Why Type 245 Cables Matter in South Africa

If you spend enough time inside a South African underground mine—whether it’s a longwall coal operation in Mpumalanga, a chrome mine in North West, or a platinum mine in Limpopo—one pattern becomes obvious:

Only the toughest, most flexible, and electrically stable trailing cables survive.

The demands placed on mining power cables in South Africa are brutal:

• Constant bending and reeling

• Exposure to moisture, mud, dust and hydrocarbons

• Tight haulage spaces

• Abrasion from rock and machinery

• High current loads

• Mandatory earth-fault monitoring

For machines like:

• Longwall shearers

• Continuous miners

• Shuttle cars

• Hydraulic systems

• Longwall panline and auxiliary equipment

…the cable is as important as the machine itself. A single trailing-cable failure can cost a mine dozens of production hours—translating to millions of rand in lost coal, ore or metal output.

This is why many South African mines increasingly prefer AS/NZS Type 245 (1.1–6.6 kV) trailing cables—originally developed in Australia for high-stress longwall conditions, but now recognised globally for their flexibility, ruggedness and electrical reliability.

What Is AS/NZS Type 245 Mining Cable?

Definition

Under AS/NZS 1802:2003, Type 245 is defined as a very flexible trailing and reeling cable designed for mobile mining machinery.

Voltage Ratings

Type 245 comes in three controlled voltage classes:

• Type 245.1 → 1.1 kV

• Type 245.3 → 3.3 kV

• Type 245.6 → 6.6 kV

These ratings match the requirements of high-power underground equipment common in South Africa.

Why It Is Categorised as “Very Flexible”

The flexibility comes from:

• High-strand-count tinned copper conductors

• Rubber-based EPR insulation

• A cradle-style cable architecture

• Textile reinforcement reducing torsional stress

• Interstitial earth conductors that bend fluidly

• Central pilots that extend and stretch without breaking

This design allows Type 245 to handle:

• Constant back-and-forth movement

• Tight bends

• High tensile loads

• Abrasion from floor drag

• Reeling and unreeling cycles

Central Pilot Conductors

Type 245 includes three extensible pilot conductors, used for:

• Earth continuity monitoring

• Control circuits for longwall safety systems

• Shutdown protection during earth faults

• Interfacing with existing South African longwall automation systems

Comparison with Other AS/NZS Cable Types

Type 245 is specifically optimised for longwall dynamics where cable flex-life and electrical stability are critical.

Standards & Compliance Requirements

Applicable Standards

Type 245 cables are manufactured according to:

AS/NZS 1802:2003

Mining and earth-moving machinery trailing and reeling cables — the main governing standard for Type 245.

AS/NZS 1125

Copper conductors (stranding, resistance, laying).

AS/NZS 3808

Insulation and sheathing compounds.

AS/NZS 5000.1

General electrical installation requirements.

These standards ensure:

• Correct electrical stress control

• Mechanical resilience

• Reliable earth-fault monitoring

• Flame retardancy and safety

Safety Requirements for South African Mines

South African mines follow:

• DMRE (Department of Mineral Resources and Energy) guidelines

• MHSA (Mine Health and Safety Act)

• Local site-specific electrical codes

Key compliance requirements:

✔ Flame retardancy

No cable may propagate fire underground.

✔ Insulation integrity

High dielectric strength & resistance to contaminants.

✔ Reliable earth-fault detection

Mandatory for coal mines.

✔ Mechanical resilience

Tensile, torsion and impact resistance tested.

Because of these demands, South African longwall operations frequently import AS/NZS Type cables—especially Type 245—due to their superior performance.

Construction of AS/NZS Type 245 Cable

Below is a professional, engineering-grade breakdown.

Conductors

• Flexible stranded tinned annealed copper

• Multi-strand for ultra-high flexibility

• Tinning prevents corrosion in wet, acidic or saline mine conditions

• Excellent thermal and electrical performance

Conductor Screening

Required for 3.3 kV and above:

• A semiconductive compound

• Equalises electric field distribution

• Prevents partial discharge

• Increases insulation lifespan under high voltage stress

Insulation — EPR

Ethylene Propylene Rubber (EPR) provides:

• High dielectric strength

• Excellent thermal performance (up to 90°C)

• Moisture resistance

• Hydrocarbon resistance

• Crack resistance under repeated bending

EPR is a key reason Type 245 outperforms PVC-based mining cables.

Insulation Screen

A semiconductive elastomer applied over the EPR:

• Smooths electric stress

• Reduces corona effect

• Ensures safe grounding during faults

Cradle Separator & Overall Core Screen

• Semiconductive PCP (polychloroprene)

• Maintains conductor spacing

• Provides mechanical protection

• Prevents screen damage during bending

• Offers short-circuit containment

Interstitial Earth Conductors

Placed between power cores:

• Flexible tinned copper

• PCP semiconductive covering

• Maintains earth path even under severe mechanical stress

These conductors are essential for South African safety regulations.

Central Extensible Pilots

Three pilots—each EPR insulated.

Used for:

• Earth continuity monitoring

• Control and signalling circuits

• Machine protection systems

• Longwall shutdown automation

Textile Reinforcement

Type 245 features an open-weave textile braid:

• Provides torsion resistance

• Reduces sheath tearing

• Improves cable flex-life

• Adds tensile strength

Sheath Materials

Standard sheath:

• Heavy-duty PCP

Optional sheaths:

• CPE (chlorinated polyethylene)

• CSP (chlorosulphonated polyethylene)

These alternatives improve:

• UV resistance

• Acid resistance

• Hydrocarbon resistance

• Heat resistance

Technical Specifications & Electrical Parameters

Conductor Sizes

From 16–150 mm², depending on:

• Voltage rating

• Current requirements

• Machine power rating

High-strand-count design ensures exceptional flexibility.

Insulation Thickness (by voltage)

Earth & Pilot Specifications

• Earth: 69/0.25 to 375/0.30

• Pilot: 28/0.25 with 0.8 mm insulation

Sheath Thickness & Diameter

• Sheath: 4.1–8.0 mm

• Overall diameter: 42.6–85.8 mm

Weight

Ranges 235–1210 kg per 100 m.

Electrical Performance Highlights

• Voltage: 1.1 kV / 3.3 kV / 6.6 kV

• High dielectric strength due to EPR

• Continuous operating temp: 90°C

• Excellent partial-discharge resistance

Applications in Mining & Heavy Industry

Longwall Shearer Cables

Type 245 is the primary global standard for:

• Longwall shearers

• AFC (armoured face conveyors)

• Roof supports

• Stage loaders

Flex-life is critical because the cable is dragged along the panline thousands of times per shift.

Continuous Miners

Reliable power delivery to:

• Cutting heads

• Traction drives

• Conveyor systems

• Hydraulic power modules

Longwall Auxiliary Systems

Type 245 is frequently used for:

• Pumps

• Ventilation fans

• Roof bolters

• Shuttle cars

• Feeder breakers

Underground & Surface Mines

Suitable for:

• Coal (Mpumalanga, Limpopo)

• Platinum (Bushveld Complex)

• Gold (Gauteng)

• Chrome (North West)

• Manganese (Northern Cape)

Mpumalanga Longwall Coal Mine

Background

A large longwall operation in Mpumalanga struggled with:

• Frequent trailing-cable failures

• Poor insulation quality from imported low-budget cables

• Earth-fault alarms stopping the shearer

• Productivity losses of 30+ hours per month

Problems Identified

1. Insulation breakdown due to weak materials

2. Earth continuity loss from pilot fatigue

3. Mechanical abrasion caused by panline friction

4. Sheath tearing under torsion

Intervention

The mine replaced its inferior cables with:

• AS/NZS Type 245.3,

• 95 mm² conductors,

• 3.3 kV rating,

• Reinforced installation using strain-relief clamps and roller systems

Results After 6 Months

• Cable failures reduced by 43%

• Monthly downtime reduced by 30 hours

• Maintenance costs dropped significantly

• Earth-fault monitoring became stable

• Shearer performance improved due to consistent power supply

Why Type 245 Performed Better

• EPR insulation resisted moisture and heat

• Textile reinforcement prevented torsion damage

• High-quality pilot system eliminated false earth alarms

• Robust sheath withstood drag and abrasion

Advantages of AS/NZS Type 245 Cables

✔ Engineered for dynamic mining conditions

Designed for constant movement and tight bending radii.

✔ Excellent electrical stress control

Semiconductive screening ensures stable performance.

✔ High mechanical durability

Resistant to:

• Tension

• Compression

• Torsion

• Abrasion

• Impact

✔ Superior chemical and moisture resistance

The EPR + PCP combination withstands:

• Oil

• Water

• Hydrocarbons

• Acids and alkalis

✔ Reliable safety systems

Pilot conductors ensure:

• Continuous earth monitoring

• Rapid fault detection

• Machine protection

Installation, Handling & Maintenance Tips

Proper Installation

• Use correct roller or hook systems

• Avoid dragging the cable over sharp edges

• Maintain correct bend radius

Handling in Wet Underground Areas

• Prevent the cable from lying in stagnant water

• Use strain-relief clamps to reduce tension

Routine Testing

• Insulation resistance (Megger test)

• Earth continuity loop test

• Pilot circuit continuity test

• Visual inspection for:

  Sheath damage

  Hot spots

  Exposed screens

  Crushed areas

Recommended Inspection Intervals

• Daily operator checks

• Weekly electrician inspections

• Monthly detailed technical evaluation

Common Problems & Troubleshooting

Mechanical Damage

Caused by:

• Shuttle car impacts

• Panline friction

• Over-tensioning

Detection:

• Hot spots

• Damaged outer sheath

• Visible screen material

Earth Continuity Alarm Issues

Common causes:

• Pilot conductor fatigue

• Incorrect terminations

Overheating

Triggered by:

• Overloading

• Poor ventilation

• Bundled cable routes

Premature Insulation Failure

Often linked to:

• Non-EPR insulation used in counterfeit cables

• Excessive heat

• Moisture ingress

FAQ

What is the difference between Type 245.1, 245.3 and 245.6?

Only the voltage rating differs: 1.1 kV, 3.3 kV, 6.6 kV.

Can Type 245 be used for reeling?

Yes, but mainly for medium-duty reeling; continuous reeling may require Type 241 or Type 260.

What makes Type 245 better than PVC trailing cables?

EPR insulation = higher dielectric strength, better flexibility, better heat resistance.

How do I select the correct conductor size?

Match conductor cross-section to the machine's full-load current + distance + voltage drop limits.

Is Type 245 compatible with modern longwall safety systems?

Yes. The pilot conductors integrate seamlessly with SA longwall control units.

How often should the cable be tested?

Weekly electrically, daily visually.

Does the cable meet South African flame retardancy rules?

Yes, when manufactured to AS/NZS 1802 and tested to IEC/AS flame standards.

What is the typical service life underground?

Anywhere from 8 to 24 months, depending on handling and mining conditions.

Conclusion

AS/NZS Type 245 cables stand out as one of the most reliable, flexible and high-performance trailing cables available for South African longwall and continuous mining machines.

They deliver:

• Superior mechanical toughness

• Outstanding electrical integrity

• Reliable pilot circuits

• Long service life

• High resilience in the tough conditions of SA coal and hard-rock mines

For mines looking to reduce downtime, avoid safety shutdowns, and maintain stable power delivery to high-demand mobile equipment, Type 245 (1.1–6.6 kV) remains one of the best-engineered solutions available.