JULY 2026
ELECTRICAL NEWS
www.sparkselectricalnewsmagazine.co.za
REGULARS: CONTRACTORS’ CORNER | FEATURES: CABLES AND CABLE ACCESSORIES | STANDBY, BACK UP, AND EMERGENCY POWERLIGHTING | LIGHTING
POWERING PROGRESS ACROSS SOUTH AFRICA’S EVOLVING ELECTRICAL INDUSTRY
WIRED TO INSPIRE ELECTRICAL PANELS EXPERTLY BUILT
S outh Africa’s electrical industry is undergoing a smart technologies, and energy-efficiency initiatives, the sector is evolving faster than ever. For electrical contractors, EPCs (Engineering, Procurement, and Construction companies), property developers, and commercial and industrial businesses, staying ahead requires access to reliable products, technical expertise, and trusted supply partners who understand the market’s changing demands. One of the most significant trends shaping the industry in 2026 is the shift towards integrated energy solutions. While backup power remains important, the focus has broadened to include energy resilience, cost optimisation, and sustainability. Businesses are increasingly investing in solar PV systems, battery energy storage solutions (BESS), hybrid power systems, and intelligent energy management technologies. Developers are embedding energy-efficient infrastructure into new projects from the outset, while EPCs are delivering increasingly sophisticated energy solutions across large- scale commercial, industrial, and infrastructure developments. Alongside this shift, cable technologies continue to evolve to support modern electrical applications. The rapid growth of renewable energy projects, industrial automation, data centres, and electric vehicle charging infrastructure has increased demand for cable solutions that deliver enhanced performance, safety, and long-term reliability. As projects become more complex, stakeholders require products that meet stringent quality standards and support the efficient transmission and distribution of power. significant transformation. Driven by the continued growth of renewable energy, battery energy storage, Lighting technology is advancing rapidly. While LED lighting has become the standard across most sectors, the industry is increasingly adopting intelligent lighting controls, occupancy sensors, daylight harvesting systems, and connected building technologies. These solutions help commercial and industrial facilities reduce energy consumption, improve operational efficiency, and support environmental sustainability goals. For developers and facility owners, smart lighting systems are becoming an
important component of future-ready buildings. The rise of smart buildings and digital infrastructure is further fuelling demand for integrated electrical solutions. Modern developments increasingly require systems that enable monitoring, automation, and energy optimisation. This trend is creating
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Get in touch with Carin on 072 1425 330 or carinh@crown.co.za if you would like to take advantage of the extra exposure in the September issue of Sparks Electrical News. Visit us at stand LN01 and pick up a copy of September 2026 magazine.
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CONTRACTORS’ CORNER
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The TBM2807: Raising the Bar for multimeter performance and value T he world of electrical measurement tools is constantly evolving, with professionals seeking instruments
built-in EMI shielding ensure reliable performance in industrial settings, while UL certification further attests to its quality and dependability. The TBM2807 not only matches its predecessors—it surpasses them with innovative features. Non-contact electrical field detection enables safer live-wire identification, with high- and low-sensitivity settings for flexibility. The unique BeepLit™ feature provides audio and visual cues for continuity and diode testing, improving the speed and accuracy of diagnostic work. Additionally, VFD-V and VFD-Hz measurement functions make the TBM2807 an ideal choice for technicians working with Variable Frequency Drives in modern installations. The TBM2807 delivers on every front: it’s easy to use, robustly built, and packed with features that streamline troubleshooting and ensure user safety. With the discontinuation of the TBM807 and TBM805, the TBM2807 serves as a worthy successor, offering enhanced performance and exceptional value for professionals who demand the best from their tools.
readings per second, eliminating the need for tedious manual dial adjustments. The large 26 mm digital LCD display, with a 6000-count resolution and a bright LED backlight, ensures readings are easy to see in any environment. The Relative Zero function is particularly useful for technicians, as it compensates for lead resistance and enables more precise measurements. Durability and safety are central to the TBM2807’s design. The device is certified to CAT III 1000V and CAT IV 600V safety standards, making it suitable for a wide range of electrical environments. Its rugged, flame-retardant housing and
that are accurate, durable, and easy to use. HellermannTyton’s TBM2807 digital multimeter is a recent addition to the market, designed to replace the popular TBM807 and TBM805 models. With its impressive feature set and enhanced reliability, the TBM2807 sets a new standard for value across industrial and commercial applications. One of the standout qualities of the TBM2807 is its user-friendly design. Fast auto-ranging allows users to take up to five
HellermannTyton’s TBM2807 digital multimeter is a recent addition to the market, designed to replace the popular TBM807 and TBM805 models. With its impressive feature set and enhanced reliability, the TBM2807 sets a new standard for value across industrial and commercial applications.
www.hellermanntyton.co.za
Powering hospitality: WDY Electrical’s expertise in custom solutions
opportunities for contractors, EPCs, and developers to deliver greater value through innovative technologies that enhance building performance and operational efficiency. Supply chain resilience remains a critical consideration across the industry. As demand for electrical products continues to grow across renewable energy, commercial construction, infrastructure development, and industrial projects, reliable product availability is essential to maintaining project timelines. Businesses increasingly rely on supply partners with strong supplier relationships, effective inventory management, and extensive distribution capabilities to ensure continuity and minimise delays. At the same time, the growing complexity of electrical projects has heightened the importance of technical expertise. From navigating evolving regulations and compliance requirements to integrating new energy technologies, industry stakeholders need access to knowledgeable partners who can provide practical guidance and support throughout the project lifecycle. As these trends continue to reshape the market, Voltex remains committed to supporting the full spectrum of the electrical industry. Through our extensive range of cable solutions, power backup and energy storage products, lighting technologies, industrial electrical equipment, renewable energy solutions, technical support services, and a nationwide branch network, we provide the products and reliability needed to support electrical contractors, EPCs, developers, and commercial and industrial customers. By combining innovation, availability, and industry knowledge, Voltex continues to help power South Africa’s transition towards a more efficient, resilient, and sustainable future. POWERING PROGRESS ACROSS SOUTH AFRICA’S EVOLVING ELECTRICAL INDUSTRY CONTINUED FROM PAGE 1
WDY Electrical has established itself as a leading force in the electrical contracting space, with a particular focus on hospitality projects, including restaurants and boutique hotels. With a proven track record across multiple sectors—including commercial, industrial, and domestic— the company’s core expertise shines through in high-end hospitality projects where quality, safety, and customisation are paramount. A major area of specialisation for WDY Electrical is the design and execution of complex lighting systems. The team excels at translating designers’ creative visions into reality while navigating the often-challenging intersection of aesthetic ambition and strict regulatory compliance. For instance, when working with LED strip lighting, WDY Electrical collaborates closely with designers and shopfitters to ensure all wiring routes and driver installations meet both functional needs and industry standards, such as SANS 10142-1 and the Electrical Installation Regulations (EIR). This process requires innovative problem- solving to satisfy both the practical and creative demands of each project. WDY Electrical’s portfolio includes prominent hospitality clients, including SPUR Group, Life and Brand, and NoName Hospitality Group (NNHG). Each client presents distinct requirements and operational philosophies. SPUR Group operates within a highly standardised framework, ensuring consistency across all locations. Each brand under the SPUR umbrella, such as Rocomamas and Panarottis, maintains its own style, but the underlying electrical and lighting layouts are uniform, enabling efficient, repeatable execution. In contrast, projects for Life, Brand, and NNHG are highly bespoke, with each build presenting unique challenges. Here, WDY Electrical becomes an integral partner from the outset, collaborating with design
to inverter-and-battery setups. The approach is never one-size-fits-all; each system is custom-designed based on client expectations, load requirements, and on-site surveys. In the restaurant sector, for instance, SPUR Corp locations typically use standardised UPS installations to keep essential systems online, while Life and Brand venues require more complex arrangements to maintain both POS functionality and emergency lighting. NNHG projects often require full-scale backup systems to ensure uninterrupted operation under any circumstances. WDY Electrical’s experience in the demanding hospitality industry has informed its approach in other sectors as well. The high stakes of hospitality— where a single power outage can result in immediate revenue loss—have instilled a culture of safety, reliability, and meticulous execution. This mentality is carried into every project, whether corporate, industrial, or residential, allowing WDY Electrical to deliver pristine finishes and maintain minimal downtime across all its engagements.
teams to create complex ambient lighting systems, hidden cable routes, and custom accent lighting for bar areas. Automation plays a significant role as well—Life and Brand, for example, prioritises automated lighting systems to establish specific moods, and WDY Electrical has been instrumental in helping NNHG adopt similar technologies. One of the company’s most notable recent projects has been the transformation of the former Amalfi boutique hotel in Sea Point. As a brownfield conversion, the project posed substantial challenges, particularly in planning new electrical routes within existing concrete structures. Despite initial delays and structural obstacles, the WDY Electrical team overcame these hurdles through careful planning and determination. The reward lies in revitalising an outdated hotel into a modern, energy-efficient, and premium space—a testament to the team’s dedication and expertise. Beyond lighting and general electrical work, WDY Electrical is also a trusted provider of backup power solutions tailored to each client’s needs. Solutions range from UPS systems and generators
www.wdyelectricsolar.co.za
www.voltex.co.za
SPARKS ELECTRICAL NEWS
JULY 2026
CONTRACTORS’ CORNER | EDITOR’S COLUMN
3
Editor’s note: powering reliability W elcome to the July issue of Sparks! This month, our spotlight is on Standby, Backup,
Whether it’s hospitals, data centres, manufacturing plants, or even our own homes, the consequences of power interruptions are too significant to ignore.
systems, expert commentary on evolving standards, and real-world case studies that show how organisations are building resilience against outages. We’ve gathered insights from industry leaders and innovators who are reimagining emergency power for a more connected, electrified world. At Sparks, we believe that sharing knowledge is the first step towards progress. We hope this issue empowers you to make informed decisions about your power strategies and inspires you to think proactively about reliability and safety.
and Emergency Power – a topic that has never been more vital. As global demand for uninterrupted power continues to rise, the need for reliable backup solutions has moved from the periphery to the very heart of every critical infrastructure plan. Whether it’s hospitals, data centres, manufacturing plants, or even our own homes, the consequences of power interruptions are too significant to ignore. In this issue, you’ll find in-depth features on the latest advances in standby and backup
Minx Avrabos sparks@crown.co.za
How to tell whether your mini-substation is truly new or refurbished A s demand grows for reliable electrical infrastructure across mining, industrial and commercial projects,
For companies investing in electrical infrastructure that underpins critical operations, understanding the origin and condition of equipment is essential. “Electrical infrastructure is not an area where shortcuts should be taken,” Claassen concludes. “Companies should ensure they are working with reputable suppliers who can demonstrate the integrity, traceability and quality of the equipment being supplied. Knowing exactly what you are buying is critical to protecting both your operations and your investment.”
One of the most effective ways for buyers to protect themselves, Claassen notes, is to ensure that suppliers can provide full traceability and documentation for the equipment supplied. “A genuine new mini-substation should include full manufacturer’s documentation,” he says. “This includes serial numbers for major components, factory acceptance test (FAT) reports, compliance certificates and detailed engineering documentation.” “Customers are encouraged to witness key points during the manufacturing process, such as inspecting the active part of the transformer prior to tanking (in the case of oil-type transformers) and the FAT of the transformer, as well as the FAT of the completed minisub,” Claassen says, adding that Trafo Power Solutions offers this to customers either in person or remotely via video link. Claassen also points out that refurbished equipment has a place in the market when it is properly described and supplied for suitable applications. “Refurbished electrical infrastructure can be a viable option in certain circumstances, provided it has been properly inspected and tested and clearly labelled as refurbished,” he explains. “The key is transparency, so the buyer understands exactly what they are purchasing.” 2. Verifies all connections are sound. 3. Powers up the load cell and measures no-load mV for bridge balance. 4. Measures resistance through the strain gauge bridge — input, output, and balance — in sequence. 5. Performs an insulation test at 50 V (measured in MΩ) to detect water ingress, with low readings highlighted onscreen. If a load cell has been overloaded, the zero balance will be out of spec. Water penetration shows up in the insulation test. The full result is summarised on the backlit graphic display. Indication and calibration To show units, set sensitivity, range, decimal, and units. Zero trim for deadweight, span trim for accuracy. Tare and other functions are included. Supports one 350 Ω load cell or up to three 1000 Ω cells (5 V excitation). For load cell amplifier calibration, inject a known mV value through the 4 mm sockets and simultaneously measure the corresponding mA output. The mA measurement is isolated from
“These units are responsible for safely stepping down and distributing power within a facility or operation,” he says. “If a company unknowingly installs equipment that has already experienced significant operational wear, it may introduce serious reliability risks into its power system.” The potential consequences can be severe. Electrical equipment that has unknown maintenance history, or hidden deterioration in key components such as insulation systems or protective devices. “In the worst cases, companies only discover the true condition of the equipment when a failure occurs,” says Claassen. already seen years of service may have a reduced operational life, an “That can lead to costly downtime, damage to connected equipment, and, in extreme cases, safety incidents.” Claassen emphasises that Trafo Power Solutions fully supports open competition in the electrical equipment market but stresses that transparency and honest representation of equipment are essential. “We believe in a competitive market, but the issue here is about intent,” he says. “If refurbished electrical equipment is clearly labelled as refurbished, the customer can make an informed decision. The problem arises when equipment is misrepresented as new.” spreadsheet software. • Compact and rugged - 86 x 155 x 43 mm, IP54 rated for dust and splash resistance. • Lithium-Ion battery with approximately eight hours of run time (measured and sourced combined), with temperature sensing built in. • Programmable auto-off and selectable date/time settings. • Standard accessories included: battery charger, carry case, non-slip rubber cover, and safety leads. • Two-year guarantee against faulty materials and workmanship. Field testing without removing load cells A key benefit of the Calog-LC II is in situ load cell testing—no need to remove the load cells. Test each cell and get a diagnostic readout in under ten seconds. The automated test sequence: 1. Detects whether the wiring is 4-wire or 6-wire (3- or 5-wire results flag a fault condition).
mini-substations are increasingly being installed to support new developments, expansions and upgrades. However, a concerning trend is emerging in parts of the market, where previously used equipment is cosmetically refurbished and sold as new. According to David Claassen, Managing Director of Trafo Power Solutions, many buyers may not even realise they are purchasing refurbished equipment until problems begin to emerge. “In some cases, mini-substations are removed from facilities that are being upgraded or demolished, and these units are then bought very cheaply,” Claassen explains. “They are cleaned, repainted and sometimes fitted with a new nameplate before being sold back into the market as supposedly new equipment.” While the exterior of such equipment may appear new, the internal components, including the transformer, switchgear and protection systems, may already have years of operational history. Claassen notes that this practice is particularly concerning because mini- substations form a critical part of the electrical infrastructure in industrial operations. designed and manufactured Calog calibrator range, including the 4-20mA Loop Calibrator, delivers. Built around modern component technology, an intuitive interface, and a rugged IP54-rated housing, the Calog series is engineered for the demands of real industrial field calibration work. Common features across the Calog Calibrator Range All Calog calibrators offer a consistent set of key features, providing the same practical tools for engineers regardless of the specific model: • Key-per-digit numeric entry for fast source value setup - scroll each digit independently up or down without cycling through the full range. • 128 x 64 backlit LCD display - switchable between numeric or trending views with programmable timing. • Data-logging via SD card or USB - download to a PC and open in
www.trafo.co.za
Field calibration made easy W hen electrical contractors need reliable, portable process calibrators, Instrotech’s locally
the mV source to prevent ground loops. Alternatively, enter the sensitivity and range, set a target mass value, and the calibrator calculates and outputs the correct mV equivalent — or vice versa. The Calog-LC II can also simulate a load cell transmitter by sourcing mA directly into a display or SCADA system, with the output configurable in mA or scaled to mass units.
www.instrotech.co.za
SPARKS ELECTRICAL NEWS
JULY 2026
CONTRACTORS’ CORNER
4
Diagnosing hardware failures in PV systems using I-V curve tracers P hotovoltaic (PV) systems are
Case study: In a commercial PV installation, technicians noticed a drop in system performance. I-V curve tracing revealed a low Voc in one string. Testing the bypass diodes confirmed a shorted diode. Replacing the affected module restored the system’s performance. Microcracks in PV cells Microcracks are small cracks in PV cells that can occur during manufacturing, transportation, and installation, and due to weather events such as high winds or hail. These cracks can grow over time, leading to reduced performance and potential failure. Symptoms: • Stepped or irregular I-V curve: The I-V curve may show steps or irregularities, indicating current mismatch. • Reduced current output (Isc): The overall current output may be lower than expected. Troubleshooting steps: 1. I-V curve tracing: Identify deviations and steps in the I-V curve. 2. Electroluminescence testing (EL): EL testing applies a reverse-bias current to a string of modules and uses a specialised camera to detect microcracks. This is the most accurate way to detect microcracks, but EL equipment is currently expensive, and the test is labour-intensive. 3. Infrared (IR) imaging: Use an IR camera to detect hot spots, which may be indicative of microcracks. 4. Replacement: Replace modules with significant microcracks. Case study: A utility-scale PV farm experienced a gradual decline in performance. I-V curve tracing and IR distribution equipment, lighting systems, and power transfer infrastructure as major ignition sources. Understanding core material risk The report evaluates the fire performance of several common combustible-core sandwich panel materials, including expanded polystyrene (EPS), polyurethane (PU), polyisocyanurate (PIR), phenolic foam, mineral wool and vacuum insulated panels. A central focus is the Limiting Oxygen Index (LOI), which measures the minimum oxygen concentration required to sustain combustion. Materials with an LOI below 24% are considered capable of sustaining combustion in normal atmospheric conditions, while higher-LOI materials are less likely to propagate fire. The report distinguishes between standard EPS cores and fire-retardant EPS products. While standard EPS can sustain combustion and contribute to fire spread, fire-retardant EPS with an LOI above 24% will generally self- extinguish once an ignition source is removed. Van Niekerk notes that many misconceptions exist regarding combustible-core sandwich panel systems. “Most combustible sandwich insulation panels are not structurally integral to
subject to various hardware issues that can significantly impact their performance. Diagnosing these issues accurately is crucial for maintaining system efficiency and longevity. I-V curve tracing is a powerful tool that helps technicians identify specific hardware failures in PV systems. This article provides a detailed guide on troubleshooting common hardware issues using I-V curve tracers. Common hardware issues in PV systems PV systems can experience several module-related problems that affect their performance. Here are some of the most common issues: Shorted Bypass Diodes Bypass diodes are integrated into PV modules to protect cells from overheating and damage caused by partial shading or internal module issues. A shorter bypass diode can cause significant performance issues, leading to reduced output voltage. Symptoms: • Low open-circuit voltage (Voc): The I-V curve will show a significantly lower Voc. • Stepped I-V curve: The curve may display steps or abrupt changes in slope. Troubleshooting steps: 1. I-V curve tracing: Use the I-V curve tracer to identify deviations in the Voc and detect steps in the I-V curve. 2. Visual inspection: Inspect the module for visible signs of damage or overheating. 3. Multimeter test: Test the bypass diodes with a multimeter. A shorted diode will show continuity in both directions. 4. Replacement: Replace the affected module or bypass diode as necessary. engineering consultancy ASP Fire is challenging blanket assumptions around combustible-core sandwich panels, arguing instead for a rational, risk- based approach that balances fire safety requirements with commercial realities in sectors such as agriculture, manufacturing and industrial processing. Authored by ASP Fire CEO Michael van Niekerk, the report assesses the relative risks associated with various combustible- core sandwich panel materials and outlines practical fire prevention and mitigation strategies for existing and new buildings. “Combustible-core sandwich panels are not without risk, but careful selection and the implementation of sound fire protection strategies can reduce those risks to levels that are as low as reasonably practicable,” says van Niekerk. The report notes that plastic-based construction materials, particularly insulated panel cores, have long presented challenges for fire engineers. However, van Niekerk argues that the focus should shift from simplistic material bans towards understanding ignition sources, fire propagation risks and practical engineering controls. According to the report, the leading causes of industrial fires remain electrical failures and heat-source malfunction, rather than the combustible-core sandwich
: I-V curve tracing is a powerful tool that helps technicians identify specific hardware failures in PV systems.
imaging identified microcracks in several modules. Replacing these modules improved the system’s overall output. Connector failures Connectors are critical components in PV systems. Failures can result from corrosion, poor installation, or physical damage, leading to increased resistance and reduced performance. Symptoms: • Low voltage ratio: The I-V curve will show a lower-than-expected voltage ratio (Vmp/Voc). • Irregular I-V curve: The curve may display irregularities or a lower-than- expected current output. Troubleshooting Steps: 1. I-V curve tracing: Identify irregularities in the I-V curve. 2. Visual inspection: Inspect connections for signs of corrosion, damage, or poor installation. 3. Electrical testing: Use a multimeter to test for continuity and resistance in connectors. structural integrity remains dependent on the steel, concrete or masonry framework.” The report also stresses that combustible- core sandwich panels typically become significantly involved only after flashover conditions are reached within a building, generally at enclosure temperatures above 600°C, by which point the building’s contents are already contributing substantial heat release. Practical mitigation strategies Rather than advocating the wholesale replacement of combustible-core sandwich panels, the report outlines layered fire prevention and suppression strategies that can substantially reduce ignition risk. Recommended interventions include: • Rigorous electrical inspection, monitoring and thermal scanning programmes • Earth leakage, arc fault detection devices and overload protection systems • Thermal CCTV monitoring linked to 24/7 response capability • Early warning fire detection systems linked to 24/7 response capability • Automatic gaseous suppression within electrical distribution boards • Improved compartmentalisation • Spark-arresting and ember-trap systems for direct, solid-fuel heating applications
4. Thermal imaging: Use a thermal camera to detect connectors that are operating at a higher temperature when compared to other connectors under the same environmental conditions. 5. Replacement or repair: Repair or replace faulty connectors. 6. Case study: A solar carport installation had inconsistent performance. I-V curve tracing showed irregular I-V curves. Inspection revealed corroded connectors. Replacing the connectors restored consistent performance. Conclusion I-V curve tracing is an invaluable tool for diagnosing module failures in PV systems. By identifying specific issues such as shorted bypass diodes, microcracks, connector failures, PID, and hotspots, technicians can take targeted actions to restore and optimise system performance. Regular use of I-V curve tracers, combined with thorough inspections and appropriate repairs, ensures that PV systems operate efficiently and reliably.
www.comtest.co.za
Balancing fire safety and commercial reality in combustible-core sandwich panels A new technical report by fire panels themselves. Citing NFPA research on industrial and manufacturing fires between 2017 and 2021, the report highlights electrical the building itself,” he explains. “In many cases they function as cladding or internal environmental enclosures. The actual • Sprinkler protection where building size or storage height thresholds require it. The report argues that these measures can often offer a more practical and cost-
effective way to reduce risk than the wholesale replacement of combustible- core sandwich panels, particularly in commercially marginal industries. “Low-margin sectors such as poultry production simply cannot absorb the cost of replacing entire building envelopes with premium non-combustible systems,” says van Niekerk. “The engineering challenge is therefore to identify and manage the real ignition and propagation risks appropriately.” Commercial realities remain critical The report further highlights the cost differential between core materials. According to the assessment, polyurethane and PIR panels can cost up to nearly double the price of fire-retardant EPS systems, while mineral wool and vacuum-insulated panels can be even more expensive. At the same time, some non-combustible solutions may not be technically suitable in certain environments. Mineral wool and glass wool systems, for example, can be problematic in high-humidity or condensation-prone applications due to the risk of mould formation.
www.aspfire.co.za
SPARKS ELECTRICAL NEWS
JULY 2026
CABLES & CABLE ACCESSORIES
5
Reduce plant downtime and improve cable life with Aberdare Cables
Proven performance in demanding applications Aberdare Cables’ resin-encapsulated joints have been successfully trialled and deployed in underground mining operations and installations with high groundwater levels. These applications have demonstrated the effectiveness of resin technology in preventing water ingress and improving overall network reliability. Customers operating in similar environments can benefit from a proven solution that reduces the risk of moisture- related failures and helps maintain an uninterrupted power supply. Engineering support and site-specific solutions Every installation environment presents unique challenges. For this reason, Aberdare Cables works closely with customers to assess site conditions and recommend the most suitable cable and jointing solutions for each application. By combining technical expertise with practical field experience, Aberdare Cables helps customers select products that maximise reliability, minimise downtime, and improve the long-term performance of power networks and industrial facilities. Conclusion Water ingress remains a leading cause of cable and cable joint failures in wet operating environments. Selecting the appropriate cable jointing technology is therefore essential to ensure system reliability, operational safety, and extended service life. For installations exposed to continuous moisture, groundwater, flooding, or submergence, resin-encapsulated cable joints offer a robust, proven solution. Through ongoing innovation and customer collaboration, Aberdare Cables continues to support industries with reliable cable systems designed to perform in even the most demanding environments.
tested, can perform satisfactorily in wet environments. These technologies utilise adhesive sealing systems and offer the advantage of relatively quick and simple installation. However, in environments with continuous water exposure, these sealing systems may not always provide sufficient protection against water ingress. As a result, moisture can gradually penetrate the cable system, potentially leading to repeated failures and extended outages. Experience has shown that many cable joint failures in high-water environments are directly attributable to water ingress.
By: Donemore Torerwa; GM: Product Development and Applications, Aberdare Cables Pty Ltd
Introduction: the impact of water on cable systems The presence of water in contact with power cables and cable joints presents significant risks to the long-term performance and reliability of electrical networks. These risks are particularly severe when cables and accessories have not been specifically designed or selected for wet operating conditions. Water exposure can occur in various forms, including soil moisture, groundwater, flooding, chemical liquids, and installations where cables operate fully or partially submerged. As electrical infrastructure continues to expand into challenging environments, selecting suitable cable jointing solutions becomes increasingly important to ensure network reliability and reduce maintenance- related downtime. Why waterproofing in cable joints is critical The primary objective of waterproofing a cable joint is to prevent moisture from reaching the cable insulation. When water penetrates the insulation system, it can initiate degradation processes such as water treeing, which progressively weakens the insulation and reduces its dielectric strength. In medium voltage and high voltage cable systems, even small amounts of moisture can significantly accelerate insulation deterioration and lead to premature cable or joint failures. Effective waterproofing, therefore, plays a critical role in extending cable service life and maintaining network integrity. Challenges in high water environments Many cable users struggle to identify suitable cable jointing solutions for environments where water exposure is unavoidable. Such environments include coastal regions, swampy areas, underground mining operations, and locations with high groundwater levels. In some underground mining applications, cables may remain submerged for more than 60% of their operating life. Despite these challenging conditions, continuity of power supply remains essential to ensure operational reliability, minimise production downtime, and maintain safety. This is particularly important in critical facilities such as underground mines, hospitals, and industrial plants. Consequently, the correct selection of both the cable and the cable joint is vital to achieving reliable long- term performance. Conventional jointing technologies in wet conditions Heat-shrink and cold-shrink cable joints are widely used in many installations and, when properly designed and
www.aberdare.co.za
Many cable users struggle to identify suitable cable jointing solutions for environments where water exposure is unavoidable. Such environments include coastal regions, swampy areas, underground mining operations, and locations with high groundwater levels.
Development of resin-encapsulated joint technology Recognising the challenges faced by customers operating in harsh environments, Aberdare Cables collaborated with end users to develop a more robust cable jointing solution for applications where water ingress is a significant risk. This collaboration led to the development of resin- encapsulated joints for low voltage and medium voltage cable systems up to 33 kV. The objective was to provide a jointing solution capable of delivering superior water ingress protection while maintaining long-term electrical and mechanical performance. Advantages of Resin-Encapsulated Cable Joints Resin-encapsulated joints utilise epoxy or polyurethane resin to completely fill all voids within the joint assembly during installation. This process creates a fully sealed, water-blocked system that significantly reduces the risk of moisture penetration. In addition to delivering exceptional waterproofing performance, the resin bonds tightly to the cable’s internal components, enhancing mechanical strength and protecting the joint from external damage. Resin encapsulation also improves resistance to hydrostatic pressure, making these joints particularly suitable for submerged installations and continuously wet environments. The result is a highly reliable jointing solution designed to withstand some of the most demanding operating conditions.
SPARKS ELECTRICAL NEWS
JULY 2026
CABLES & CABLE ACCESSORIES
6
The latest technologies in electrical cables and accessories T he world of electrical cables and accessories is experiencing a technological revolution, driven by the growing demand for safer, more efficient, and environmentally friendly electrical systems. From cutting-edge materials to smart cable management solutions, the latest innovations are setting new standards in performance and reliability. Here’s a look at some of the most exciting technologies shaping the future of electrical cables and their accessories. High-performance conductors and insulation Traditional copper and aluminium conductors are now being complemented by advanced materials such as superconducting cables, which offer minimal electrical resistance and dramatically reduce power losses. High-temperature superconductors (HTS) are especially promising for high-capacity power transmission in urban areas. On the insulation front, cross-linked polyethene (XLPE) and ethylene-propylene-rubber (EPR) are increasingly used, offering enhanced thermal stability, flexibility, and longevity compared to conventional PVC. Fire-resistant and low-smoke cables Safety regulations and urbanisation have spurred the development of fire-resistant, flame-retardant, and low-smoke, zero-halogen (LSZH) cables. These cables are designed to emit minimal toxic fumes when exposed to fire, making them ideal for use in public infrastructure such as airports, subways, and hospitals. The use of non-halogenated compounds not only increases safety but also supports green building initiatives. Smart cables and IoT integration The integration of the Internet of Things (IoT) into cable technology is revolutionising cable management and maintenance. Smart cables now feature embedded sensors that monitor parameters such as temperature, current flow, and mechanical strain in real time. This data enables predictive maintenance, reducing downtime and preventing failures before they occur. Such technology is vital for critical infrastructure, including data centres and industrial plants.
LESCO’s Cable manufacturing excellence: An exclusive interview with Melusi Sibiya
LESCO Manufacturing has firmly established itself as a benchmark of quality, innovation, and local production within South Africa’s cable sector. In a recent discussion with Melusi Sibiya, Cable Production Leader at LESCO Manufacturing, we explored the operational mechanics, triumphs, and hurdles shaping the company’s manufacturing landscape. While historically celebrated for its premium switch ranges, LESCO has strategically expanded its footprint by investing heavily in advanced production lines for extension cords and garden leads. “Our goal is to provide versatile power solutions that never compromise on the strictest safety standards,” Sibiya notes. Uncompromising quality & rigorous testing At LESCO, quality control isn’t just a final check—it is the foundation of the entire assembly line. The company uses dedicated, full-time quality inspectors who oversee multi-stage testing throughout the production cycle. Total compliance: Every item is evaluated at each stage of manufacturing to ensure alignment with domestic and global safety benchmarks. Continuous upskilling: Regular training regimes ensure the workforce remains highly adept at maintaining quality, health, and safety protocols. Navigating raw material volatility Sourcing raw materials presents distinct challenges, particularly given the volatility in pricing and supply of essential commodities like PVC and brass. LESCO mitigates these vulnerabilities through a dual-pronged approach: Strategic stockpiling: Maintaining optimal inventory reserves to buffer against market dips. Supplier synergies: Cultivating robust relationships with domestic and global vendors. “We prioritise local sourcing wherever feasible,” Sibiya highlights. “This not only injects life back into the South African economy but drastically insulates us from international supply chain disruptions.” From concept to conductor: the engineering journey The transition from a design blueprint to a market-ready cable is a highly calculated process: [Standard Review] → [Material Selection] →
Melusi Sibiya.
[Prototyping] → [Rigorous Internal Testing] → [Mass Production] Every project begins with an exhaustive analysis of local and international regulatory frameworks. Engineers then meticulously select the appropriate cable gauge, housing materials, and plug configurations tailored to the product’s specific application. Only prototypes that pass internal trials without issue progress to the final assembly line. Driving efficiency through targeted automation Innovation remains a primary catalyst for growth at LESCO. The integration of a semi-automated cable preparation machine has revolutionised operational throughput, delivering a remarkable 75% productivity surge to meet client demand. “This capital investment has dramatically elevated both our volume capacity and product consistency,” says Sibiya. Complementing this upgrade is a newly introduced semi- automated packaging system, further demonstrating LESCO’s commitment to lean manufacturing practices. Bespoke client collaboration When it comes to specialised, custom cable designs, LESCO adopts a highly collaborative approach. The engineering team works hand in hand with clients to dissect unique specifications and create initial prototypes for client verification. Because production is localised, LESCO can offer significantly faster turnaround times for bespoke orders than international competitors. Sustainable & eco-conscious manufacturing Environmental stewardship is deeply woven into LESCO’s daily operations. The factory actively minimises waste by: • Recycling production-line plastics. • Repurposing brass components salvaged from any rejected units. “We are deeply committed to keeping ecological responsibility at the heart of our manufacturing philosophy,” Sibiya affirms. The power of local heritage What truly elevates LESCO above the competition is its fierce commitment to local manufacturing. In a market saturated with cheap imports, LESCO’s cables are proudly made in South Africa and engineered to withstand rugged, demanding environments. Sibiya emphasises that this reliability is rooted in human capital: “Our dependability begins with our workforce.” By pairing strategic semi-automation with skilled local craftsmanship, LESCO supports the domestic job market while boosting production efficiency. Through continuous evolution, rigorous quality governance, and an unwavering commitment to its workforce and the environment, LESCO Manufacturing continues to lead the future of South African cable production.
Discover more: www.lescosk.com
SPARKS ELECTRICAL NEWS
JULY 2026
CABLES & CABLE ACCESSORIES
7
Cutting-edge plastic Echain protects cables in cleanrooms A dvanced polymer manufacturer igus has developed a new cleanroom energy chain with an innovative guide system that enables abrasion-resistant travel over distances of up to 30 metres. It is ideal for applications in microelectronics, semiconductors, pharmaceuticals, or battery production, wherever it is essential that the surroundings are free of particles while maintaining high production rates. With increasing automation and constantly growing systems, the routes for material transport are also becoming longer. A key challenge here is ensuring that energy and data cables can move freely while minimising wear and tear. According to igus managing director, Ian Hewat, standard energy chains usually require complex extraction systems for microparticles, while the new igus C6 energy chain, in combination with the new e-spin upper run guide wheel, offers a solution that enables compact, durable energy supply in cleanrooms, even for long runs. “Cleanrooms have strict requirements for cleanliness and the exclusion of particles, which makes manual transport within the cleanroom unfeasible. This has led to the development of cleanroom-compatible energy chains that are durable and cost-effective alternatives to costly hoists and manual systems,” says Ian. He explains that igus solved the dilemma by developing a special guide system called e-spin for the C6 cleanroom energy chain. It consists of guide wheels that, like all igus energy chains, are made of tribologically optimised high-performance plastic, which is optimised for friction and wear. The wheels are located between the upper and lower run of the energy chain. As a result, the chain parts roll on top of each other rather than glide to prevent particle emissions. This enables use without an extraction unit and allows design engineers to reduce the complexity of energy supply in transport systems and save costs in the process. Laboratory tests showed that the high- performance plastics achieved the highest cleanroom Class ISO 1 at a speed of 0.5 m/s. This is ideal for a wide range of applications,
South African city declars war on cable thieves Alderman JP Smith has revealed that the City of Cape Town arrested 88 suspected copper cable
thieves and recovered more than a kilometre of stolen cabling over 10 months. The operations took place from July 2025 to April 2026. Smith said authorities also recovered more than 800 kg of stolen metal. “That’s the result of about 5,979 patrols in hotspot areas, 1,257 scrapyard compliance inspections, and responses to more than 423 public complaints,” he told Cape Talk. In addition to the arrests, authorities issued 3,095 fines and closed 42 large scrap-metal- dealing operations and 94 smaller ‘bucket’ shops. Smith explained that these dealers were failing to document the sources of the materials they purchased. “Very often, those registers are not being kept. The reason for these closures was non- compliance with the legislation,” he
all substations,” Padayachee said. “This technology allows for faster electronic indication of where theft occurs, enabling us to respond and deploy people to deal with the problem.” Padayachee stressed that addressing the copper market in South Africa, including cutting off the scrap market, would arrest the problem. “South Africa tried that two years ago when the Department of Trade, Industry and Competition placed a temporary prohibition on the export of copper, which worked reasonably well,” Padayachee said.
said. “They were found guilty of some offence, or they didn’t bother to register as a secondhand goods dealer or a metal recycler, which is required in terms of the Second-Hand Goods Act.” Smith explained that the theft of metals was a global crisis driven by the continued rise in metal prices. “It becomes a commodity that people are willing to steal or commit a crime to risk obtaining,” he said, adding that nearly all non-ferrous metals were being targeted. These are metals that do not contain iron.
Smith said the Passenger Rail Agency of South Africa (PRASA) had been among the major victims of the crime. “Whatever is not bolted down or locked
ai178115969120_CCG 1-2 Page 130x180 IndGland.pdf 1 2026/06/11 08:34 Article courtesy of MYBROADBAND
down,” he said. “Every bit of metal rail, pipe, bars, around structures to protect them from vandalism, and of course, electrical substation components.” Smith added that perpetrators were often hard-up and desperate individuals who were sometimes involved in gangs. However, he added that higher-ups benefited from the criminal activities. “The people further up the food chain are the ones who become rich out of this, and they are the ones who own the scrapyards or bucket shops,” he said. Copper theft chaos in Johannesburg Former Eskom executive manager and City Power engineering operations director, Vally Padayachee, previously warned that cable thieves were becoming more sophisticated and extreme in their methods. He explained that these thieves were venturing into tunnels beneath the City of Johannesburg’s roads, which housed many of City Power’s cables, to steal them at great personal risk. “You don’t want to be in a tunnel when stealing a cable. Whether it’s live or dead, it’s a massive risk because you are grinding, and those sparks can start a fire,” Padayachee said. He explained that there had been an ongoing debate about how to address copper cable theft during his time at the Johannesburg power utility, which spanned 2001 to 2009. He said the primary challenge was deciding whether to allocate resources to increased security or to invest in technology to prevent theft. The toss-up was between allocating guards to substations across the country and employing technology that notifies the energy distributor of vandalised infrastructure. “What we tried to do, and we’re still doing it, is to implement more technology because you can’t practically deploy the manpower needed at
www.igus.co.za
Ian Hewat.
SPARKS ELECTRICAL NEWS
JULY 2026
STANDBY, BACKUP AND EMERGENCY POWER
10
How batteries can help SA avoid a grid crisis B attery energy storage is critical to stabilise SA’s energy future. Earlier this year, Spain and “Sunlight is a big natural resource for South Africa. Even though it took an energy crisis to significantly develop an energy
and store energy when it’s cheapest, use generated energy on tap, and wheel energy into the grid,” says Gurie. The range of BESS solutions supports everything from small to utility-scale sites and serves industries including mining, agriculture, light and heavy industry, and commercial. These are enabling large individual businesses, commercial and industrial parks, and entire communities to store and access power reliably without placing stress on the national grid. But BESS is more than just storage—it’s a pathway to modern energy technologies. BESS solutions incorporate Industry 4.0 technologies that modernise energy operations. For example, leading BESS vendors such as WEG also offer digital power management systems to increase control, visibility, and automation of energy systems. Stabilising the future’s energy supply Renewable energy abundance is replacing South Africa’s energy shortages. But that abundance will be wasted and even damaging if it cannot be stored and managed. Energy infrastructure and operations must be modernised and upgraded. It’s here that BESS will play a fundamental role, says Gurie. “Batteries are not just storage. They are the bricks and mortar that we can use to create our modern energy foundation. We are building the capacity to produce cheap, abundant energy. Now, we’ll start investing in making sure that abundance always serves our needs. BESS is a central part of that investment.”
Magazine said that the issue was due to grid codes causing inverters to disconnect in response to grid frequency changes. Saying that grids need to be redesigned, he added, “blaming renewables for Spain’s blackout is like faulting the thermometer for the fever.” The above situation underscores that grids will have to catch up with energy innovation, says Gurie. “An abundance of energy can create issues, but it’s a good problem to have. The events in Spain and Portugal reveal the importance of balancing generation with demand. It’s a reminder that the way we operate energy distribution needs to evolve. This shift in perspective has made battery energy storage systems more topical.” Stability through battery storage Energy storage is a cornerstone in helping stabilise and upgrade grids, and Battery Energy Storage Systems (BESS) are becoming important facilitators of these outcomes. BESS are large battery systems that plug into local grids, including public utilities, large business premises and community substations. They store energy for later use, such as during peak periods when grid power becomes pricier, or to inject power when there is insufficient sunshine or wind to drive renewables. “BESS infrastructure helps take pressure off grids, giving them room to adjust and upgrade without disrupting energy delivery to communities and businesses. BESS helps shave the peaks and reduce the overall load on the grid. These systems let companies do energy stacking to generate which remains a major hurdle. Without substantial state support, a domestic cell factory is unlikely to be competitive in the near term. For now, importing cells – which account for roughly 40-45% of the final product cost – remains the most practical route, especially given China’s mature, integrated supply chain. The remaining 55-60% of value, however, can be produced locally, and this is where companies like ACTOM Static Energy compete strongly. Despite importing cells, ACTOM Static Energy matches imported complete products on price and outperforms many due to its unique technical design, backed by the bankability that comes with more than a century of manufacturing history. Sustained demand is also the foundation for meaningful job creation and skills development. The larger and more predictable the pipeline, the more manufacturers can invest in Research and Development (R&D), which is essential in a sector where battery technology evolves continuously. Designs do not stand still for a decade; cell capacities, chemistries and configurations shift rapidly, and keeping pace requires both capital and specialised talent. Balancing operations with R&D Manufacturers must balance day-to-day operations with ongoing R&D. In a stable market, this balance is far easier, enabling companies to expand their engineering capability, attract young talent to the sector, and build a broader skills base. Over the next two to three years, the sector anticipates significant growth and the creation of new
industry around that resource, we’re already enjoying major advantages like helping to reduce loadshedding, improving energy independence, and supporting economic growth.” However, this revolution is just starting, and there is now an additional concern that needs our attention, Pervin Gurie adds. “With capacity rising, there are now more questions about access to power reserves and grid stability.” The stability and access question In late April 2025, parts of Spain and Portugal experienced massive power outages. The causes of these blackouts are still being debated, but the general view is that the grid produced too much power. Critics used the outage to attack renewables, blaming them for creating the instability. But experts soon dismissed these claims and noted the event instead underscored how traditional grid designs are no longer keeping up with energy innovations. Xavier Daval, Chair of the Solar Commission at the French Renewable Energy Association,
Portugal lost up to 60% of their electrical power in mere seconds. The underlying issues exposed tensions between traditional grid infrastructure and the future of energy. It’s crucial that SA avoids a similar grid crisis, and battery energy storage systems (BESS) are vital for that transition. SA’s renewables revolution South Africans are very familiar with energy challenges. When local power plants couldn’t keep up with the growing demand, the country implemented an energy management strategy called loadshedding, which periodically limited access to electricity. Eventually, both the public and private sectors began investing in renewable energy sources, and the results have been remarkable. Last year, SA had 8.97 GW of solar PV capacity, 11% higher than in 2023, according to the South African Photovoltaic Industry Association (SAPVIA). Looking back, the shift seemed almost inevitable, says Pervin Gurie.
www.weg.net
Battery energy storage is key to powering a new chapter in South Africa’s manufacturing sector By Richard van Moltke, General Manager at ACTOM Static Power S outh Africa’s manufacturing sector is under increasing strain, squeezed by soaring energy costs,
renewables sector is the surge in imported products that destabilise the market. Local manufacturers cannot compete with ultra- low-cost PV modules from China or the growing influx of cut-price batteries. The result is a volatile environment in which domestic producers are undercut before they can scale, let alone secure the long- term investment needed to anchor a local energy-storage industry. A further constraint is the stop-start flow of orders on large renewable projects. Without a steady “heartbeat” of demand, manufacturers cannot operate or plan efficiently. Irregular bursts of work leave factories idling, skills underutilised, and margins eroded. When developers source cheaper products from the East, local producers lose not only the order but also the continuity needed to remain viable. A predictable baseline of demand is essential to keep South Africa’s manufacturing capacity alive. Cell manufacturing is, by nature, capital- intensive and highly specialised. While the government is exploring the feasibility of a local cell plant – given South Africa’s access to key raw materials – its viability ultimately hinges on consistent demand and long-term bankability. Demonstrable financial stability A manufacturer offering 10-year warranties must demonstrate 10-year financial stability,
an unreliable power supply and mounting competition from imported technologies. Yet this coincides with a key national pivot towards renewable energy, which presents a significant opportunity in the form of the rise of battery energy storage systems and the chance to build a competitive local manufacturing base around them. As South Africa accelerates its shift to renewables, battery storage has become indispensable for maintaining system stability. Variable generation inevitably strains the grid, from voltage swings to frequency fluctuations, and Eskom has increasingly turned to storage as the fastest, most effective way to smooth those pressures. A distributed network of batteries near generation sites can provide the flexibility the grid currently lacks and absorb the midday oversupply of solar power that is now being curtailed. By storing that excess energy for the evening and early-morning peaks, battery systems strengthen both grid reliability and the economics of renewable power.
Richard van Moltke
jobs across both low- and high-skilled categories. A successful battery-storage industry in South Africa will depend on technology tailored to local realities, from climate and grid conditions to the skills available to maintain equipment in remote areas. Imported systems are often judged by headline specifications, yet they are not always suited to African operating environments, nor do they account for long- term maintenance, safety, or lifecycle costs. Ultimately, the local market needs solutions engineered for durability, reliability and ease of maintenance, backed by companies with the financial strength to honour decade-long warranties. As the sector matures, the ability to provide complete, locally appropriate systems – not just battery modules – will be essential to building trust, ensuring performance and supporting the country’s broader energy transition.
Market challenges However, a significant challenge for the
www.actom.co.za
SPARKS ELECTRICAL NEWS
JULY 2026
JULY 2026
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