In-Depth Analysis of SANS 1520 Mining Cable Standards: Understanding Low-Voltage, High-Voltage, and DC Trailing Cables in South Africa’s Mining Industry

Introduction

South Africa’s mining industry remains a backbone of the national economy, contributing significantly to employment, exports, and industrial growth. From deep-level gold mines to large open-cast coal operations, a common thread that unites them all is the critical dependence on reliable power infrastructure. Without robust and compliant mining cables, modern mining operations would grind to a halt.

The South African National Standards (SANS), issued by the South African Bureau of Standards (SABS), play a crucial role in regulating this infrastructure. Among them, SANS 1520 is one of the most important, providing specifications for flexible trailing cables used in underground and surface mines.

This article takes a deep dive into the SANS 1520 standard, examining its structure, cable classifications, associated references, and the broader importance of compliance. Drawing on recent developments in South Africa’s mining sector—such as renewed investment in platinum group metals, debates about safety compliance, and technological innovation—we explore how these cables not only power mining machinery but also safeguard lives.

What is SANS 1520?

SANS 1520 is the national standard for flexible trailing cables used in mining applications. It ensures that cables can withstand extreme conditions—abrasion, mechanical stress, moisture, chemical exposure, and even explosive environments—while maintaining safe and reliable power supply.

The standard is divided into three main parts, reflecting the diverse electrical requirements in mining operations:

• Part 1 – Low-voltage alternating current (a.c.) cables with ratings of 640V/1.1kV and 1.9/3.3kV.

• Part 2 – High-voltage alternating current (a.c.) cables with ratings from 3.8/6.6kV to 19/33kV.

• Part 3 – Direct current (d.c.) cables for mining supply systems, rated up to 1.5kV d.c.

By regulating construction, materials, and testing, SANS 1520 ensures that mining cables remain safe, durable, and efficient throughout their lifecycle.

SANS 1520 Part 1: Low-Voltage Flexible Trailing Cables

Part 1 addresses low-voltage mining applications, which form the backbone of everyday underground operations. These include shuttle cars, drill rigs, pumps, and conveyor systems, all of which rely on dependable trailing cables.

Cable Types under Part 1

• Type 41 and Type 61 Cables

  Three-core design: two power cores and one pilot core.

  Four-core design: three power cores and one pilot core.

  Six-core design: three power cores and three pilot cores.

The inclusion of pilot cores is critical. They act as monitoring and safety circuits, enabling equipment shutdown in case of fault conditions, preventing electrical hazards.

Key Characteristics

• Voltage rating: 640V/1.1kV and 1.9/3.3kV.

• Construction: flexible elastomeric insulation, heavy-duty rubber sheaths, abrasion-resistant design.

• Applications: portable mining machinery, continuous miners, and pump installations.

Part 1 cables are indispensable in South Africa’s deep-level gold mines, where narrow shafts demand cables that are both flexible and mechanically tough.

SANS 1520 Part 2: High-Voltage Flexible Trailing Cables

Part 2 expands into high-voltage applications, essential for large-scale mining machinery where substantial power transmission is required.

Cable Types under Part 2

• Type 63 and Type 66: widely used in both mining and non-mining industrial environments.

• Type 611, 622, and 633: designed for specialized heavy-duty mining operations.

Voltage Ratings

• From 3.8/6.6kV up to 19/33kV, covering both medium- and high-voltage ranges.

Applications

• Dragline excavators in open-pit coal mines.

• Electric shovels and haulage systems.

• Industrial applications beyond mining, such as ports and steel plants.

High-voltage trailing cables are designed with robust insulation systems, enhanced screening for electromagnetic interference, and reinforced sheathing to resist both tensile and torsional forces.

SANS 1520 Part 3: Low-Voltage Direct Current (D.C.) Cables

Part 3 focuses on d.c. supply systems, crucial in niche but high-risk environments.

Applications

• Battery-operated mining equipment such as shuttle cars and drilling machines.

• Hazardous zones where explosion risk demands special insulation and construction.

These cables are engineered to minimize sparking and arcing, addressing one of the primary risks of operating d.c. systems in underground mines.

Associated SANS Standards

SANS 1520 does not operate in isolation. It references and complements several other key standards:

• SANS 1339 – XLPE insulated cables for voltages 3.8/6.6kV to 19/33kV.

• SANS 1411-1 – Conductors for insulated cables.

• SANS 1411-3 – Elastomer materials for cable insulation.

• SANS 5526 – Dielectric resistance testing.

• SANS 6281-3 – Test methods for paper-insulated cables.

These references ensure interoperability, consistent testing, and material compliance, reinforcing the integrity of the mining cable industry.

Why SANS 1520 Matters in South Africa

Mining as an Economic Driver

South Africa is the world’s largest producer of platinum group metals, a top producer of gold, and home to vast coal and manganese reserves. The safe, continuous power supply enabled by compliant cables directly influences productivity.

Safety and Reliability

Non-compliance can lead to:

• Electrical fires.

• Equipment breakdowns.

• Worker injuries or fatalities.

In fact, following a 2024 report on mining fatalities released by the Department of Mineral Resources and Energy (DMRE), poor electrical infrastructure was highlighted as a contributing factor in several incidents. This renewed emphasis on SANS compliance has placed cable standards in the spotlight.

Durability and Performance

SANS 1520-compliant cables are built to endure:

• Abrasion from sharp rocks.

• Chemical exposure from mining fluids.

• High tensile stress from moving machinery.

Their durability translates into lower maintenance costs and reduced downtime, a critical factor in today’s competitive mining environment.

Case Study: Safety Compliance in Platinum Mines

In early 2025, media reports highlighted a near-miss incident in a platinum mine near Rustenburg, where a non-compliant trailing cable overheated during continuous use. Investigations confirmed that the cable did not meet SANS 1520 Part 1 requirements for insulation thickness and pilot core monitoring.

While no fatalities occurred, the mine faced temporary shutdown and financial penalties, underscoring the importance of adherence to national standards. This case accelerated efforts among operators to audit their cable infrastructure and replace non-compliant stock with certified alternatives.

Feichun’s Role in SANS 1520 Compliance

Feichun has emerged as a trusted supplier of SANS 1520-compliant mining cables in South Africa.

Expertise and Services

• Design & Manufacturing: Cables built to SANS 1520 Part 1, 2, and 3 requirements.

• Testing & Certification: Compliance with dielectric resistance (SANS 5526) and other test protocols.

• Technical Support: Assistance with cable selection, specification, and project integration.

• Project Management & Logistics: Ensuring cables are delivered and installed according to mining schedules.

Additionally, Feichun provides cables manufactured to other SANS standards such as SANS 1507-4, broadening their capability across the energy sector.

Frequently Asked Questions (FAQ)

What is the purpose of SANS 1520?

It regulates the construction, materials, and performance of flexible trailing cables used in mining, ensuring safety, durability, and compliance.

What types of cables are covered by SANS 1520?

• Part 1: Low-voltage a.c. cables (640V/1.1kV and 1.9/3.3kV).

• Part 2: High-voltage a.c. cables (3.8/6.6kV to 19/33kV).

• Part 3: Low-voltage d.c. cables (up to 1.5kV d.c.).

What are pilot cores in SANS 1520 cables?

They are auxiliary conductors used for control and monitoring, enabling safety shutdown mechanisms in mining equipment.

Can SANS 1520 cables be used outside mining?

Yes. Part 2 cables, such as Type 63 and Type 66, are suitable for industrial and port applications where flexibility and durability are required.

How can I ensure my cables meet SANS 1520 standards?

Partner with reputable suppliers like Feichun, who provide certified cables and technical support.

What testing is required?

Cables must undergo dielectric resistance (SANS 5526), mechanical stress tests, and compliance with material standards (SANS 1411).

Where can I get technical support?

Feichun’s team provides full support, from design consultation to on-site testing and compliance verification.

Conclusion

The SANS 1520 standard is far more than a regulatory requirement; it is the backbone of safe, efficient, and sustainable mining operations in South Africa. By defining the design and performance of trailing cables, it reduces risks, enhances reliability, and supports one of the country’s most vital industries.

As recent incidents show, non-compliance can carry heavy costs, not just financially but in terms of worker safety. That is why trusted suppliers like Feichun are vital partners, offering not only SANS 1520-compliant cables but also technical expertise and project support.

In a mining sector where both safety and productivity are paramount, SANS 1520 compliance is non-negotiable. Choosing the right cable is, ultimately, choosing safety, reliability, and long-term success.