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
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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
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