Introduction

In South Africa’s toughest industries — mining, heavy manufacturing, ports, rail, and bulk material handling — large moving machines depend on one unsung hero: the reeling cable. Whether powering a stacker-reclaimer in Saldanha Bay or feeding a mobile crusher in Limpopo, reeling cables face intense stress that few electrical components can survive.

As mining operations modernise, the demand for high-performance low-voltage reeling cables has grown sharply. Machines are moving faster, loads are heavier, automation levels are rising, and equipment cycles are longer than ever before. This means torsion, tension, torque, abrasion, chemical exposure, and high travel speeds are now the daily reality for any cable installed on reeling systems.

That’s where the PUR-HF TROMMEL LV Reeling Cable enters the picture.

This cable is engineered purposely for brutal, continuous mechanical movement — both vertical and horizontal. Using a halogen-free polyurethane system, high-flex Class 5 conductors, and a textile anti-twist core, it has become a favourite among South African OEMs and maintenance teams who need reliability, safety, and long service life.

This article provides a deep, technical, practical, and industry-informed analysis of the cable. We unpack its construction, performance, use cases, standards, selection guidelines, and the real-world benefits proven in South African mines.

What Makes PUR-HF TROMMEL LV Reeling Cable Special?

Designed for High Mechanical Stress

Most conventional LV cables struggle when exposed to mechanical forces. Mining machinery, for example, imposes:

• Torsional stress – the cable twists internally as the equipment turns or retracts.

• Tensile stress – the cable is pulled during vertical travel or long reeling distances.

• Torque load – rotational forces build up as the drum winds and unwinds.

In South African mines — especially platinum operations in Limpopo and gold mines in Gauteng — machinery such as stackers, reclaimers, rail-mounted transfer cars, and mobile crushers constantly subject cables to these combined stresses.

PUR-HF TROMMEL LV Cable is engineered specifically to survive these conditions thanks to:

• Anti-twist textile braid

• Central strength member

• Highly elastic PUR sheaths

• Class 5 stranded copper

• Corrected torsion capabilities of ±25°/m

These features make it suitable for machinery that stops, starts, lifts, drops, rotates, or changes direction abruptly.

Built for Continuous Movement

This cable is designed for dynamic operation — meaning it moves constantly, sometimes non-stop for hours.

It operates as both a vertical and horizontal drum-reeling cable, supporting:

• High-speed drum reeling

• Festoon systems

• Automated reeling machines

• Long travel distances

• Compact drum geometries

The cable can operate at speeds of up to:

200 m/min (festoon and drum systems)

This makes it perfect for:

• Ship loaders at Durban Harbour

• Coal stacker reclaimers in Mpumalanga

• High-speed gantry cranes in industrial plants

• Mobile crushers moving along conveyor lines

Enhanced Reliability for Harsh Environments

South African mining is wet, dusty, abrasive, and chemically harsh. Oils, diesel, alkalines, process water, and cleaning solvents can rapidly degrade PVC- or rubber-based cable jackets.

PUR-HF (halogen-free polyurethane) solves these issues:

• Exceptional hydrolysis resistance

• High chemical resistance to oils and solvents

• High abrasion resistance

• High elasticity withstands repeated bending

• Halogen-free, flame-retardant properties

Combined with a central textile strength member, the cable’s durability is significantly higher than traditional NBR sheath reeling cables.

Cable Construction – Inside the PUR-HF TROMMEL LV Cable

To understand why this cable performs so well, we must analyse its internal construction.

Conductor – Class 5 Flexible Stranded Copper

The conductor uses Class 5 high-flex stranded copper, ideal for continuous movement.

Why flexibility matters:

• Prevents strand breakage during bending

• Reduces internal stress during torsion

• Extends cable service life

• Enables tighter bending radii

Comparison:

ClassFlexibilityTypical UseClass 2RigidFixed installation; not for reelingClass 5FlexibleIdeal for reeling, festoons, and drag chainsClass 6Extra flexibleRobotics; not always needed for mining

For heavy-duty mining machines, Class 5 gives the perfect balance of flexibility and strength.

Insulation – LSZH

The LSZH insulation provides:

• Low smoke emission

• Zero halogen content

• Non-corrosive and non-toxic acids during fire

• Compliance with IEC 60332-1 flame tests

This is crucial in:

• Underground mines

• Processing plants

• Conveyor tunnels

• Chemical processing areas

In fire situations, LSZH saves lives and reduces equipment damage — a major advantage over PVC insulation.

Cable Lay-Up – Stability Against Twisting

The cable cores are laid up in concentric layers around a central strength member.

Benefits:

• Reduces torsional forces

• Improves flexibility

• Enhances cable balance

• Minimises electrical stress concentration

• Prevents core migration during movement

This geometry is key to the cable’s long service life.

Sheath System – Inner & Outer PUR-HF Jackets

Both the inner and outer sheaths are PUR-HF (halogen-free polyurethane).

Advantages of PUR-HF:

• Exceptional tear strength

• Superior abrasion resistance

• High elasticity

• Zero halogen toxicity

• Excellent chemical and oil resistance

• Better UV resistance than PVC or rubber

Compared with PVC or NBR, PUR-HF survives:

• Wet conditions in Limpopo PGM mines

• Coal dust abrasion in Mpumalanga

• Salt spray at Richards Bay

• Heavy oil exposure in factories

Anti-Twisting Textile Braid

This component prevents the cable from twisting excessively during high-speed reeling.

Benefits:

• Maintains core geometry

• Prevents conductor breakage

• Eliminates internal friction

• Extends cable service life

This is especially critical for vertical travel applications, where torsion and tension act simultaneously.

Core Identification

The cable follows:

• VDE 0293-308

• IEC core colour standards

Core options:

• 4-core: G/Y, Brown, Black, Grey

• 5-core: G/Y, Blue, Brown, Black, Grey

• 6+ cores: white cores with black numbering

Clear identification improves installation accuracy and safety.

Technical Specifications Explained in Practical Terms

Voltage Rating – 0.6/1kV

This voltage class is perfect for:

• Mobile crushers

• Stacker-reclaimers

• Conveyors

• Port cranes

• Industrial machinery

Most LV mining machinery operates at 1.1 kV, making this cable compatible with South African systems.

Temperature Ratings

• Fixed installation: –50°C to +90°C

• Mobile operation: –40°C to +90°C

High-altitude South African mines, like those in Thabazimbi or Rustenburg, experience cold start-ups at dawn. A cable that becomes rigid in cold weather is likely to crack, tear, or fail internally.

PUR-HF remains flexible even under extreme cold.

Mechanical Limits

• Tensile load: up to 20 N/mm²

• Torsion: ±25° per metre

• Minimum bending radius:

  • 6× OD fixed

  • 8× OD mobile

These parameters must be respected — exceeding them dramatically reduces cable lifespan.

Speed & Travel

The cable handles up to:

200 m/min in both festoon and reeling applications

This is essential for:

• Automated cranes

• Rapid reeling systems

• High-speed industrial equipment

Minimum direction change distance: 20× OD to avoid excessive bending stress.

Dimensions & Current Carrying Capacities

A full technical table is provided in your outline. Below is a practice-oriented explanation.

Core Selection

• 4-core → general power

• 5-core → TN-S systems

• 7–42 cores → hybrid power/control systems

Weight Considerations

Cable weight affects:

• Drum torque

• Energy consumption

• Motor strain

• Acceleration/deceleration control

Lighter PUR-HF sheaths reduce power load on reeling machines.

Current Derating

Reeling cables always carry less current than fixed cables due to:

• Heat build-up

• Reduced cooling

• Mechanical loading

Temperature Derating

High ambient temperature reduces cable current rating.
For instance, at 55°C, a derating factor of 0.76 applies.

Standards & Compliance

The cable meets:

• IEC 60228 (conductors)

• IEC 60502 (LV cables)

• IEC 60332-1 (flame behaviour)

• VDE 0250 / 0293 (mechanical tests, markings)

• HD/EN/IEC 60811 (material testing)

Why this matters in South Africa

• Critical for mine safety inspections

• Ensures compatibility with OEM equipment

• Demonstrates ESG compliance (halogen-free)

• Supports insurance and HA-level approval requirements

Real South African Case Study

Case Study: Limpopo PGM Mine Reeling System Upgrade

Problem

A platinum mine in Limpopo suffered cable snapping every 6–8 months on their mobile crusher reeling system. Failures were caused by:

• Internal core twisting

• NBR jacket cracking

• Excessive torsion during long vertical travel

Investigation Findings

Engineers identified:

• Poor torsional stability

• Inadequate chemical resistance to diesel and hydraulic oils

• Jacket abrasion from sharp ore particles

Solution

Switch to PUR-HF TROMMEL LV Reeling Cable, equipped with:

• Anti-twist textile braid

• Central strength member

• Dual PUR-HF sheaths

Results

• Service life doubled (2×)

• 28–30% reduction in downtime

• Reduction in maintenance costs

• Safer operations

• Higher machine availability

Lesson Learned

Correct torsion management and a strong PUR jacket significantly improve OPEX in demanding mining environments.

Applications Across South Africa

Mining

Used on:

• Longwall equipment

• Shuttle cars

• Stacker-reclaimers

• Mobile crushers

• Heavy conveyors

LSZH and PUR-HF significantly improve underground safety.

Industrial Plants

Ideal for:

• Gantry cranes

• High-speed automation

• Mobile robotics

• Motorised platforms

Ports & Terminals

Essential for:

• Durban ship loaders

• Richards Bay coal terminals

• Saldanha iron ore operations

These areas require extreme chemical and salt resistance.

Renewable Energy & Infrastructure

Used for:

• Wind turbine servicing platforms

• Rail maintenance machines

• Mobile installation tools

Installation, Handling & Maintenance Best Practices

Installation

• Respect minimum bending radii

• Ensure correct drum winding tension

• Use proper terminations

• Avoid sharp edges on guide rollers

Operating Conditions

• Monitor torsion levels

• Avoid sudden directional changes

• Ensure perfect alignment of reeling path

Preventive Maintenance

• Inspect sheaths regularly

• Check tension on textile strength member

• Monitor operating temperature, especially at high loads

Common Problems & How PUR-HF TROMMEL LV Cable Solves Them

Traditional Problems

• PVC/NBR jacket cracking

• Torsion fatigue

• Oil and solvent attack

• Stiffness in cold weather

• Core displacement

PUR-HF Solutions

• Superior abrasion resistance

• Halogen-free flame retardance

• Chemical resistance

• Flexible in sub-zero conditions

• Textile braid prevents twisting

FAQ

1. Can PUR-HF reeling cables be used on older drum systems?

   
   Yes, provided the drum geometry and tension control are compatible.

2. What is the maximum reeling speed?

   
   200 m/min.

3. Suitable for underground mining?

   
   Yes — LSZH + PUR makes it an excellent choice.

4. How does halogen-free material improve safety?

   
   It prevents toxic acid gases during fires.

5. How to calculate derating in hot areas?

   
   Multiply the nominal current by the derating factor (e.g., 0.76 at 55°C).

6. What cable size for 1.1kV equipment?

   
   Depends on current and installation — often 16–50 mm².

7. Main cause of reeling cable failure?

   
   Torsion fatigue + incorrect bending radius.

8. How to prevent torsion damage?

   
   Use anti-twist braid and correct drum alignment.

9. Inspection frequency?

   
   Monthly for heavy mining; weekly for high-speed cranes.

10. Can reeling cables be repaired?

    
    Yes, but repairs must follow OEM instructions and may reduce lifespan.

Conclusion

The PUR-HF TROMMEL LV Reeling Cable stands out as one of the most reliable and technically advanced low-voltage reeling cables available in South Africa. Engineered for mechanical endurance, chemical resistance, torsion stability, and fire safety, it delivers unmatched performance in some of the world’s harshest environments.

From mining operations in Limpopo and Mpumalanga to port cranes in Durban and Richards Bay, this cable consistently proves its value by delivering:

• Longer service life

• Lower total cost of ownership

• Superior operational safety

• Compliance with international and South African standards

• Reliable performance at high speeds and harsh conditions

For operations that demand uptime, reliability, and safety, the PUR-HF TROMMEL LV Reeling Cable is not just a good choice — it is the best choice.