the stand and watch for wobble at the flange rims.
2. Look into the arbor hole for cracks running outward.
3. Press on each stave; none should move.
4. Check the inside faces of the flanges for nails or splinters that could cut cable jacket.
5. Make sure no old lagging nails protrude from the rims.

Which reels we offer for re-spooling

Most often: nailed wood reels from 30 to 48 inches, plywood reels from 18 to 24 inches for building wire and small cable, and occasionally larger nailed or bolted reels from 60 inches up for power cable. Fiber optic reels, which often have a starting slot for the inner end, suit rewinding fibre or communications cable. We do not offer steel reels, because they belong to their makers.

Loading and handling reels you buy

Reels for rewinding arrive empty, so they are light compared with the loads they will carry. A loaded reel is a different object: a 48-inch reel full of copper feeder cable can weigh well over a ton. Plan the reel stand, the jack or the payoff, and the route the loaded reel will take, before you choose the reel size. Never lift a loaded reel by its flanges. Use a spindle through the arbor hole or forks under the drum, and chock it whenever it stands on its rims.

Winding direction and the inner end

Fiber optic and communications reels often have a starting slot or a hole in the flange to bring the inner end of the cable out, so both ends can be reached for testing. Power cable reels may have a test hole for the same reason. If you need access to the inner end, ask for reels that have one. Mark the winding direction on the flange with an arrow after you load the reel; whoever pays it out later will roll it the right way.

Who asks

Electrical contractors cutting their own lengths, cable and wire distributors who sell by the foot, rigging shops winding wire rope, irrigation and landscaping firms winding hose and drip line, and event companies storing power cable. Each wants something slightly different, so say what is going on the reel and roughly how much of it.

Arbor adapters and bushings

If a reel's arbor hole is larger than your stand's spindle, steel bushings or plywood adapter discs reduce it. Stand makers sell adapters for common sizes.

What gets wound besides cable

Re-spooling customers wind far more than electrical cable: hydraulic and air hose, welding leads, innerduct and conduit, rope, chain, tubing, banding, netting and tarp straps. Each product has a weight per foot and a stiffness that decide which drum diameter and flange strength suit it. Tell us the product, its outside diameter and the length you plan to wind; we will suggest reels whose drum, traverse and flange depth fit, and say whether a plywood, nailed or bolted build is sensible.

Payoff stands, level winders and take-up

Shops winding onto reels use payoff stands, level-wind guides and powered take-up units. Arbor size and flange true-running matter more on machines than by hand.

Questions

Will you guarantee a reel for a particular cable weight?

No. Reels are used packaging. We describe the condition honestly, and the decision about loading is yours, using the cable maker's guidance.

Do the reels come with lagging?

Usually not. Lagging is removed when the original cable is installed. Most rewinding work does not need it.

Can I buy reels with a particular stencil removed?

Stencils on one-way reels can be sanded off. Stencils that mark a reel as returnable cannot, because the reel is not ours to sell.