Introduction

South Africa’s mining landscape is among the toughest power environments on earth. From the high-stress coal faces of Witbank, to the deep rock temperatures of the Rustenburg platinum belt, to the abrasive iron-ore operations around Kolomela and the manganese giants of the Northern Cape, local engineers constantly battle mechanical stress, moisture, chemical exposure, and unpredictable machine movements.

In such conditions, ordinary cables simply don’t survive. Even some locally designed mining cables reach their limits under extreme dragging, repeated flexing, wet stopes, and aggressive mining chemicals.

This is where ICEA S-75-381 enters the South African conversation.

Although ICEA standards originate from North America, South African mines are increasingly using American-designed portable and feeder mining cables—especially where mines import shovels, draglines, continuous miners, high-power pump stations, or autonomous equipment built around U.S. electrical practices.

And ICEA S-75-381 remains one of the world’s most comprehensive standards for portable, mobile, and high-mechanical-stress mining cables.

This article provides a deep, engineering-level, South African-focused study of ICEA S-75-381 cables—including their structure, performance, materials, suitability for local environments, and real case studies from mines in SA.

What Is the ICEA S-75-381 Standard?

Background of the ICEA

The Insulated Cable Engineers Association (ICEA) is one of the most influential cable standards bodies worldwide. Since the early 20th century, ICEA has defined robust performance rules for cables used in harsh industries—mining, offshore, construction, power utilities, and industrial automation.

While SANS standards govern local South African cable manufacturing, ICEA standards are widely recognised globally—particularly in mining.

In short:
SANS governs the local market.
ICEA governs the global mining industry.

Scope of S-75-381

ICEA S-75-381 is formally titled:

“Portable and Power Feeder Cables for Use in Mines and Similar Applications.”

It covers:

• Portable power cables for moving equipment

• Trailing cables

• Reeling cables

• Shielded mining cables

• Feeder cables between mobile substations

• Power and control cables on machines exposed to mechanical abuse

• Cables operating between 600 V and 2 kV

This makes it especially relevant to South African mines using highly mobile, diesel-electric or electrically powered machinery.

Why South Africa Uses ICEA-Compliant Cables

South African mines typically turn to ICEA S-75-381 cables when:

1. Importing U.S.-spec mining machinery, which is designed to run on ICEA-rated cables.

2. Operating in extremely harsh mechanical environments where reinforced ICEA designs outperform some standard trailing cables.

3. Upgrading to autonomous or semi-autonomous mining fleets, which require shielded cables for low-interference communication and control.

4. Seeking improved flame, tear, and moisture performance in deep or ultra-deep mines.

In large open-cast mines like Kolomela, Sishen, or Kathu, ICEA S-75-381 cables often power shovels, drills, stacker-reclaimers, and mobile substations—where distances are long, equipment constantly moves, and cable damage risks are high.

Cable Types Defined in ICEA S-75-381

The standard defines several specialised cable families. Below is a practical explanation tailored to South African mining conditions.

Portable Cable Types for Mining Machines

Type W — Portable Cable Without Grounding Conductors

• Used mainly for non-critical mobile equipment.

• Common in quarry crushers, temporary pump setups, and mobile lighting.

• Simple construction—but no grounding means not suitable for high-risk equipment.

Type G — Portable Cable With Grounding Conductors

• Includes four grounding conductors.

• Provides safer fault protection for wet or metallic environments.

• Applied in pumps, smaller loaders, drills, and underground fans.

Type G-GC — Portable Cable With Grounding and Ground-Check

• Adds a dedicated ground-check wire, enabling real-time ground monitoring.

• Ideal for high-risk trailing operations, continuous miners, and deep-level installations.

In South Africa, Type G-GC has become common in:

• Underground coal pump stations in Mpumalanga

• Platinum shaft signalling systems

• Mobile conveyor drives

Shielded Mining Cable Types (SHD Family)

These cables include individually shielded power conductors, designed for electrically noisy or highly automated machines.

SHD Flat

• Used where cable must lay flat or pass under machinery.

• Common in underground rail haulage systems and pump skids.

SHD-PCG

• Shielded power + centre grounding conductor + control conductors.

• Found in automated longwall systems and machine control rigs.

SHD-CGC

• Similar to SHD-PCG but includes a central ground-check conductor.

SHD-GC

• Shielded power + grounding + ground-check.

• Increasingly used for LHDs (load-haul-dump units) and hybrid electric haulers.

Mine Power Feeder Cables

MP-GC (Mine Power Ground-Check Cable)

• Connects mobile substations, power skids, or distribution boxes.

• High mechanical toughness + strong electrical shielding.

• Popular in large open-pit mines with long cable runs.

Functional Differences Explained

South African examples:

• Kumba Iron Ore uses MP-GC feeders for mobile substations.

• Impala Platinum uses SHD-GC for LHD machine power and control.

• Manganese quarries in Hotazel favour Type W and G for crushers and screening plants.

Key Performance Requirements Under ICEA S-75-381

Mechanical Resistance

Mining cables face:

• Dragging across sharp rock

• Dynamic bending

• Tension loads

• Impact from machinery

• Reeling stress

ICEA S-75-381 sets minimum levels for:

• Abrasion resistance

• Tear resistance

• Tensile strength

• Jacket toughness

This is essential for SA mines where rocks like chromitite, manganese, and hematite are extremely abrasive.

Environmental Protection

Moisture Resistance

Vital for coal galleries in Witbank or deep platinum stopes.

Chemical Resistance

ICEA jackets withstand:

• Hydraulic oils

• Diesel

• Explosives residue

• Cement dust

UV & Ozone Resistance

Critical in the Northern Cape, which has some of the world’s highest UV levels.

Electrical Specifications

• Voltage classes: 600 V, 2 kV

• High dielectric integrity

• Stable insulation under heat and moisture

• Shielding to prevent interference on automated equipment

Fire & Flame Resistance

ICEA flame tests ensure:

• No rapid flame propagation

• Self-extinguishing capability

This is life-saving in narrow declines of platinum and gold mines where fire spreads fast.

Cable Design & Materials Under ICEA S-75-381

Conductor Materials

Most ICEA S-75-381 cables use:

• Annealed copper

• Finely stranded conductors for high flexibility

• Optional tinned copper for corrosion resistance

Insulation Systems

Two major insulation families:

XLPE (Cross-Linked Polyethylene)

• Higher dielectric strength

• Lower smoke generation

• Good for feeder cables

EPR (Ethylene Propylene Rubber)

• Flexible even at low temperatures

• Outstanding moisture and thermal resistance

• Common in portable or trailing cables

Jacket Types

TPE (Thermoplastic Elastomer)

• Excellent tear resistance

• Superior abrasion resistance

• Preferred in quarries and iron-ore mines

Screening & Shielding

Shielded designs include:

• Semi-conductive layers

• Copper braid or tape shields

• Individual conductor shielding

These improve:

• Interference resistance

• Automated control accuracy

• Ground fault detection reliability

Where ICEA S-75-381 Cables Are Used in South Africa

Mining

• Longwall coal equipment

• LHDs and drill rigs

• Underground pump stations

• Hybrid electric loaders

• Conveyor drives

• Decline development machinery

Tunnelling & Construction

Used in:

• TBM tunnelling

• Road & rail tunnel ventilation systems

• Heavy drilling systems

Quarrying

Granite and sandstone quarries around Rustenburg frequently use Type W and Type G cables in crushers and mobile screens.

Hybrid Renewable-Mining Systems

Northern Cape solar-mining hybrid facilities use ICEA cables for:

• Mobile power trucks

• Temporary distribution

• Rapid deployment substations

Case Studies from South Africa

Rustenburg Platinum Mine — SHD-GC for LHD Units

Problem:
Older trailing cables suffered frequent jacket tearing, causing unplanned downtime.

Solution:
Upgraded to SHD-GC cables with high-tear TPE jackets and shielded conductors.

Result:

• 30% reduction in cable-related failures

• Improved electrical safety

• Longer maintenance intervals

Mpumalanga Coal Mine — Type G-GC for Pump Stations

Problem:
Constant moisture and corrosive water caused regular insulation breakdown.

Solution:
Replaced standard trailing cables with Type G-GC, providing moisture-resistant EPR insulation and continuous ground monitoring.

Result:

• Significant reduction in ground-fault trips

• Extended cable life in wet stopes

Northern Cape Manganese Quarry — Type W for Crushing Equipment

Problem:
Extreme abrasion from manganese rock quickly destroyed general-purpose cables.

Solution:
Adopted Type W portable cables with ultra-tough TPE jackets.

Result:

• Dramatic increase in cable lifespan

• Lower operational costs

• Improved uptime of mobile crushing stations

Benefits of Using ICEA S-75-381 Cables in South Africa

High Durability & Reduced Maintenance

Designed for:

• Rock impact

• Dragging

• Chemical exposure

• Frequent movement

Lower failure rates = higher operational efficiency.

Improved Electrical Safety

Features like:

• Grounding

• Ground-check wires

• Shielding

Help prevent electrocution, arc faults, and machine damage.

Versatility & Mobility

Ideal for:

• Mobile substations

• Reeling systems

• Long trailing distances

• Dynamic machine layouts

Compatible with Modern Mining

Supports:

• Automation

• Real-time system feedback

• High-power electric machinery

How ICEA S-75-381 Compares to Other Standards

ICEA vs SANS 1520-1

They complement—not replace—each other.

ICEA vs MSHA (U.S.)

MSHA focuses on safety approval;
ICEA focuses on design, construction, and performance.

When SA Mines Prefer ICEA

• Imported machinery

• Harsh mechanical environments

• Long-distance trailing

• Automated equipment

Common Misunderstandings About ICEA S-75-381 Cables

“All mining cables are the same.”

False—each type is specialised.

“Ground-check is optional.”

Not for high-risk trailing systems.

“Imported ICEA cables don’t suit SA mines.”

Incorrect—ICEA designs often exceed local durability expectations.

“XLPE is always better than EPR.”

Depends on the application:

• XLPE = feeders

• EPR = portable flexibility

Frequently Asked Questions (FAQ)

Q1: What is the main difference between Type G and Type G-GC?
A: G-GC includes a ground-check for continuous monitoring.

Q2: Can ICEA cables be used with SANS systems?
A: Yes—mines often mix standards depending on equipment origin.

Q3: Are they suitable for long trailing distances?
A: Yes, especially Type G-GC and SHD-GC.

Q4: Which jacket is best for abrasive SA mines?
A: TPE jackets on Type W and SHD are top performers.

Q5: Are SHD cables necessary for automated machines?
A: Yes—shielding stabilises control signals.

Q6: Can they be spliced underground?
A: Yes, but must follow proper mining cable splicing procedures.

Q7: What voltages are most used?
A: 600 V and 2 kV.

Q8: How often should cables be inspected?
A: Daily visual checks + weekly electrical tests.

Q9: Do ICEA cables reduce arc-flash risks?
A: Yes—via insulation, grounding, and shielding.

Q10: Are ICEA cables more expensive?
A: Initially yes, but lifecycle cost is lower due to durability.

Conclusion

ICEA S-75-381 cables are engineered for some of the harshest working environments in global mining—and South Africa’s extremely demanding geological conditions make them an excellent fit. Whether powering a continuous miner in Rustenburg, dewatering pumps in Witbank, or mobile substations in the Northern Cape, ICEA cables deliver:

• Superior durability

• High electrical safety

• Consistency under mechanical stress

• Compatibility with modern automated mining

• Internationally recognised performance

For South African mine managers, engineers, and maintenance teams, selecting ICEA S-75-381 cables is not just a technical decision—it’s an investment in safer, more efficient, and future-ready mining operations.