Introduction: What Makes the CORDAFLEX XPRT “Expert-Grade”

The CORDAFLEX XPRT (N)SHTOEU is the newest addition to the Klaus Faber / Prysmian low voltage reeling cable portfolio — a cable engineered for high and very high mechanical loads in port crane, container handling, and heavy industrial reeling operations. Designated “XPRT” (Expert), this cable represents a distinct engineering philosophy: every material in the cable’s construction is explicitly specified to the highest DIN VDE compound grade, every parameter is pushed to its mechanical maximum, and the tensile rating uses the Fzp “permanent tensile” designation — confirming that the cable’s maximum tensile applies not just during installation but during continuous operational reeling.

The CORDAFLEX XPRT shares the 30 N/mm² conductor tensile and tinned copper Class “FS” conductor with the legendary CORDAFLEX (SMK) — but diverges in three critical areas: it specifies EPR 3GI3 insulation (the highest standard EPR grade per DIN VDE 0207-20, providing full compound traceability), uses rubber 5GM5 for both inner and outer sheath (the highest PCP-based rubber grade per DIN VDE 0207-21), and achieves a 5×OD moving bending radius — one grade tighter than the CORDAFLEX (SMK)’s 6×OD, making it the tightest moving bend radius in the standard CORDAFLEX product family.

Full Technical Specification

Available Configuration

Fzp Verification: The permanent tensile force Fzp for the 04×16 configuration can be verified: 30 N/mm² × (4 × 16 mm²) = 30 × 64 = 1,920 N — exactly matching the datasheet value. This confirms the 30 N/mm² is applied to the total copper cross-section under Fzp (permanent) conditions.

Conductor Resistance Verification: The resistance of 1.24 Ω/km for 16 mm² confirms tinned copper — IEC 60228 specifies a maximum of 1.24 Ω/km for Class 5/FS tinned copper at 16 mm². Bare copper at the same cross-section would measure 1.21 Ω/km maximum. The ~2.5% increase in resistance is the characteristic signature of tin coating on fine-stranded conductors.

Weight Analysis: The cable weight of 1,289 kg/km for a 04×16 cable at 26.7 mm OD compares directly with the CORDAFLEX (SMK) 04×16 (Part 051536) at 1,315 kg/km and 26.7 mm OD — confirming dimensional compatibility while achieving a 26 kg/km weight reduction (approximately 2%) through the optimised 5GM5 rubber compound system.

30 N/mm² and Fzp: Permanent Tensile for Continuous Operation

The CORDAFLEX XPRT achieves 30 N/mm² maximum tensile strength at the conductor — the same absolute highest value as the CORDAFLEX (SMK) and double the 15 N/mm² of the standard TROMMELFLEX (K). However, the XPRT’s tensile designation is Fzp — “permanent tensile” rather than the SMK’s Fzv (“tensile during installation”). This distinction is critical for cable specification engineers.

Fzp (permanent) means the cable is rated to sustain the maximum tensile force continuously during normal reeling operation — not just during the initial installation pull. In practical terms, this allows the CORDAFLEX XPRT to be specified for applications where the cable remains under sustained tensile load throughout its operational cycle, such as long-travel crane reeling where the cable hangs from the drum at full extension, or high-speed reeling applications where dynamic tensile forces approach the cable’s rated maximum. The Fzp designation provides additional engineering confidence that the cable’s mechanical life will not be compromised by sustained tensile loading within the rated envelope.

For comparison, the Cordaflex (SMK)-V vertical reeling variant uses Fzd (dynamic tensile) for its configurations, while the standard Cordaflex SMRT uses both Fzp and Fzd depending on the configuration. The CORDAFLEX XPRT’s consistent use of Fzp across its product line simplifies engineering specification and eliminates ambiguity about operational tensile limits.

EPR 3GI3 Insulation: Full DIN VDE Compound Traceability

The CORDAFLEX XPRT explicitly specifies EPR (Ethylene Propylene Rubber) 3GI3 insulation — the highest standard EPR compound grade defined in DIN VDE 0207-20. The “3GI3” designation provides complete compound traceability: “3G” indicates rubber compound group 3G (EPR-based), “I” indicates insulation application, and “3” indicates the highest performance sub-grade within that group. This compound provides excellent dielectric properties, outstanding flexibility at low temperatures (maintaining insulation integrity down to −50°C in fixed installation), and superior long-term ageing resistance at the continuous 90°C conductor temperature rating.

This explicit compound specification is a unique differentiator. The CORDAFLEX (SMK) datasheet omits the insulation compound designation entirely — suggesting a proprietary Prysmian compound that may not correspond to a standard DIN VDE material code. The CORDAFLEX XPRT’s explicit 3GI3 specification gives procurement engineers, quality inspectors, and certification auditors a clear DIN VDE standard to verify against, simplifying incoming inspection and ensuring that replacement cables from alternative manufacturers (including Feichun) can be verified to the identical compound specification.

5GM5 Rubber System: The Highest DIN VDE Sheath Grade

Both the inner sheath and outer sheath of the CORDAFLEX XPRT are specified as rubber 5GM5 — the highest polychloroprene (PCP) based compound grade per DIN VDE 0207-21. The “5GM5” designation indicates: “5G” = rubber compound group 5G (PCP-based), “M” = sheath (Mantel) application, and “5” = the highest performance sub-grade. This compound delivers maximum abrasion resistance, tear propagation resistance, oil resistance (per EN 60811-404), ozone resistance (per DIN EN 60811-2-1), and UV resistance for unrestricted outdoor service.

The use of 5GM5 for both inner and outer sheath is notable. Many competitor cables use a lower-grade compound (such as 5GM3) for the inner sheath to reduce cost, reserving the premium 5GM5 grade only for the outer sheath where abrasion resistance is most critical. The CORDAFLEX XPRT specifies 5GM5 throughout — providing the same premium mechanical protection on the inner surface (where the polyester torsion braid is vulcanised between sheaths) as on the outer surface (where the cable contacts drum flanges, guide rollers, and sheaves). This dual-5GM5 construction contributes directly to the cable’s industry-leading 5×OD moving bending radius.

5×OD Moving Bend: The Tightest in the CORDAFLEX Family

The CORDAFLEX XPRT achieves a 5×OD moving bending radius — meaning the cable can be repeatedly bent around a sheave or roller with a diameter of just 5 times the cable’s outer diameter during continuous reeling operation. For the 04×16 configuration at 26.7 mm OD, this translates to a minimum moving bend radius of just 133.5 mm (or a sheave diameter of 267 mm). This is the tightest published moving bend radius of any standard CORDAFLEX variant and represents a significant engineering advantage.

This tighter bending radius enables the CORDAFLEX XPRT to be installed on smaller-diameter reels and sheaves — reducing the physical footprint of the cable reel assembly on the crane structure. On STS and RTG cranes where space is at a premium, the ability to use a 20% smaller sheave diameter can be the difference between a feasible cable routing and a design compromise. It also enables more compact cable guide systems and reduces the bending fatigue amplitude per cycle, potentially extending cable mechanical life.

CORDAFLEX XPRT vs. CORDAFLEX (SMK): Side-by-Side Comparison

Application: High and Very High Mechanical Load Reeling

The CORDAFLEX XPRT is engineered for motorised drum reeling operations where the cable is subjected to high and very high mechanical loads — including sustained tensile forces, repeated bending cycles over sheaves and guide rollers, and torsional stresses from drum rotation. Typical applications include STS (Ship-to-Shore) container cranes, RTG (Rubber Tyred Gantry) cranes, E-RTG (Electrified RTG) cranes, RMG (Rail Mounted Gantry) cranes, and heavy industrial reeling systems for steel mills, automotive plants, and shipyards.

The cable’s 240 m/min operating speed matches the highest reeling speed in the CORDAFLEX family, supporting modern high-throughput port crane operations where rapid trolley and gantry travel is required. The −35°C moving temperature rating enables year-round operation in cold-climate ports (Northern Europe, Scandinavia, Russia, Canada, Northern China) without cable stiffening or jacket cracking. The PCP-based yellow outer sheath provides the abrasion resistance, oil resistance, and UV resistance needed for multi-year outdoor service in the harshest port and industrial environments.

The cable’s environmental resistance — flame retardancy per IEC 60332-1-2, oil resistance per EN 60811-404, ozone resistance, UV resistance, and full water resistance — ensures compliance with port authority and industrial safety requirements worldwide. The yellow colour coding identifies the cable as a reeling cable per industry convention, preventing confusion with static installation cables during maintenance operations.

Cost-Effective Alternative from Feichun

Feichun Lead Times: Standard 04×16 configuration: 4–6 weeks (stock available). Custom XPRT-equivalent configurations (any size from 04×1.5 to 3×240+3×120/3): 8–12 weeks. European OEM equivalent: 16–24 weeks.

Technical FAQ

How does EPR 3GI3 compare to the CORDAFLEX (SMK)’s insulation? The CORDAFLEX (SMK) datasheet does not specify its insulation compound — it may be a proprietary Prysmian formulation. The XPRT’s explicit 3GI3 designation means any manufacturer can verify insulation compliance against DIN VDE 0207-20. EPR 3GI3 provides excellent dielectric strength (typically > 10 kV/mm), low dielectric loss, outstanding flexibility, and long-term thermal stability at 90°C continuous operation. Feichun’s XPRT equivalent uses an EPR compound verified to 3GI3 specifications with third-party testing certification available.

Why is the weight 1,289 kg/km vs. 1,315 kg/km for the SMK 04×16? The 26 kg/km (2%) weight reduction reflects the XPRT’s optimised 5GM5 compound formulation — the explicit DIN VDE compound grade allows tighter manufacturing tolerances on sheath wall thickness while maintaining full mechanical performance. Less material waste per kilometre translates to both lower cable weight (beneficial for crane structural loading) and lower raw material consumption (contributing to the cost advantage).

Can Feichun manufacture XPRT-equivalent cables in configurations beyond 04×16? Yes. The CORDAFLEX XPRT’s construction — tinned copper Class FS, EPR 3GI3, 5GM5 dual sheath, polyester torsion braid — can be manufactured by Feichun in any configuration from 04×1.5 to 3×240+3×120/3, including multi-core power, multi-core control, and hybrid power+screened control configurations. All configurations maintain the 30 N/mm² tensile, 5×OD moving bend, and Fzp permanent tensile rating. Contact our engineering team with your Faber part number or configuration requirement for dimensional and performance verification.

What does “DIN VDE 0250-814 (with ref. to)” mean? The “(with ref. to)” notation indicates that the cable is designed with reference to the DIN VDE 0250-814 standard rather than fully listed under it. This is standard practice for premium reeling cables that exceed the baseline requirements of VDE 0250-814 — the cable meets or exceeds all requirements of the standard but may include additional features (such as the 5×OD bending radius or Fzp tensile designation) that are not explicitly covered by the standard’s scope. The VDE certification mark on the cable confirms independent verification of compliance.

Is the CORDAFLEX XPRT suitable for mining applications? The current Klaus Faber datasheet does not include mining certification per VDE 0168/0118 for the CORDAFLEX XPRT. For mining applications requiring explicit VDE 0168/0118 compliance, the CORDAFLEX (SMK) remains the appropriate choice. However, the XPRT’s premium construction (tinned FS, 5GM5 dual sheath, PCP-based flame retardancy) meets or exceeds the material requirements for mining cables — Feichun can provide mining-compliant equivalents with appropriate testing and documentation upon request.