A Complete Guide to Type SHD-GC 2kV Portable Mining Cables in South Africa

Why Type SHD-GC Cables Matter in South African Mining

South Africa is a global mining powerhouse, producing vast quantities of gold, platinum, coal, and manganese. These mining operations, whether deep underground in the goldfields of Gauteng or the platinum belt of Limpopo and North West provinces, rely heavily on mobile machinery such as longwall shearers, loaders, conveyors, and pumps.

Operating equipment in such harsh environments is inherently challenging. Underground mines present cramped, wet, and abrasive conditions, while surface mines must contend with UV exposure, temperature fluctuations, and mechanical stress. These challenges make the power supply to mobile mining equipment a critical safety and operational concern.

Enter the Type SHD-GC Three-Conductor Round Portable Power Cable (2kV, CPE Jacket) – a robust solution designed specifically for high-performance, safe, and reliable power delivery in demanding mining environments. This article explores why SHD-GC cables are increasingly preferred in South African mines, their design features, applications, and real-world performance.

By the end of this article, readers will understand SHD-GC cable construction, performance characteristics, installation best practices, and why these cables have become a standard in South Africa’s mining industry.

What Is a Type SHD-GC Portable Power Cable?

The SHD-GC cable is a portable, three-conductor power cable designed to withstand the harsh conditions of industrial and mining operations. Its name reflects its key characteristics:

• SHD – Super Heavy Duty: Indicates that the cable is built for extreme mechanical stress and frequent movement.

• GC – Ground Check: Includes a dedicated conductor to monitor the integrity of the grounding system, ensuring operator safety and equipment protection.

Rated for 2kV, SHD-GC cables offer the perfect balance between power delivery and flexibility. While higher voltage cables exist, the 2kV rating suits most underground and surface mining machinery, particularly those with portable, high-flex applications.

The combination of flexibility, mechanical strength, and electrical safety has made SHD-GC a preferred choice for South African mining operations, particularly in environments where frequent cable handling and reeling are common.

Typical Applications in Mining and Heavy Industry

Underground Mining Equipment

• Longwall Shearers – These machines extract coal or other ores along a continuous wall. The power cable must withstand constant movement and abrasion.

• Continuous Miners – Used in hard rock and coal mining, these machines demand flexible cables capable of enduring heavy torsion and bending.

• Loaders and LHDs (Load-Haul-Dump Machines) – Mobile loaders require reliable cable systems for power-intensive operations.

• Drills and Roof Bolters – High-frequency, repetitive movements necessitate cables with excellent flex life.

Surface and Auxiliary Equipment

• Conveyors and Pumps – Essential for material transport and slurry management in processing plants.

• Mobile Substations – Provide temporary power in remote mining areas, requiring heavy-duty portable cables.

In all these applications, grounding conductors, ground check conductors, and metallic shielding are critical. They reduce the risk of electric shock, provide fault detection, and ensure compliance with South African mining safety regulations.

Cable Construction Overview

The strength of SHD-GC cables lies in their meticulous design, combining mechanical robustness with electrical performance.

Conductor Design

SHD-GC cables use stranded annealed tinned copper conductors. Benefits include:

• Flexibility – Essential for frequent handling and movement.

• Corrosion Resistance – Tinning protects against moisture and chemicals common in mines.

Insulation System

Ethylene Propylene Rubber (EPR) insulation provides high dielectric strength, excellent thermal resistance, and stable performance up to 90°C conductor temperature. EPR also resists cracking and degradation in wet, hot, or chemically aggressive environments.

Insulation Shield

A tinned copper or textile braid shield is placed over the insulation, serving multiple functions:

• Containment of fault currents

• Reduction of electrical stress

• Enhanced operator safety

Grounding and Ground Check Conductors

• Grounding conductor – tinned copper, ensures safe dissipation of fault currents.

• Ground check conductor – tinned copper with yellow polypropylene insulation, continuously monitors the integrity of the ground system, alerting operators to potential hazards before failures occur.

Ground monitoring is particularly important in South African mines, where regulations mandate rigorous grounding verification to prevent electrocution risks.

Outer Jacket

The extra-heavy-duty Chlorinated Polyethylene (CPE) jacket is oil, chemical, abrasion, and flame resistant. Its design protects the cable in tough mining environments, from drag chains and reeling drums to wet and abrasive underground surfaces.

Optional Design Variations

Cables can be customised for specific operational needs:

• Alternative jacket materials – CSP, PCP, NBR, PVC, or TPU.

• Two-layer jacket construction – Reinforcing fibre between layers enhances tensile strength and extends service life.

• Custom lengths and conductor sizes for mine-specific power requirements.

These variations allow South African mines to tailor SHD-GC cables for unique conditions such as extreme heat, chemical exposure, or high-frequency flexing.

Mechanical and Thermal Performance

SHD-GC cables are designed to handle tough mechanical and thermal conditions:

• Minimum bending radius: 6 × overall diameter

• Maximum conductor temperature: +90°C

• Resistance to crushing, impact, and repeated flexing

These properties make SHD-GC cables ideal for hot, wet, and abrasive underground environments, ensuring reliable power delivery and reduced downtime.

Electrical and Technical Specifications Explained

Voltage rating, ampacity, and shielding directly affect operational safety and efficiency. Key considerations include:

• Voltage rating: 2kV class, ideal for underground equipment.

• Ampacity: Conductor size must match mining equipment load to prevent overheating.

• Shielding and grounding: Improves electrical safety and reduces EMI.

Selecting the correct conductor size balances power transmission efficiency, voltage drop, and equipment reliability.

Dimensions, Weight, and Ampacity Overview

SHD-GC cables come in various core configurations (3×6 AWG to 3×500 kcmil). Key factors include:

• Nominal insulation and jacket thickness – balances flexibility with mechanical protection.

• Overall diameter and weight – impacts reel capacity, handling, and installation.

• Ampacity – must be sufficient for the expected load.

Correct sizing ensures safe, reliable, and easy-to-handle cables for mobile mining equipment.

Compliance With International and Industry Standards

SHD-GC cables meet international standards, including:

• ICEA S-75-381 / NEMA WC 58

• ASTM B172 & B33 (tinned copper conductors)

• CAN/CSA-C22.2 No.96

Compliance ensures:

• Safety and reliability for South African mines

• OEM compatibility with mining machinery

• Procurement and export eligibility

Adhering to these standards enhances confidence in cable performance under harsh conditions.

SHD-GC Cables in Underground Platinum Mining

A platinum mine in Limpopo faced frequent cable failures on its continuous miners and conveyor systems. Operating in damp, abrasive tunnels, the previous power cables had poor flexibility and inadequate grounding systems.

Solution: SHD-GC 2kV cables were installed with:

• Reinforced CPE jackets for abrasion resistance

• Ground check conductors for continuous monitoring

• Shielded insulation for fault containment

Results:

• Improved safety – ground faults were detected before incidents occurred

• Reduced cable failures – downtime decreased by 35% over 12 months

• Extended service life – cables survived extreme flexing, moisture, and dust

This case demonstrates SHD-GC’s effectiveness in South African underground platinum operations, highlighting both safety and cost benefits.

Installation and Handling Best Practices

To maximize cable life and performance:

• Follow minimum bending radius recommendations during installation

• Avoid sharp bends and kinks during reeling and dragging

• Inspect cables regularly for abrasion, cuts, or insulation damage

• Avoid chemical exposure where possible, even with CPE protection

Common mistakes include over-bending near equipment, improper reeling on drums, and neglecting ground check monitoring.

Comparison With Other Portable Mining Cables

• SHD-GC vs SHD-GC-H – SHD-GC-H offers higher heat resistance but similar mechanical protection.

• SHD-GC vs Type G-GC – G-GC lacks the super heavy-duty outer jacket, making SHD-GC more suitable for highly abrasive conditions.

• Voltage selection – 2kV is optimal for portable equipment; higher voltages are suited for stationary or high-power applications.

Choosing the right cable requires understanding equipment needs, operating environment, and safety compliance.

FAQ

Q1: Is Type SHD-GC suitable for continuous flexing applications?
A1: Yes, its tinned copper conductors and flexible EPR insulation are designed for repeated movement.

Q2: Why is a ground check conductor essential in mining?
A2: It continuously monitors grounding integrity, alerting operators to potential faults before accidents occur.

Q3: Can SHD-GC cables be customised for South African mine conditions?
A3: Yes, options include alternative jackets, two-layer reinforcement, and conductor sizing.

Q4: How does CPE compare with TPU or NBR jackets?
A4: CPE offers excellent abrasion, chemical, oil, and flame resistance, making it ideal for underground mining.

Q5: What factors determine the correct cable size selection?
A5: Load current, length, voltage drop, mechanical stress, and flexing requirements are all considered.

Choosing the Right SHD-GC Cable for Safer, More Reliable Mining Operations

Type SHD-GC Three-Conductor Round Portable Power Cables (2kV, CPE Jacket) are a cornerstone of safe and efficient mining operations in South Africa. With their:

• Super heavy-duty mechanical design

• EPR insulation and tinned copper shielding

• Ground check monitoring

• CPE outer jacket resistance to chemical and mechanical stress

They ensure continuous power supply, operator safety, and longer service life.

For South African mines, selecting high-quality, compliant SHD-GC cables translates into reduced downtime, fewer accidents, and enhanced operational efficiency. Whether powering continuous miners, loaders, or conveyors, these cables remain a trusted choice for the industry.