Application & Operating Conditions
SANS 1520-1 Type 61A is a 640/1100 V heavy-duty flexible reeling and trailing cable engineered for shuttle cars, load-haul-dump (LHD) loaders, continuous miners, and mobile underground face machinery where extreme rock-floor abrasion, high reeling tension, oil exposure, and low-visibility haulage hazards rapidly destroy standard rubber jackets.
Shuttle Cars & LHD Reeling Drums
Combines an elastomeric CR inner bedding and 16-string open nylon reinforcement braid with an extra-tough TPU outer jacket (4.3 kN rated pull at 95 mm²) for high-cycle constant-tension reeling.
Quartzite, Gold & Platinum Hard-Rock Mines
Thermoplastic polyurethane (TPU) outer sheathing tested to ICEA S-75-381 Table 3-3 delivers superior cut-through, tear, and drag-abrasion resistance across sharp hard-rock haulageways.
Optional High-Visibility Reflective Sheath
Available in heavy-duty black TPU or transparent TPU over an internal orange-silver reflective tape so underground vehicle operators can spot trailing cables instantly in dark headings.
Type 61A (TPU Reeling) vs Type 61B (RS 6 CR Non-Reeling): Choose SANS 1520-1 Type 61A when your machine uses dynamic reeling drums or requires maximum TPU rock-cut resistance (or subterranean reflective visibility). Choose SANS 1520-1 Type 61B when specification calls for triple-extruded RD 3 EPR insulation with 80% tinned copper braid screening and RS 6 polychloroprene sheaths in non-reeling service.
Cable Construction (SANS 1520-1 Type 61A)
Type 61A pairs a flexible elastomeric core assembly (EPR insulation + CR inner bedding + open nylon anti-torsion braid) with an external heavy-duty polyurethane armor skin.
| Layer / Component | Material & SANS 1520-1 Engineering Specification |
|---|---|
| 1. Power & Pilot Conductors | Class 5 flexible stranded tinned annealed copper in accordance with SANS 1411-1 (0.51 mm power strand wires and 0.41 mm pilot strand wires on 95/16 mm²). |
| 2. Core Insulation | Thermosetting Ethylene Propylene Rubber (EPR) compound to SANS 1411-3 rated for -25 °C to +90 °C continuous operation. |
| 3. Power Core Screens | Individual composite braid of 0.31 mm tinned copper wires and nylon yarn (43 mm² equivalent screen cross-section on 95 mm²) over each of the three power cores. |
| 4. Six-Core Lay-Up & Centre | Three screened power cores (Red, Yellow, Blue) and three unscreened insulated pilot cores positioned in the outer interstices around a central rubber filler cradle. |
| 5. Inner Sheath | Vulcanized Polychloroprene (CR) rubber inner sheath absorbing impact shock and maintaining circularity under drum compression. |
| 6. Reinforcement Braid | Open nylon braid (minimum 16 strings) locking the inner CR bedding to prevent torsional corkscrewing during dynamic reeling. |
| 7. Outer Sheath | Heavy-duty Thermoplastic Polyurethane (TPU) meeting ICEA S-75-381 Tab. 3-3 — supplied in standard Black, or Transparent TPU with embedded orange-silver reflective warning tape. |
SANS 1520-1 Type 61A: 3 composite nylon/tinned-copper screened EPR power cores + 3 unscreened interstitial pilot cores around a rubber centre, CR inner sheath, 16-string open nylon braid, and heavy-duty TPU outer sheath.
Technical Characteristics
Mechanical, thermal, and environmental performance parameters for SANS 1520-1 Type 61A TPU-sheathed trailing cables.
| Parameter | SANS 1520-1 Rated Value |
|---|---|
| Reference Standards | SANS 1520-1; SANS 1411-1; SANS 1411-3; ICEA S-75-381 Table 3-3 |
| Rated Voltage (Uo/U) | 640 / 1100 V AC |
| Operating Temperature Range | -25 °C to +90 °C |
| Minimum Bending Radius | 6 × Overall Cable Diameter (approx. 355 mm at 3×95+3×16 mm²) |
| Installation Duty | Dynamic Reeling and Non-Reeling Operation for Portable Mining Machinery |
| Environmental Resistance | Extreme Abrasion & Tear Resistant, Oil Resistant, UV / Sunlight & Ozone Resistant |
| Maximum Dynamic Tension | 4.3 kN (for 3×95+3×16 mm² configuration) |
| Sheath Colour Options | Standard Matte Black TPU | Optional Transparent TPU with Orange-Silver Reflective Tape |
SANS 1520-1 Type 61A Dimensional Specification Table
Verified factory dimensional, screen cross-section, tensile load, and mass data for the benchmark 95 mm² underground reeling configuration, plus custom cross-section capabilities.
1. SANS 1520-1 Type 61A — Verified Benchmark Dimensions & Mechanical Data
| Configuration (mm²) | Power Wire Dia. (mm) | Power Cond. Dia. (mm) | Screen Wire Dia. (mm) | Screen Cross-Sec. (mm²) | Pilot Size (mm²) | Pilot Wire Dia. (mm) | Pilot Cond. Dia. (mm) | Max. Tension (kN) | Overall Dia. (mm) | Nominal Weight (kg/km) |
|---|---|---|---|---|---|---|---|---|---|---|
| Type 61A 3×95 + 3×16 | 0.51 | 13.5 | 0.31 | 43 | 16 | 0.41 | 5.3 | 4.3 | 59.1 | 6,340 |
3×95+3×16 mm² shuttle-car and continuous-miner reeling size listed above, TEBAOFLEX custom-manufactures the complete SANS 1520-1 Type 61A conductor range (16 mm², 25 mm², 35 mm², 50 mm², 70 mm², 95 mm², 120 mm², and 150 mm²) in either Black TPU or Transparent TPU with orange-silver reflective tape. Request a custom size engineering sheet.SANS 1520-1 & SANS 1520-2 South African Mining Cable Selection Matrix
Compare Type 61A (640/1100 V heavy-duty TPU reeling cable) against Type 41, Type 61B, and medium-voltage SANS 1520-2 reeling cables.
| SANS 1520 Model | Voltage, Core & Pilot Architecture & Primary Mining Duty |
|---|---|
| SANS 1520-1 Type 41 (640/1100V) | SANS 1520-1 Type 41 (640/1100V): 640/1100 V 4-core (3 composite-screened power cores + 1 unscreened pilot, 2.5–25 mm²) CR-sheathed reeling & trailing cable for drills, pumps, and portable underground tools. |
| SANS 1520-1 Type 61A (640/1100V TPU) (This Product) | 640/1100 V heavy-duty 6-core (3 composite-screened power cores + 3 interstitial pilots) reeling & trailing cable with abrasion-resistant TPU outer sheath (black or reflective transparent). |
| SANS 1520-1 Type 61B (0.64/1.1kV) | SANS 1520-1 Type 61B (0.64/1.1kV): 0.64/1.1 kV 6-core (35–150 mm²) non-reeling coalface cable with triple-extruded RD 3 EPR, 80% tinned copper braid screens, 3 interstitial pilots, and RS 6 CR sheaths. |
| SANS 1520-2 Type 63 (1.9/3.3kV) | SANS 1520-2 Type 63 (1.9/3.3kV): 1.9/3.3 kV medium-voltage 6-core (25–240 mm², up to 520 A) composite-screened reeling & trailing cable for 3.3 kV continuous miners, shearers, and jumbo drills. |
| SANS 1520-2 Type 66 & 66-ECC (3.8/6.6kV) | SANS 1520-2 Type 66 & 66-ECC (3.8/6.6kV): 3.8/6.6 kV screened reeling & section feeder cable (25–240 mm²) with 3 interstitial pilots (Type 66) or 2 pilots + 1 bare ECC earth conductor up to 17.0 kA 1s (Type 66-ECC). |
| SANS 1520-2 Type 611 & 611-ECC (6.35/11kV) | SANS 1520-2 Type 611 & 611-ECC (6.35/11kV): 6.35/11 kV medium-voltage dragline, shovel, and reeling cable (25–240 mm²) with triple-extruded EPR insulation, strippable semi-con screen, and CR outer sheath. |
| SANS 1520-2 Type 622 & 622-ECC (12.7/22kV) | SANS 1520-2 Type 622 & 622-ECC (12.7/22kV): 12.7/22 kV heavy-duty open-cast dragline, excavator, and mobile pit substation feeder cable (25–150 mm²) in 3-pilot or high-fault ECC topology. |
| SANS 1520-2 Type 633 & 633-ECC (19/33kV) | SANS 1520-2 Type 633 & 633-ECC (19/33kV): 19/33 kV highest-voltage SANS 1520-2 screened reeling & pit feeder cable (25–120 mm²) delivering up to ~14.8 MVA three-phase bench capacity. |
Frequently Asked Questions (FAQ)
Key engineering questions regarding TPU sheath durability, reflective visibility options, and coupler sizing for SANS 1520-1 Type 61A.
Why choose a TPU outer sheath (Type 61A) over a conventional CR rubber sheath in underground mining?
Extra-heavy-duty Thermoplastic Polyurethane (TPU) formulated to ICEA S-75-381 Table 3-3 provides three to four times higher abrasion, rock-cut, and tear propagation resistance than standard polychloroprene (CR) rubber. On high-speed shuttle cars and LHD loaders dragging cables across abrasive quartzite, kimberlite, or coal roadways, TPU substantially reduces jacket gouging and premature core exposure.
How does the transparent TPU sheath with orange-silver reflective tape work?
During extrusion, a helically lapped high-visibility orange and silver retro-reflective warning tape is applied over the reinforced inner bedding, and crystal-clear abrasion-resistant TPU is extruded directly over it. Cap lamps and LHD headlights reflect brightly off the protected tape through mud and water without the reflective layer ever peeling off.
How many pilot cores are inside SANS 1520-1 Type 61A?
Following the SANS 1520 6-series architecture, Type 61A incorporates six cores in total: three composite-screened EPR power cores (Red, Yellow, Blue) and three unscreened insulated pilot/control cores laid in the outer interstices around a central rubber cradle.
Can TEBAOFLEX supply Type 61A in cross-sections other than 95 mm²?
Yes. While 3×95+3×16 mm² (59.1 mm OD, 6,340 kg/km) is the primary South African colliery and hard-rock reeling size, we manufacture custom runs across 16 mm² to 150 mm² to match existing flameproof coupler glands and reel groove widths.
Need SANS 1520-1 Type 61A Heavy-Duty TPU Mining Cable?
Specify Black TPU or Transparent Reflective-Tape TPU, required conductor cross-section, and drum length for fast factory quotation.
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