Built to Survive Anything: Why CORDAFLEX (N)SHTOEU Might Be South Africa’s Toughest Low-Voltage Reeling Cable

Why Reeling Cables Matter in South Africa’s Toughest Environments

South Africa’s mining, port, and heavy industries operate in some of the most challenging conditions on the planet. From the dusty, abrasive surfaces of platinum and chrome mines to the salty air at Durban and Saldanha Bay ports, equipment faces constant mechanical and environmental stress. At the heart of these high-stress operations is an often-overlooked hero: the low-voltage reeling cable.

Reeling cables are not ordinary electrical conductors. They power equipment that moves continuously — cranes, stacker-reclaimers, shuttle cars, electric shovels, and automated loaders — while enduring constant bending, torsion, and abrasion. South African operations, with their unique combination of heavy machinery and harsh environmental conditions, demand cables that survive and perform under extreme mechanical stress.

Enter CORDAFLEX (SMK) (N)SHTOEU, a premium low-voltage reeling cable engineered according to DIN VDE 0250-814 standards, globally recognised and tested for extreme performance. It combines flexibility, mechanical robustness, chemical resistance, and long-term reliability — qualities essential for South African mining and industrial operations.

Understanding What Makes a Reeling Cable “High-Performance”

Not all cables are created equal. Understanding why a reeling cable is considered “high-performance” requires looking at its function, mechanical demands, and environment.

Reeling vs Trailing vs Festoon Cables

• Trailing cables are dragged behind moving equipment but do not undergo continuous reeling or torsion.

• Festoon cables slide or hang in loops along cranes and gantries.

• Reeling cables, like CORDAFLEX (N)SHTOEU, are wound and unwound continuously on drums, requiring extreme flexibility, torsion resistance, and mechanical strength.

Core Mechanical Requirements

A high-performance low-voltage reeling cable must withstand:

1. High mechanical endurance – to survive thousands of bends, twists, and abrasion cycles.

2. Torsion resistance – essential when equipment rotates or changes direction, especially in South African surface mines with long reeling paths.

3. Impact resistance – protection against stones, sharp edges, and moving machinery.

4. Stable electrical behaviour under movement – voltage drops or signal loss must be minimal, even at high speeds.

South African Operational Challenges

South African mines and ports present unique challenges:

• High dust and abrasive materials – e.g., Rustenburg platinum mines or Kathu iron ore operations.

• Long travel lengths – stacker-reclaimers or gantry cranes covering hundreds of meters.

• Extreme outdoor conditions – high UV exposure, temperature swings from −35°C to +50°C in some regions.

• Automation integration – modern mines require data and control signals alongside power, demanding advanced shielding and optional fibre optics.

CORDAFLEX (N)SHTOEU addresses all these needs with engineered precision.

Construction Overview of CORDAFLEX (SMK) (N)SHTOEU

The cable’s design is a culmination of decades of engineering expertise, specifically tailored for extreme industrial use.

Conductor System

• Material: Tinned electrolytic copper.

• Stranding: Very finely stranded, Class FS for maximum flexibility.

• Benefits:

  • Corrosion resistance in humid or salty environments (e.g., Durban port, Saldanha Bay).

  • Reduced conductor fatigue during repeated bending and reeling.

Insulation Layer – PROTOLON MS (EPR-Based)

• Compound: High-quality EPR (minimum 3GI3).

• Properties:

  • High mechanical, thermal, and electrical stability.

  • Light-coloured for easy maintenance and core identification.

• South African relevance: Ensures safety and quick troubleshooting in underground tunnels and surface operations with limited visibility.

Individual Screen Options

• Type: Tinned copper braid, transfer impedance optimised at 30 MHz.

• Variants: Shielded, twisted-pair, or fibre-optic integrated cores.

• Applications:

  • Automated loaders and conveyor systems requiring high signal fidelity.

  • Industrial Ethernet and CAN-Bus connectivity for smart mining.

Core Arrangement

• Layering: Up to three layers.

• Advantages:

  • Even stress distribution, reducing localized fatigue.

  • Stable performance during high-speed reeling (up to 240 m/min).

Multi-Layer Sheath System – PROTOFIRM Special

Inner Sheath (PCP-Based)

• High-grade PCP compound; bright yellow for visibility underground.

Anti-Torsion Braid

• Polyester-reinforced braid vulcanised between sheaths.

• Maintains cable stability during multidirectional movement.

• Crucial for long surface reeling operations prone to twisting.

Outer Sheath (PCP-Based Rubber)

• Abrasion- and tear-resistant.

• Designed for stones, sand, and harsh weather.

Marking System

• Standard marking for traceability.

• VDE approval ensures import compliance and easy NRCS inspection in South Africa.

Technical Specifications and Electrical Parameters

Voltage Ratings

• Rated: 0.6/1kV

• Max permissible AC: 0.7/1.2 kV

• Max permissible DC: 0.9/1.8 kV

• AC Test Voltage: 3.5 kV for 5 minutes

Conductor Temperature and Thermal Limits

• Continuous: 90°C

• Short-circuit: 250°C

• Operating temperature ranges:

  • Fixed: −50°C to +80°C

  • Flexible: −35°C to +80°C

• Vital for South Africa’s varying climates, from Mpumalanga coal belt to Northern Cape deserts.

Mechanical Properties

• Max tensile load: 30 N/mm²

• Torsional stress: ±50°/m

• Minimum bending radius: per DIN VDE 0298-3

• Suitable for high-speed gantry and festoon operations.

Chemical & Environmental Resistance

• Oil, ozone, UV, and moisture resistant

• Long-term water resistance confirmed

• Ideal for dusty, corrosive areas such as Rustenburg, Kathu, or Richards Bay.

Size Range and Variants Available

Power Cable Variants

• 3-core (split earth), 4-core, 5-core

• Cross-sections from 4 mm² to 300 mm²

• Current-carrying capacity, bending radius, and short-circuit ratings tailored for heavy-duty mining.

Control Cable Variants

• Multi-core (1.5 mm² and 2.5 mm²)

• Maintains high signal integrity for control circuits.

Bus Cable Versions

• ASI-Bus, CAN-Bus, Profibus, Industrial Ethernet

• Variants: 6x(2x0.5), 3x(2x1), 9x(2x1), etc.

Fibre-Optic Integrated Versions

• FO combinations: 50/125, 62.5/125, E9 fibres

• Essential for smart mining and digital automation in South Africa.

Applications in South Africa

Surface Mining

• Reeling systems on electric shovels, stacker-reclaimers, cone crushers

• Case example: A North West chrome mine replaced conventional trailing cables with CORDAFLEX (N)SHTOEU, reducing downtime from sheath tearing and torsion failures.

Underground Mining

• Harsh bending cycles in tunnels

• Suitable for winches, shuttle cars, and mobile substations.

Ports and Bulk Handling

• Durban, Richards Bay, and Saldanha Bay port machinery:

  Ship loaders, bulk conveyors, RTG & RMG cranes

• Enhanced cable durability reduces maintenance interruptions and enhances safety.

Industrial Machinery

• Steel mills, automotive plants, and paper mills

• Continuous motion and oil exposure require resilient reeling cables.

Automation & Smart Mining Integration

• Integrated FO and bus systems enable real-time monitoring

• Supports Industry 4.0 and predictive maintenance in South African mining operations.

South African Case Study: Improved Reliability & Reduced Failure Rates

• Background: Frequent cable breakage due to torsion and abrasion caused significant downtime.

• CORDAFLEX Implementation:

  • 40% reduction in cable downtime

  • Enhanced signal quality for automated equipment

  • Lower total cost of ownership

• Site: Northern Cape manganese operation (fictionalised for confidentiality).

• Result: Demonstrated superior performance and extended service life under harsh South African conditions.

Advantages of CORDAFLEX (SMK) (N)SHTOEU for South African Users

• Extreme mechanical stress resistance

• High flexibility without sacrificing robustness

• Climatic and chemical resistance tailored for South African conditions

• Supports long travel lengths and high reeling speeds

• Versatile: available in power, control, bus, and FO configurations

• VDE compliance aligns with NRCS and import regulations

How to Select the Right (N)SHTOEU Cable

Key factors for South African users:

1. Voltage class – 0.6/1 kV standard, confirm operational needs.

2. Cross-section – depends on current-carrying requirements.

3. Number of cores – power, control, or combined systems.

4. Shielding/FO requirements – for automation or high-signal fidelity.

5. Reeling speed and bending radius – for gantries, stacker-reclaimers, or underground.

6. Environmental factors – dust, humidity, ambient temperature, mechanical load.

Installation & Maintenance Guide (South-Africa-Friendly Tips)

• Proper drum winding and reeling direction

• Respect minimum bending radius

• Inspect regularly for cuts, torsion marks, or conductor pull-out

• Optimise guide rollers and lubrication

• Prevent premature sheath damage in mines with sharp rock formations

Frequently Asked Questions (FAQ)

1. What makes (N)SHTOEU different from regular rubber reeling cables?

   Special sheath system, anti-torsion braid, and high-quality EPR insulation for extreme durability.

2. Is CORDAFLEX suitable for underground mines in South Africa?

   Yes, tested for harsh bending cycles and tight tunnels.

3. How does the anti-torsion braid improve lifespan?

   Reduces twisting and mechanical stress on conductors, extending cable life.

4. Can these cables carry data (bus or fibre-optic)?

   Yes, optional FO and bus variants support automation and Industry 4.0 systems.

5. What is the maximum safe reeling speed?

   Up to 240 m/min standard; consult manufacturer beyond that.

6. Can (N)SHTOEU cables handle oil-contaminated environments?

   Yes, fully oil-resistant according to DIN standards.

7. How do I choose between standard and FO-combined versions?

   Depends on power vs data requirements in your automation setup.

8. What certifications apply to import and testing?

   VDE, GOST-R, aligned with South African NRCS approval.

9. What is the expected lifespan under heavy-duty operation?

   Significantly longer than conventional trailing cables; site-specific results available.

10. Are customised designs available for unique South African mining setups?

    Yes, CORDAFLEX can be tailored to operational requirements.

Conclusion

In South Africa’s demanding mining, port, and industrial environments, CORDAFLEX (SMK) (N)SHTOEU stands out as a high-performance, reliable low-voltage reeling cable. Its robust construction, extreme mechanical endurance, and versatile electrical capabilities make it suitable for power, control, and smart mining systems.

By reducing downtime, supporting high-speed reeling, and enabling digital automation, CORDAFLEX proves that durability, flexibility, and intelligence can coexist in one cable — a true hero in the harshest South African operations.