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BHS and Rexel Simplify Reel Spooling for Lawson Electric
July 21, 2026
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Categories: Blogs, Case Studies
A single 2,500-foot master reel of 500 kcmil copper wire weighs more than 4,150 pounds. Every reel is a potential logistical burden — but with the right partners, each reel can also be an opportunity for process optimization.
Rexel USA is one of the world’s largest electrical distributors, serving millions of customers in the United States via innovative supply chain models that reduce inventory, boost productivity, and cut installation costs.
In 2025, Rexel USA received a request from Lawson Electric Company, one of Tennessee’s largest full-service electrical contracting companies. Lawson’s team was researching reels and wire take-up machines; their goal was to find a way to spool their reels more efficiently.
The Problem: Finding a Durable Solution for Electrical Payout
The tools that electrical contractors use during installations have improved significantly over the past few decades. but the actual reels haven’t changed much. Practically, that’s because there’s not many options for innovation: Reels (or spools) are simple devices with a drum, flange, and arbor hole. Most commercial and industrial units are made from wood, which is inexpensive and relatively lightweight.
But there’s still room for improvement. Steel reels, while more expensive upfront, are much more durable and less susceptible to warping. They can accommodate wire gauges of various sizes, and they can be configured to work with specialized wire- and cable-handling equipment. At scale, steel is simply a better material for long-term use — particularly when paired with high-accuracy spooling and payout equipment.
Lawson was interested in whether BHS equipment could help them cut down on waste, improve throughput, and reduce manual effort for operators.
The Solution: Steel Reels and Cable Handling Equipment for Electrical Suppliers
Rexel USA guided Lawson through the features of BHS Reels and cable handling equipment. BHS PRP Reels (R) had several key benefits for Lawson Electric’s operations:
- Flexible Design: BHS PRP Reels have multiple components with predrilled arbor holes to accommodate a variety of wire gauges (0.75 inches to 2.5 inches). Hub plates feature through-holes that allow locking multiple compartments together, and custom sizes are available.
- Durability: The heavy-duty steel construction and powder-coat finish provide significantly better durability than wood reels.
- Material Handling Compatibility: PRP Reels are designed to work efficiently with BHS equipment. For suppliers, they provide an opportunity to provide cable paralleling and other value-added services.
Of course, the unique design of the PRP Reel pays dividends when paired with two key pieces of material handling equipment.
Parallel Reel Payout (PRP)
The PRP has key features that make it an ideal choice for larger electrical installations:
- Multi-Compartment Reel System: The PRP simplifies the paralleling process by keeping different wire gauges organized and separate throughout the pull.
- Variable Arbor Hole Sizes: The reels are equipped with predrilled arbor holes in 0.75-inch, 1-inch, and 2.5-inch diameters, ideal for diverse jobsite requirements.
- Integrated Four-Way Fork Pockets: The base frame includes four-way fork pockets that allow a forklift or pallet truck to transport the unit from either the ends or the sides. That means precise positioning in tight construction corridors, even when the unit is fully loaded.
- Optional Casters: With guidance from Rexel, Lawson opted for quick-disconnect urethane casters, which provide manual maneuverability.
- Shaft Security and Stability: To prevent unwanted movement during operation, the PRP includes shaft safety locks equipped with locking pins. Optional corrosion-resistant urethane casters and floor locks are also available for manual maneuvering and stationary stability.
Perhaps most importantly, the PRP is designed with ergonomics in mind. Operators spend less effort and take fewer risks when handling each install, which boosts efficiency and reduces the potential for on-the-job injuries.
Related: The Ergonomics of Cable Pulling: Improving Safety at Electrical Installations
Spool Winding Trolley (SWT)
The SWT’s design significantly reduces manual exertion and the ergonomic hazards associated with handling heavy cable spools. That can improve retention rates in the long term — and in the short term, it’s a much faster way to prepare cable for the job site.
Key features:
- Precision Encoder Counting: Lawson opted for a unit with a distance counter (SWT-DC), which tracks every linear foot of cable. Operators can match Building Information Modeling (BIM) data to the exact inch, which minimizes conductor scrap and ensures accuracy for cut-to-length orders.
- Hydraulic-Actuated Roller Arms: Dual 6-inch diameter, urethane-coated rollers maintain constant friction with the reel rim to spin heavy reels safely.
- Direct-Coupled Hydraulic Drive: The drive system offers high and low speed settings for granular control. Operators use the low-speed setting for precision when beginning or finishing a spool and the high-speed setting to maximize efficiency during bulk respooling.
- Manual Level-Wind Control: A wired pendant and a manual control slide allow the operator to manage the left-right motion of the cable during the winding process. The result: a tight, professional wrap for the highest possible yield per reel.
- Extended Reel Compatibility: The SWT-LITE is engineered to work with reels up to 48 inches wide. It’s compatible with any PRP configuration and can handle various materials, including electrical wire, tubing, and industrial hoses.
The Result: A More Efficient, Ergonomic Approach to Electrical Cable Runs
Today, Lawson has a scalable system that reduces labor hours and enhances ergonomic safety. Clear communication between all Lawson, Rexel, and BHS ensured a smooth implementation.
By using the SWT-LITE to spool wire directly onto PRP units, Lawson Electric can now prepare materials in the warehouse and transport them efficiently to the point of use.
Build a better approach to cable material handling.
Contact BHS or call 1-800-BHS-9500 to discuss your next project.
