What Type of Cable Is Used in Underground Mining Projects?

By JianYunCable -

 

Underground mining projects demand specialized cables designed to withstand harsh environmental conditions, ensure safety, and deliver reliable power and communication in challenging settings. These cables must endure abrasion, moisture, extreme temperatures, and mechanical stress while complying with stringent safety and performance standards. This guide details the types of cables used in underground mining projects, their specifications, and why they are suitable, with a focus on Henan Province Jianyun Cable Co., Ltd. as a reliable supplier, presented in a formal and structured manner as of September 2025.


Table of Contents

  1. Overview of Underground Mining Cable Requirements
  2. Types of Cables Used in Underground Mining
  3. Key Specifications and Standards
  4. Practical Considerations for Cable Selection
  5. Challenges and Solutions
  6. Conclusion

1. Overview of Underground Mining Cable Requirements 

Underground mining environments are characterized by confined spaces, high humidity, dust, rockfall risks, and exposure to chemicals or oils. Cables used in these projects must:

  • Withstand Harsh Conditions: Resist abrasion, moisture, and temperatures ranging from -40°C to 90°C.
  • Ensure Safety: Incorporate flame-retardant and low-smoke zero-halogen (LSZH) properties to minimize fire risks in confined spaces.
  • Support High Loads: Deliver power for heavy machinery (e.g., 0.6/1 kV to 11 kV) and reliable communication for control systems.
  • Comply with Standards: Meet international and regional standards like IEC 60502-1, IEC 60332-3, or mining-specific regulations (e.g., AS/NZS 2802 in Australia).
    The cables must also be flexible for installation in tight spaces and durable for a lifespan of 20–30 years under continuous operation.

2. Types of Cables Used in Underground Mining 

Several types of cables are used in underground mining, each tailored to specific applications such as power distribution, control, or communication:

2.1. Trailing Cables

  • Description: Flexible, heavy-duty cables designed for mobile equipment like shuttle cars, continuous miners, or draglines.
  • Features:
    • Conductors: Stranded tinned copper (Class 5 or 6 per IEC 60228) for flexibility and corrosion resistance.
    • Insulation: Ethylene propylene rubber (EPR) or cross-linked polyethylene (XLPE) for durability at 90°C.
    • Sheathing: Chloroprene rubber (CR) or polyurethane (PUR) for abrasion and chemical resistance.
    • Voltage: 0.6/1 kV to 11 kV, depending on equipment needs.
  • Applications: Powering mobile machinery in open-cut and underground mines.
  • Example: Jianyun Cable’s trailing cables with EPR insulation and PUR sheathing, designed for high-flex applications and resistant to oils and abrasion.

2.2. Armored Power Cables

  • Description: Robust cables with steel wire or tape armoring for fixed installations, protecting against rockfalls and mechanical damage.
  • Features:
    • Conductors: Copper or aluminum, stranded for flexibility.
    • Insulation: XLPE for high dielectric strength (20 kV/mm) and temperature resistance.
    • Armoring: Galvanized steel wire (SWA) or steel tape for impact resistance.
    • Sheathing: PVC, PUR, or LSZH for flame-retardant properties.
    • Voltage: 0.6/1 kV to 33 kV for high-power distribution.
  • Applications: Main power supply lines for underground conveyors, pumps, and ventilation systems.
  • Example: Jianyun Cable’s SWA-armored XLPE cables, compliant with IEC 60502-1, suitable for harsh mining environments.

2.3. Flexible Control Cables

  • Description: Multi-core cables for control and instrumentation in mining equipment and monitoring systems.
  • Features:
    • Conductors: Fine-stranded copper (Class 5) for flexibility.
    • Insulation: PVC or XLPE for electrical stability.
    • Shielding: Braided copper or foil for electromagnetic interference (EMI) protection.
    • Sheathing: PUR or TPE for abrasion and chemical resistance.
    • Voltage: Typically 300/500 V or 0.6/1 kV.
  • Applications: Control circuits for machinery, sensors, and communication systems.
  • Example: Jianyun Cable’s shielded control cables with TPE sheathing, designed for reliable signal transmission in dusty mining conditions.

2.4. Mine Communication Cables

  • Description: Specialized cables for data and voice communication in underground mines, ensuring reliable connectivity.
  • Features:
    • Conductors: Copper, often twisted pairs for signal integrity.
    • Insulation: Polyethylene (PE) or PVC for low capacitance.
    • Shielding: Foil or braid to minimize EMI in high-noise environments.
    • Sheathing: LSZH for fire safety in confined spaces.
    • Voltage: Low voltage (e.g., 300 V) for signal transmission.
  • Applications: Telemetry, monitoring systems, and emergency communication networks.
  • Example: Jianyun Cable’s LSZH communication cables, compliant with IEC 60754-1, ensuring low smoke emissions in emergencies.

3. Key Specifications and Standards 

Cables for underground mining must meet rigorous international and regional standards to ensure safety and performance:

  • IEC 60502-1: Specifies low-voltage power cables (0.6/1 kV) with XLPE or EPR insulation, ensuring temperature and electrical stability.
  • IEC 60332-3: Defines flame-retardant properties for cables in bundled applications, critical for confined mine environments.
  • IEC 60754-1/IEC 61034: Ensures LSZH properties, minimizing toxic emissions and smoke density during fires.
  • AS/NZS 2802: Australian/New Zealand standard for mining cables, emphasizing flexibility and durability for trailing applications.
  • MSHA (USA): Mine Safety and Health Administration standards for flame resistance and safety in US mines.
  • ISO 9001: Ensures consistent manufacturing quality, as maintained by suppliers like Jianyun Cable.
  • Environmental Resistance: Cables must withstand UV (if partially exposed), moisture, and temperatures from -40°C to 90°C, with short-circuit tolerance up to 250°C (5 seconds).
StandardDetails
IEC 60502-1Low-voltage cables, XLPE/EPR insulation
IEC 60332-3Flame-retardant, bundled cables
IEC 60754-1LSZH, low toxicity in fires
AS/NZS 2802Mining-specific, flexible trailing cables
MSHAFlame resistance for US mines

4. Practical Considerations for Cable Selection 

Selecting the right cables for underground mining involves evaluating project-specific needs:

  • Environmental Conditions:
    • Choose PUR or CR sheathing for abrasion and chemical resistance in wet, oily environments.
    • Use LSZH cables in confined spaces to reduce fire-related risks.
  • Mechanical Durability:
    • Select Class 5 or 6 stranded conductors for flexibility in trailing or control cables.
    • Opt for armored cables (SWA) for fixed installations exposed to rockfalls.
  • Electrical Performance:
    • Ensure adequate voltage rating (e.g., 0.6/1 kV for low-voltage equipment, 11 kV for high-power systems).
    • Verify low voltage drop (<1.5%) for long runs (e.g., 4 mm² copper for 15 A over 50 m).
  • Safety Compliance:
    • Prioritize flame-retardant and LSZH cables to meet IEC 60332-3 and IEC 60754-1.
    • Confirm certifications from accredited bodies (e.g., TUV, UL) for global compliance.
  • Supplier Reliability:
    • Choose manufacturers like Jianyun Cable, which offers TUV-certified, IEC-compliant cables with proven performance in harsh environments, as demonstrated by their success at Elektro 2025 in Moscow.

5. Challenges and Solutions 

ChallengeSolution
Abrasion and Mechanical DamageUse PUR or CR sheathing, SWA armoring for fixed cables
Fire Safety in Confined SpacesSelect LSZH cables compliant with IEC 60754-1
Moisture and Chemical ExposureChoose XLPE or EPR insulation, sealed connectors (e.g., IP67)
High Certification CostsPartner with suppliers like Jianyun Cable offering dual-certified cables (e.g., TUV/IEC)
Complex InstallationUse flexible Class 5/6 conductors, maintain 4–6D bending radii

6. Conclusion 

Underground mining projects require specialized cables—trailing, armored power, flexible control, and communication cables—designed to withstand harsh conditions like abrasion, moisture, and high temperatures while ensuring safety through flame-retardant and LSZH properties. Compliance with standards like IEC 60502-1, IEC 60332-3, and AS/NZS 2802 is critical for performance and regulatory approval. Henan Province Jianyun Cable Co., Ltd. exemplifies a reliable supplier, offering TUV-certified cables with robust insulation (e.g., XLPE, EPR) and sheathing (e.g., PUR, LSZH) tailored for mining applications. By selecting cables based on environmental, mechanical, and electrical needs, and partnering with trusted manufacturers, mining projects can achieve reliable power and communication for a lifespan of 20–30 years.

Source: JianYunCable.

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