How BS 6708 TYPE 201 Cable Keeps the Gold and Coal Flowing

Introduction

In South Africa’s bustling mining industry, where gold veins run deep beneath the Gauteng highlands and coalfields stretch across Mpumalanga, the machinery powering daily operations demands more than just electricity—it requires reliability. Trailing cables, often overlooked by the untrained eye, are the arteries delivering power from the surface to the heart of underground operations. A single cable failure can halt production, endanger workers, and incur costly maintenance delays.

Enter BS 6708 TYPE 201, a robust, heavy-duty flexible trailing cable designed for dynamic mining equipment. Originating from the British Standards Institution, BS 6708 sets out rigorous specifications for cables in harsh environments like quarries, open-pit, and underground mines. Among its various types, TYPE 201 stands out for its ability to withstand mechanical stress, abrasion, moisture, and extreme conditions—all essential for South African mines.

This article dives deep into the anatomy, materials, electrical properties, and applications of BS 6708 TYPE 201 cables. By the end, mining engineers, electricians, and technical enthusiasts will understand why this cable is a cornerstone of safe and efficient mining operations in South Africa.

Structure of BS 6708 TYPE 201 Cable

At first glance, a trailing cable might seem like a simple black cord. However, BS 6708 TYPE 201 is a masterpiece of engineering, designed to endure the unforgiving environments of mines and quarries. Its layered construction balances flexibility, durability, and electrical performance.

Core Components

The cable comprises multiple essential elements:

• Conductors: High-quality, tinned, stranded copper wires designed for maximum conductivity.

• Insulation: Ethylene Propylene Rubber (EPR) envelops each conductor to prevent short circuits.

• Screening: Tinned copper/nylon braid around each core reduces electromagnetic interference (EMI).

• Layup: Cores are carefully laid in contact with one another to minimize mechanical stress.

• Bedding: Rubber-based compound cushioning the cores.

• Armour: Galvanised steel pliable armour protects against crushing and abrasion.

• Outer Sheath: Heavy-duty chloroprene outer sheath for resistance to chemicals, moisture, and UV exposure.

Design Rationale

Every layer serves a purpose:

• Flexibility: The combination of stranded conductors and pliable armour ensures the cable bends without damage, essential for trailing machinery.

• Mechanical Protection: The steel armour absorbs impact and prevents crushing from mining vehicles or falling debris.

• Environmental Resistance: Chloroprene outer sheathing shields against moisture, oils, and abrasive dust.

Visual Aid

A cross-sectional illustration can help:

• Center: 3 tinned copper cores, each insulated with EPR

• Surrounding: Rubber bedding

• Armour layer: Galvanised steel

• Outer sheath: Chloroprene covering

This design ensures BS 6708 TYPE 201 is both robust and adaptable to dynamic environments.

Materials Used in BS 6708 TYPE 201 Cable

High-quality materials distinguish TYPE 201 from generic trailing cables. Let’s explore why each choice matters for South African mines.

Conductor Material

• Electrolytic, stranded, tinned copper wire (IEC 60228 Class 5)

• Why it matters: High conductivity ensures minimal voltage drops even across long runs. Tin coating prevents corrosion in humid mine environments. Stranded construction enhances flexibility—critical for trailing cables moving with machinery.

Insulation and Sheath

• Insulation: EPR

  Flame retardant and flexible

  Excellent dielectric properties for up to 1.1 kV operation

• Bedding: Rubber-based compound

  Provides cushion against vibrations and bending stresses

• Armour: Galvanised steel pliable armour

  Absorbs mechanical impact and resists crushing

• Outer Sheath: Heavy-duty chloroprene

  Resists oil, chemicals, abrasion, UV exposure, and water ingress

Screening

• Tinned copper/nylon braided screen

  Reduces electromagnetic interference

  Protects signal integrity for sensitive control circuits

Material Benefits for South African Mining

In Gauteng gold mines or Mpumalanga coalfields, cables face:

• Dust-laden air

• Wet, humid conditions

• Heavy machinery impact

The combination of EPR insulation, steel armour, and chloroprene sheath ensures TYPE 201 cables remain operational, flexible, and safe—minimizing downtime and maintenance.

Technical Specifications

BS 6708 TYPE 201 cables are available in multiple cross-sections, each tailored for specific power demands.

Key insights:

• Heavy-duty cables accommodate high-power machinery.

• Minimum bending radius ensures flexibility without stressing the conductor.

• Cable weights are manageable for installation teams.

Standards Compliance

• BS 6708 compliant

• Rated voltage: 640/1100 V

• Test voltage: 3 kV

• Armour thickness tailored for mechanical protection

These specifications guarantee both performance and safety in South African mines.

Electrical Parameters

Electrical characteristics are crucial for selecting the right cable.

Current Ratings

• Ensures machinery receives adequate power without overheating

• Enables long-term continuous operation

Resistance Values

• Phase conductor DC resistance (Ω/km at 20°C): 1.95–0.164 depending on size

• Armour resistance: 2.0–0.74 Ω/km

• 3 screens in parallel: 0.5–1.61 Ω/km

Low resistance values minimize voltage drop, ensuring energy efficiency in high-power applications like underground crushers or conveyor systems.

Performance Insights

The combination of:

• High conductivity

• Thick insulation

• Armour protection

ensures efficient and safe power transmission, even in humid, dusty, or high-vibration environments typical of South African mining operations.

Applications in Mining and Quarries

BS 6708 TYPE 201 is a workhorse cable, used in diverse scenarios:

Primary Uses

• Supplying power to excavators, crushing machines, and conveyor systems

• Supporting dynamic equipment that moves or vibrates during operations

• Powering temporary lighting and auxiliary equipment in underground workings

South African

In local operations:

• Gauteng gold mines: powering crushers and shuttle cars

• Mpumalanga coal mines: feeding draglines and coalface equipment

• Limestone and aggregate quarries: trailing mobile crushers and screeners

Cables must survive frequent movement, heavy loads, and exposure to water, dust, and oil.

Advantages

• Flexible yet mechanically robust

• Reduces downtime by resisting abrasion and crushing

• Enhances safety with flame retardant and electrically stable design

Application in a South African Gold Mine

Background:
At a large Gauteng underground gold mine, engineers sought a reliable trailing cable for underground crushers operating in narrow, dust-laden tunnels. Traditional cables frequently failed, causing production halts and maintenance headaches.

Implementation:
BS 6708 TYPE 201 cables were deployed, connecting crushers and conveyors. Their flexible armour and chloroprene sheath made them suitable for constant movement and occasional wet conditions.

Challenges Addressed:

• Abrasion: Armour prevented damage from conveyor rollers.

• Moisture: Sheath resisted water ingress from underground seepage.

• Space constraints: Flexibility allowed installation in confined tunnels.

Outcomes:

• Significant reduction in unscheduled downtime

• Maintenance costs dropped by over 20%

• Enhanced safety, with fewer electrical incidents

Lessons Learned:

• Proper cable selection must consider local environmental conditions

• Armour and sheath thickness should match operational stress

• Regular inspections complement material durability

This case illustrates how TYPE 201 cables support sustainable mining practices, aligning with South African regulations and operational demands.

Frequently Asked Questions (FAQ)

1. What makes BS 6708 TYPE 201 suitable for South African mines?

Its durable construction, including steel armour and chloroprene sheath, withstands humid, abrasive, and mechanically stressful conditions typical in local mines.

2. How do I select the right cross-section?

Consider equipment power ratings, cable length, and ambient temperature. Larger cross-sections carry higher currents with lower voltage drop.

3. What are common installation pitfalls?

• Exceeding the minimum bending radius

• Incorrectly connecting the screening layers

• Insufficient support for heavy sections over long spans

4. Is it compatible with other standards?

BS 6708 TYPE 201 compares favorably to SANS and IEC equivalents, often exceeding basic mechanical and electrical requirements.

5. Maintenance tips

• Regular inspection for sheath abrasions

• Check for water ingress or crushing

• Replace damaged sections promptly to avoid failures

Ensuring Reliable Mining Operations

BS 6708 TYPE 201 is more than a cable—it is the lifeline of South Africa’s mining sector. From underground gold tunnels in Gauteng to open-pit coalfields in Mpumalanga, it delivers safe, efficient, and durable power to dynamic equipment.

As mines modernize, future standards may introduce eco-friendly insulation and advanced armour materials, but the core principles of flexibility, mechanical protection, and electrical reliability will remain critical.

Call to Action: Mining engineers and maintenance teams should consult cable specialists to select and implement BS 6708 TYPE 201 correctly, maximizing uptime and ensuring safe operations in South Africa’s challenging mining environments.

Contact Anhui Feichun Special Cable Co., Ltd.

For comprehensive technical specifications and quotations, please contact our specialized mining cable engineering team:

Technical Engineering Support:

tech@feichuncables.com

Sales Engineering Department:

Li.wang@feichuncables.com

WhatsApp Contact:

Manufacturer: Anhui Feichun Special Cable Co., Ltd. (安徽飞纯特种电缆有限公司)

Manufacturing Headquarters: Building A, Private Science and Technology Park, Hefei Economic and Technological Development Zone, Anhui Province, People’s Republic of China

+86 17333223430