SEPTEMBER 2026
ELECTRICAL NEWS
www.sparkselectricalnewsmagazine.co.za
REGULARS: CONTRACTORS’ CORNER | FEATURES: EARTHING, LIGHTING & SURGE PROTECTION | TOOLS AND TOOLING | LIGHTING
PRATLEY’S ALUMINIUM ALLOY JUNCTION BOXES: SETTING A NEW BENCHMARK IN ELECTRICAL INSTALLATIONS
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Quality Copper/Aluminiu m Lugs and Ferrules
W hen it comes to robust, reliable, and versatile electrical enclosures, Pratley’s Aluminium Alloy junction boxes stand out in a competitive market. According to Tristan Blades, Technical Projects Manager at Pratley, the company’s innovative use of aluminium alloy construction delivers a range of benefits that distinguish these junction boxes from polymer-based competitors. Superior strength and durability While many junction boxes rely on polymer bases, Pratley’s adoption of an aluminium alloy as the core material results in a product that is both lightweight and remarkably durable. The strength-to-weight ratio ensures that these boxes are easy to handle and install without compromising impact resistance. This makes them especially suitable for installations where mechanical durability and long-term reliability are paramount, and where polymer enclosures might fall short. Enhanced environmental protection A key feature of Pratley’s electrical orange boxes is the powder coating on the aluminium alloy. This coating provides a robust barrier against corrosion and environmental exposure, helping the boxes retain their integrity over time, even in demanding conditions. The high-visibility orange finish also enables quick on-site identification, enhancing both safety and efficiency during installation and maintenance. Flexible cable management solutions Installation flexibility is another advantage of Pratley’s design. Each junction box includes built-in cable glands for SWA (steel wire armoured) cable, providing a secure, integrated cable entry solution. For unarmoured cables, optional compression conversion kits are available, allowing the same enclosure to be adapted to different cabling requirements. This adaptability reduces inventory needs and streamlines installation.
a variety of sizes (from Size 0 to Size 2) and entry configurations, including 2-, 3-, and 4-way options in T, right-angle, Y-type, and H-type arrangements. This range ensures suitability for everything from straightforward two-way connections to complex multi-directional cable routing, meeting the requirements of diverse electrical installations.
CONTINUED ON PAGE 3
Quality Copper XLPE Lugs and Ferrules
POLICY STATEMENT "The performance of our products must exceed all others on the World Market"
Pratley Aluminium Alloy Junction Box Unique built-in glands. For use with armoured cable. Easily convertible for unarmoured cable. For all surface applications. Lightweight and impact resistant. Powder coated for corrosion resistance. Can be painted to match installation colour requirements. Internal and external earthing boss/lug. Range of congurations and sizes.
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CONTRACTORS’ CORNER
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Proudly South African, switched on since 1999: The LESCO story W hen the first Cover Strip range switch rolled off the production line at LESCO Manufacturing in
infrastructure behind every flick of a light. Founded in 1999, LESCO Manufacturing was built on a simple promise: local manufacturing without compromising quality. That first Cover Strip Range was more than an early bestseller — it set the standard for everything that followed. Every switch, socket and lighting-related component since has carried the same
1999, founder David Shapiro could not have imagined how far a single product would take the company. Nearly three decades later, LESCO switches and sockets sit behind millions of South African homes, businesses and public buildings — the quiet
DNA: rigorous testing, safe design and proudly South African craftsmanship. From that single range, LESCO has expanded to include the Apollo, Steel, Dena & Dena Q and Pipelli ranges alongside the original Cover Strip — each engineered to meet the demands of modern lighting circuits, from sleek single-lever switches for contemporary homes to rugged, steel- clad options for commercial and industrial installations. The company remains a family business at heart. David Shapiro handed the reins to his son, Jonathan Shapiro, who took over as CEO in 2016 at the age of 26 — building on his father’s guidance and steering LESCO into a new phase of growth. Today, 45% of LESCO’s workforce comprises people with disabilities, alongside strong representation of women and young people across the business — proof that manufacturing excellence and social impact aren’t mutually exclusive. “We’ve never seen ‘Proudly South African’ as merely a badge,” says Jonathan Shapiro, CEO of LESCO Manufacturing. “It’s a commitment to building products people can trust and to building a workforce that reflects the country we’re proud to serve.” This growth has never come at the expense of LESCO’s founding values. The company holds ISO 9001 certification, is a proud member of Proudly South African, has SABS accreditation, and continues to manufacture the vast majority of its range locally — creating jobs and skills in South African communities. For electricians and retailers, that history translates into reliability: a switch or socket fitted in a home twenty years ago shares the same commitment to safety and quality as one fitted today. Looking ahead, LESCO is in discussions with potential partners to explore opportunities to expand the brand’s global footprint — the next chapter in a story that began on a single production line in 1999. The company’s commitment to innovation remains central to its strategy, with ongoing investments in advanced manufacturing technology and staff development. LESCO has recently implemented new energy-efficient processes across its factories, reducing environmental impact while maintaining the highest standards of quality. The leadership team is also exploring how to integrate smart technology into future product lines to ensure LESCO stays ahead of industry trends and customer needs. With an eye on both local and international markets, the company is poised for continued growth while retaining the values that have defined it from the beginning. The company remains rooted in where it started: proudly South African, proudly reliable, proudly powering the switch that lights every room.
Automating for Scale: Technology with soul
In an era where automation often sparks workforce displacement, LESCO demonstrates a better path forward. By deploying semi-robotic machinery integrated with floor-level AI across its operations, the manufacturer has significantly scaled output while preserving its entire core workforce. The deployment targets high-precision, repetitive tasks on the factory floor. Pairing semi-automated equipment with floor-level AI monitoring has boosted per-line efficiency by four to ten times, allowing LESCO to meet accelerating customer demand without sacrificing quality. Crucially, this operational shift relies on a hybrid model designed to assist human labour rather than replace it:
• Complete Retention: LESCO retained their permanent staff, including every position held by differently-abled employees, who represent 45% of the workforce.
• Role Upskilling: Automated systems handle physically demanding steps, freeing staff to transition into higher-value operational roles. • Maintained Standards: Expanded production strictly adheres to SABS, ISO 9001, and SMETA
accreditations across its line of switches, sockets, plugs, and extension leads.
By choosing a human-centric approach to automation, LESCO proves factories can achieve exponential output gains while maintaining complete workforce stability.
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2026/08/17 13:40:12
SPARKS ELECTRICAL NEWS
SEPTEMBER 2026
CONTRACTORS’ CORNER | EDITOR’S COLUMN
3
Electrifying updates: September highlights & Electra Mining Africa preview W elcome to the September edition of Sparks Electrical News! This month, we shine a spotlight on crucial industry topics: Earthing, Lightning
Looking ahead, our
please stop by and say hello—we value your feedback and ideas. Looking ahead, our October issue will focus on DBs, switches and sockets, Energy Measurement and Supply, and Lighting. If you have news or contributions to share, please note that the article deadline is 9 September. Thank you for your continued support. Enjoy the issue, and I hope to see you at Electra Mining Africa!
October issue will focus on DBs, switches and sockets, Energy Measurement and Supply, and Lighting.
and Surge Protection, Tools & Tooling, and Lighting. Our team has assembled a collection of insightful articles and product updates to keep you informed and inspired. A highlight this September is Electra Mining Africa, taking place at Nasrec from 7 to 11 September. I am excited to attend and look forward to meeting many of our readers and clients in person at the Crown Publications stand LNO1. If you’re there,
sparks@crown.co.za Minx Avrabos | Editor
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PRATLEY’S ALUMINIUM ALLOY JUNCTION BOXES: SETTING A NEW BENCHMARK IN ELECTRICAL INSTALLATIONS
in harsh environments. However, these boxes are intended for surface installations only and are not certified for hazardous areas or to be buried in the ground. Additional accessories and special variants To further enhance waterproofing, Pratley provides standard lid gaskets and optional entry shrouds as accessories. For
specialised applications, such as tunnel installations, the Tunnel Box variant is available, featuring fire-resistant, low- smoke red silicone shrouds and sleeves for maximum safety. Comprehensive support Each Pratley junction box is supplied with installation instructions, and comprehensive product documentation is
available online. This ensures customers have the resources they need for correct installation and regulatory compliance. With their combination of durability, flexibility, and safety, Pratley’s Aluminium Alloy junction boxes are redefining standards in electrical enclosure solutions.
Safety and compliance first Safety is a core consideration in Pratley’s design philosophy. Each box features both an internal earthing boss and an external earthing lug to ensure proper earth continuity throughout the installation. The SABS IP66/IP68 (2 m continuous) rating certifies the boxes’ resistance to dust, water jets, and even continuous immersion up to two meters, providing peace of mind
www.pratleyelectrical.com
Why variable speed drives make sense in modern irrigation
V ariable speed drives are revolutionising irrigation by shifting control from valves to pump speed. Rather than running motors at full power and throttling flow, they adjust motor speed to match crop water needs, reducing energy consumption, electrical stress, and water hammer. Discussions about variable speed drives (VSDs) in irrigation often start with the pump, but they should begin with the crop. Irrigation systems are designed to meet seasonal water demands that vary by season, zone, and daily schedule. Only after assessing the entire process—crop requirements, method, pressure fluctuations, and flow—does pump control become relevant. This is where VSD technology truly demonstrates its benefits. The traditional approach Traditionally, irrigation systems used fixed-speed motors and controlled flow with valves. Lower pressure or flow meant throttling a valve; for start-up protection, pumps started with valves closed. These systems draw extremely high inrush currents at start-up—often 300% to 800% of rated current. Rapid acceleration abruptly transfers torque into the water column, causing surges, stress, and water hammer. Skilled operators are often required, or expensive pressure-operated valves are installed—both of which increase maintenance. What changes with a VSD? With a VSD, motor speed is controlled directly rather than by valves. VSDs deliver full torque from zero speed, enabling smooth, slow starts and gentle opening of non-return valves, virtually eliminating water hammer. Motors draw only the current required, avoiding start-up peaks, whilst the pump simply runs at the speed
transforms fixed-speed pumping into a responsive, automated, energy- optimised system. www.pfs20.com
components such as start-up and pressure- control valves are often unnecessary. Pumps can be started on timers or remotely, without operator intervention. Instrumentation— pressure switches, transmitters, emergency stops—connect directly to drive inputs, eliminating additional hardware and simplifying installation and maintenance. Built-in process control Modern VSDs have on-board PID controllers, so pressure or flow signals feed directly into the drive, automatically maintaining constant pressure or flow. As zones open or close, the drive instantly adjusts motor speed. The pump always runs at the speed irrigation requires, not against valves.
Final thoughts A VSD is a process control device. When applied with a full understanding of irrigation requirements, it
Energy considerations A standard IE1 motor runs at about 0.8 power factor at full load. VSDs convert AC to DC and recreate a controlled sine wave, thereby changing the input characteristics from fixed- speed operation.
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This can improve electrical efficiency and reduce reactive impact. The greater energy savings come from the pump affinity laws: • Flow is proportional to speed; • Pressure is proportional to speed squared; and • Power is proportional to speed cubed. Even a small speed reduction significantly reduces power consumption. Rather than throttling excess energy, VSDs reduce energy use at the source—especially important for irrigation systems operating at partial load for extended periods, yielding real financial savings. K What about payback? Most agricultural VSD installations pay back within 9–14 months. This results from: • Reduced maximum demand spikes; • Energy savings through speed control; • Elimination of control valves; • Reduced maintenance; and • Extended pump and pipe life. Savings continue beyond payback. Y CM MY CY CMY
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required by the irrigation process. This has three immediate effects: • Reduced electrical stress; • Reduced mechanical stress; and • Lower maximum demand exposure (depending on tariff structure); • Eliminating valves and operators With speed as the control, traditional
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SPARKS ELECTRICAL NEWS
SEPTEMBER 2026
CONTRACTORS’ CORNER
6
Michael Toth: leading Stone Stamcor’s sales team into the future
base is methodical. Rather than casting a wide net, he focuses on identifying the company’s strongest markets and targeting similar customers. He also seeks opportunities to convert customers using competing products by emphasising Stone Stamcor’s advantages in local manufacturing, product quality, and service. New business development is another key focus, with targeted prospecting, industry networking, and engagement with wholesalers and industrial customers. Facing market challenges head-on Michael is candid about the challenges posed by imported products. His solution is to double down on local manufacturing, improving efficiency and expanding the range of locally produced items. This approach, he argues, not only ensures quality and reliability but also strengthens Stone Stamcor’s competitive edge. motivated and professional sales division driving the company’s long-term growth. He aims to foster a culture of accountability, teamwork, and continuous improvement. His goal is to help Stone Stamcor expand its market presence and reinforce its status as Vision for the future Looking ahead, Michael envisions a in 2026—its 80th year of innovation, resilience, and contribution to South Africa’s industrial landscape. Over eight decades, Aberdare Cables has grown from a modest operation into a powerhouse synonymous with quality, reliability, and technological advancement. A legacy of excellence Founded in 1946, Aberdare Cables began its journey at a time when South Africa’s infrastructure needs were rapidly evolving. Initially serving the mining and electrical sectors, the company quickly earned a reputation for high-quality cables that met the demands of a growing economy. From these humble beginnings, Aberdare expanded its product range and operations, becoming a critical partner in national electrification, urban development, and major infrastructure projects. Commitment to innovation A key factor in Aberdare Cables’ longevity is its unwavering commitment to innovation. Throughout its history, the company has invested heavily in research and development, keeping its products at the cutting edge of technology. Whether pioneering fire-resistant cables, developing eco-friendly insulation materials, or adopting advanced manufacturing processes, Aberdare has consistently set industry benchmarks. In recent years, the company’s focus on sustainability has led to the development of greener cable solutions, reducing environmental impact while maintaining stringent safety and performance standards. Aberdare’s embrace of digital transformation, smart manufacturing, and automation has further reinforced its position as a forward-thinking industry leader.
lead by example,” he says.
Stone Stamcor, a prominent South African manufacturer in the electrical industry, has long been renowned for its commitment to quality, customer service, and local manufacturing. At the helm of its dynamic sales division is Michael Toth, the newly appointed Sales Manager, whose journey through the company exemplifies dedication and vision. A journey of growth and commitment Michael’s career at Stone Stamcor spans nearly a decade. Starting in Internal Sales, moving through External Sales, and now taking the reins as Regional Sales Manager, he describes this progression as deeply rewarding. What attracted him most to his current role was the chance to support the team, strengthen customer relationships, and actively contribute to the company’s growth—a company that, in his words, has invested in his professional development. Proud to represent a South African manufacturer, Michael believes that Stone Stamcor’s reputation for quality and service is unmatched. “It’s a privilege to be part of a company that continues to its traditional role as a utility service to become a key factor in project viability, cost competitiveness and long-term sustainability. According to SLR Consulting, the shift is being driven by rising energy costs, pressure to decarbonise operations, and the growing need for a secure, resilient power supply across mining jurisdictions in Africa and globally. Tasman Graham, Managing Director at SLR Consulting, says that mining companies increasingly recognise that energy decisions now sit at the heart of both operational performance and future growth strategies. “Energy has become a significant business risk in the mining sector, with direct implications for capital and operating costs,” Graham says. “At the same time, it presents a major opportunity to unlock efficiencies, strengthen resilience and support sustainability objectives.” He notes that the rapid improvement in renewable energy economics is reshaping how mines approach power supply, with solar and onshore wind, supported by battery storage, now frequently the most cost-effective option. “In many applications, hybrid energy systems are now the lowest-cost option even before climate considerations are taken into account,” he explains. This trend is particularly relevant in Africa, where many mining operations face grid instability, rising tariffs and long lead times for new transmission infrastructure. As a result, behind-the-meter energy solutions are gaining momentum, with mines investing in combinations of solar photovoltaic systems, wind generation, battery storage and diesel or gas backup. These systems not only reduce reliance on diesel but also enhance energy security
Sales leadership shaped by experience Michael’s hands-on experience, both internally and externally, has given him a thorough understanding of the company’s products, customers, and business landscape. He emphasises the importance of communication, teamwork, and relationship- building—skills he sees as essential for leading a successful sales team. Assessing the current landscape Stone Stamcor’s sales strategy is built on a foundation of quality, technical expertise, and customer service. Michael’s approach is to build on these strengths while seeking new growth opportunities. In his first 90 days, his priorities are clear: support the sales team, deepen customer relationships, and identify avenues for business expansion, all while maintaining the high standards customers expect. Strategic growth and team development Michael’s strategy for expanding the client highlights the broader developmental role that mining-led energy infrastructure can play. “Power solutions developed for mining projects can also support surrounding communities and local economic activity, strengthening the mine’s social licence to operate and contributing to regional development,” he says. According to SLR Consulting, successful energy strategies require an integrated approach that takes into account engineering, environmental, social, regulatory and commercial factors from the earliest stages of a project. The company supports mining clients throughout the full project lifecycle, combining expertise in energy advisory, environmental performance, water management and climate risk modelling to help deliver commercially sound, sustainable outcomes. Looking ahead, Graham believes the greatest opportunities lie in flexible, site- specific hybrid energy solutions aligned with life-of-mine requirements. “The future of mining energy lies in pragmatic, well-structured systems that balance cost, reliability and sustainability,” he concludes.
a leading South African manufacturer. With Michael Toth at the helm, Stone Stamcor’s sales division is poised for sustainable growth, built on strong relationships, innovative strategies, and a steadfast commitment to local excellence.
www.stonestamcor.co.za
Aberdare Cables celebrates 80 years of powering progress A berdare Cables, a leading name in the cable manufacturing industry, marks an extraordinary milestone Empowering communities and industry Beyond its commercial success, Aberdare Cables has made significant contributions
SLR Consulting highlights energy as a strategic growth driver for mining E nergy is fast becoming one of the most influential strategic considerations in modern mining, moving well beyond and offer attractive payback periods. Beyond operational gains, Graham
to South African society. The company strongly advocates local content and skills development, investing in training programmes and supporting small and medium-sized enterprises in its supply chain. Its community outreach initiatives, including educational partnerships and electrification projects in underserved areas, have helped to empower thousands of South Africans. 80 years of partnerships Aberdare Cables’ journey has been shaped by enduring partnerships with customers, suppliers, and employees. The company’s success is a testament to the trust placed in it by utilities, contractors, and distributors across Africa and beyond. Many of Aberdare’s employees have devoted decades of service, fostering a culture of teamwork, integrity, and continuous improvement. Looking ahead As Aberdare Cables celebrates its 80th anniversary, it is poised for the future. With a strong foundation and a clear vision, the company is well placed to navigate the challenges and opportunities ahead. Its commitment to quality, innovation, and social responsibility ensures that Aberdare Cables will continue to play a pivotal role in powering progress—both in South Africa and across the continent. The 80th-anniversary celebration is not merely a reflection on the past but a bold statement of intent for the future. Aberdare Cables remains committed to delivering value, driving technological advancement, and making a positive impact for generations to come.
www.slrconsulting.com
www.aberdare.co.za
SPARKS ELECTRICAL NEWS
SEPTEMBER 2026
CONTRACTORS’ CORNER
7
An engineering symphony: the dual engine powering African Industry
Smart Building technologies and energy- efficient motor control systems that optimise building automation, reduce carbon footprints, and lower operational costs. Decades of service: more than a measure of time CGI Controlgear and ABB celebrate this achievement, fully recognising the core attribute that got us here – our relationships.
of withstanding extreme environment operations. Renewable Energy & Power: Providing grid- compliant, scalable equipment for solar, wind, and traditional power distribution infrastructure. Process, Chemical & Water: Supplying precise control gear and automation systems to protect critical pumps, drives, and fluid handling operations. FMCG & Commercial Buildings: Deploying
Through decades of collaboration, technological evolution, and shared challenges, we proudly mark this milestone with the industry we serve. Your projects have shaped our journey. Your challenges have driven our innovation, and your trust has given this partnership its purpose.
From the distribution of electrical and control
components to their integration into sophisticated mini-substations, motor control centres (MCCs), switchboards and control panels, ABB technology is an integral part of CGI Controlgear’s offering.
www.cgi.africa
of service
POWERING INDUSTRY, DELIVERING RELIABILITY.
CGI Controlgear has lent a hand in moulding South Africa’s electrical, control and instrumentation landscape for 40 years. What began as a modest idea to establish a local ecosystem connecting consumers with world-class products has evolved into a full-on turnkey service offering. At the heart of this journey has been a long-standing partnership with ABB, a relationship built on shared technical ambition, mutual trust, and an unyielding commitment to client success. From the distribution of electrical and control components to their integration into sophisticated mini-substations, motor control centres (MCCs), switchboards and control panels, ABB technology is an integral part of CGI Controlgear’s offering. Together, the two organisations have supported projects locally, across the African continent, and beyond, while contributing to the advancement of smarter, more connected power, control, and automation environments. Don’t just power industry. Advance it. ABB delivers an industry-leading global portfolio of cutting-edge low and medium- voltage technologies designed to address increasingly complex electrical, control and industrial requirements. As a leading global technology company, ABB energises the transformation of society and industry to achieve a more productive and sustainable future. ABB in Africa provides solutions to improve the efficiency, productivity and quality of customers’ operations while enabling them to reduce their environmental impact. Product lines reach full potential only when paired with the right partner. ABB, through CGI Controlgear’s integrated supply chain, deep technical leadership, and tailored commercial offerings, equips project managers and engineers with the confidence to specify ABB solutions. This cross-functional and intercompany harmony ensures that from initial design to long-term maintenance, clients receive seamless support. Versatile solutions across critical sectors Results-driven partnership: Sector-wide development: Mining, Oil & Gas: Delivering robust and heavy-duty EC&I componentry capable
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SPARKS ELECTRICAL NEWS
SEPTEMBER 2026
CONTRACTORS’ CORNER
8
Intelligent energy management in action: how Rubicon’s solution at Curro Mahikeng is building a blueprint for smarter schools
Fleet platform, which provides real- time visibility into site performance via a live operational dashboard. Facilities teams can monitor solar generation, battery performance, grid imports, energy consumption and overall system status, while historical reporting helps identify trends and supports ongoing optimisation. Importantly, Fleet also provides real-time financial visibility, allowing the customer to track system performance, including return on investment (ROI). “The intelligence comes from the system’s continuous evaluation of what’s happening across the site,” explains Smith. “Rather than simply following fixed operating rules, the APEX MCS makes dynamic decisions that help reduce unnecessary grid consumption while ensuring reliable power for essential loads.” From monitoring to active optimisation Early operational data has already demonstrated the system’s ability to optimise energy use. During one operating period, the site ran throughout the night without drawing power from the grid, with grid consumption resuming only around midday the following day. Throughout this period, the APEX MCS automatically coordinated solar generation, battery storage and site demand without operator intervention.
Beyond improving day-to-day energy management, the project demonstrates how integrated control platforms can help organisations make better use of their existing energy assets and provide the operational insight needed to support future expansion. A blueprint for smarter energy infrastructure “For many organisations, the next step isn’t simply installing more generation,” says Smith. “It’s making every kilowatt work harder. Intelligent energy management provides customers with the visibility and control to optimise performance today and prepare for tomorrow’s energy demands.” The Curro Mahikeng project demonstrates how the right combination of solar PV, battery storage and intelligent control can help organisations build more efficient, resilient and future-ready energy infrastructure. By integrating WeCo battery technology with the APEX MCS and APEX Fleet platform, Rubicon has delivered a practical blueprint for smarter school energy systems, one that goes beyond generation and storage to actively manage, optimise and report on energy performance. Installation & commissioning: Sparki Solar
I nstalling a solar PV system is only part of building a more efficient and sustainable energy system. The real value lies in how intelligently that energy is generated, stored, controlled and reported on. That was the thinking behind Rubicon’s energy solution for Curro Mahikeng, where an integrated solar PV and battery energy storage system, supported by WeCo technology and the APEX Microgrid Control System (MCS), is helping the school optimise energy use, reduce reliance on the grid, and lay the groundwork for future energy initiatives. This includes Curro’s longer-term ambition to transition its school vehicles to electric vehicles (EVs) and to power their charging infrastructure, as far as possible, from renewable energy generated on site. The APEX MCS will play a central role in managing these additional loads alongside the school’s existing energy requirements. Designed as a proof of concept, the installation is intended to serve as a blueprint for future deployments across other Curro campuses. “Curro’s vision extended beyond simply generating renewable energy,” says Rhydian Smith, Senior Sales Consultant at Rubicon. “They wanted a solution that could intelligently manage multiple energy sources, improve operational efficiency and support their longer-term sustainability objectives.” As part of the solution, Rubicon supplied and integrated a WeCo HYbo battery energy storage system with the APEX MCS,
creating a coordinated energy management environment in which solar generation, battery storage, grid power, and site loads can be managed as a single intelligent system. “That’s why Rubicon selected the APEX MCS and WeCo HYbo for this project,” adds Smith. “The WeCo system provides battery storage, while the APEX MCS provides the control intelligence needed to orchestrate solar generation, battery storage, grid supply and site demand in real time. Together, they enable us to deliver a more complete and future-ready energy solution for the customer.” Managing energy as one integrated system Rather than functioning as a conventional solar installation, the Curro Mahikeng system combines solar PV, WeCo battery energy storage and advanced energy management through the APEX MCS, enabling the site’s energy resources to work together as a single, optimised system. At the heart of the solution, the APEX MCS continuously monitors energy generation, battery state of charge, building loads, electricity tariffs, and grid interactions to determine the most efficient way to meet the site’s energy requirements. By intelligently prioritising available solar energy, determining when to charge and discharge batteries, and reducing grid consumption during higher-tariff periods, the system helps lower operating costs while increasing the use of renewable energy. The system is supported by the APEX
www.rubicon.tech
It’s making every kilowatt work harder. Intelligent energy management provides customers with the visibility and control to optimise performance today and prepare for tomorrow’s energy demands.
National Water Action Plan must prioritise technical skills, says CESA C onsulting Engineers South Africa (CESA) has welcomed President Cyril Ramaphosa’s release of the National Water Action Plan (NWAP), but is cautioning works, and nobody on site understands hydraulic design or can troubleshoot a failing plant, the taps still run dry and the rivers still turn green.”
“We have seen this movie before with load shedding. Fixing the institutions bought Eskom time, but it has been engineering and operational capability that has made the real difference, keeping the lights on up to now. We cannot dismiss the realities of the unfortunate reduction in industrial demand, combined with residential, commercial, and mining houses all implementing various forms of self-help renewable energy systems for their own energy security, all of which have contributed to reduced demand on Eskom. Water needs exactly the same discipline, technically, operationally and financially, through demand and supply management, as a water-scarce country,” Campbell highlights. He notes that South Africa’s Blue Drop and Green Drop performance, the national benchmarks for drinking water and wastewater quality, has declined in direct correlation with the loss of technical skills in municipalities over the past three decades. Reversing this trend requires sustained, practical, engineering-led skills development, not short-term interventions on the eve of looming local government elections. “The warning lights had come on more than two decades ago, and just as in the case of our energy crisis, we kicked the can down the road up to now,” he adds. “Every Blue Drop and Green Drop failure I have seen has a skills shortage behind it. Engineers, technicians, technologists and process controllers who left or retired from the public sector weren’t replaced, and incumbents, if available, were never adequately trained in the first place. The NWAP gives us the institutional architecture to fix this.
that infrastructure investment and institutional reform will only deliver results if South Africa urgently closes the technical skills gap in its water and wastewater sector. CESA is calling on national and provincial governments, municipalities, water boards, and private-sector partners implementing the NWAP to incorporate structured, ongoing technical training across all phases of the Plan’s rollout, from the immediate stabilisation of failing systems to the long-term institutional reforms mandated by the National Water Crisis Committee (WATERCOM). The NWAP, released on 23 July 2026 after a WATERCOM meeting at the Union Buildings, sets out a programme of short-, medium- and long-term interventions to address the country’s escalating water crisis. It identifies an inappropriate delivery model, characterised by the absence of ring-fenced water revenues and diffuse accountability across billing, revenue collection and technical departments, as the root cause of service failures in many municipalities. “The plan has correctly diagnosed the institutional and financial failures behind the crisis, but no amount of ring- fencing or reform will hold water if there aren’t enough competent people to run the plants, maintain the assets and make sound engineering decisions on the ground,” says CESA CEO Chris Campbell. “The government has done the hard work of naming the disease. Ring-fenced revenue, clear accountability, and private-sector investment are the required prescriptions. You can reform a municipality’s books all you like; if there is no qualified process controller on shift at the treatment
Chris Campbell
Its success depends on whether we treat capacity and competency development as core, not as a nice-to-have that gets cut when budgets tighten,” Campbell adds. “This requires a pipeline of competent, professionally registered local practitioners who can take responsibility for these assets and keep them operating for the next 30 years and beyond. Skills development is therefore integral to the water response. It is one of the foundations on which the response must be built,” he notes. “The long-term success of the NWAP will ultimately be measured by whether the infrastructure and institutional improvements remain functional and effective,” concludes Campbell.
www.cesa.co.za
SPARKS ELECTRICAL NEWS
SEPTEMBER 2026
EARTHING, LIGHTNING & SURGE PROTECTION
9
Advanced material science in earthing, lightning, and surge protection By Minx Avrabos M odern electrical installations, particularly in low-voltage (LV) and medium-voltage (MV) environments, electrodes can have high resistivity, reducing the effectiveness of fault current dissipation. New formulations now incorporate conductive admixtures such as carbon black and special metallic
Adopting advances in material science allows contractors to deliver safer, longer-lasting, and more cost-effective earthing and lightning protection solutions.
fibres, achieving resistivities as low as 0.01 Ω m (compared with the typical 100–150 Ω m of standard concrete). These advanced concretes not only lower earth resistance but also greatly improve moisture retention, providing consistent performance even in arid soils. This means smaller electrode arrays and reduced excavation costs. 2. Graphene-based earthing electrodes Graphene, a single layer of carbon atoms
require robust earthing, lightning, and surge protection systems. Recent advances in materials science have revolutionised traditional approaches, offering enhanced conductivity, corrosion resistance, and long-term reliability. This article highlights three cutting-edge innovations: highly conductive concrete, graphene-based earthing electrodes, and exothermic welding methods.
exceeding 40 years, even in aggressive soil conditions (chlorides, sulphates, or acidic environments). These electrodes are lightweight and easy to handle, facilitating rapid installation.
arranged in a hexagonal lattice, exhibits electrical conductivity up to 1,000 times that of copper. Electrodes incorporating graphene or graphene composites offer ultra-low resistance—often below 0.1 Ω for standard 3-metre rods—and exceptional mechanical strength. Most notably, graphene’s inert nature provides outstanding resistance to underground corrosion, promising service lives
3. Exothermic welding Reliable earthing depends on low-
resistance, durable connections. Exothermic welding uses a controlled chemical reaction to permanently bond conductors at the molecular level. These joints match or exceed the conductors’ conductivity, are immune to loosening caused by vibration, and resist corrosion far better than mechanical clamps or compression fittings. For LV and MV projects, exothermic welds ensure minimal maintenance and superior long-term performance. Conclusion Adopting advances in material science allows contractors to deliver safer, longer- lasting, and more cost-effective earthing and lightning protection solutions. Embracing these innovations will be key to meeting the ever-increasing demands of modern electrical infrastructure.
1. Highly conductive concrete Traditional concrete encasement of earth
www.crown.co.za/sparks-electrical-news- magazine
Protection for critical infrastructure and digital facilities By Minx Avrabos I n today’s hyper-connected world, critical 2 surge protection devices (SPDs) at service entrances and distribution boards. This shields against external surges caused by grid switching or lightning.
entering the cabin. Choose devices rated for telecom frequencies and maximum fault currents. Routine inspection: Inspect earth connections and SPD function after storms or maintenance events. Conclusion With digital infrastructure underpinning modern economies, proactive earthing and surge protection are non-negotiable. Integrating layered protection across power, data, and structural systems ensures resilience, maximises uptime, and protects critical operations. www.crown.co.za/sparks-electrical-news- magazine
locations, making them prime targets for lightning strikes. Coordinating tower and equipment cabin grounding is crucial: Design a ring earth: Surround the tower base with a buried ring conductor, connecting it to tower legs and equipment cabin earth bars. This ring collects and dissipates lightning energy. Bond all interfaces: Connect the ring earth to all metallic structures—feeder cables, antenna masts, and cabin frames—with short, direct conductors. Isolate signal grounds: Ensure signal and power earths are bonded at a single point to avoid ground loops, which can induce surges into sensitive electronics. Surge protection on all lines: Install SPDs on AC power, DC supply, and coaxial lines
infrastructure, including data centres and telecom base stations, underpins economic activity and communications. Maintaining uptime is paramount, yet these sites remain vulnerable to electrical hazards, including lightning strikes and transient surges. Robust earthing and surge protection are fundamental to safeguarding these assets. Data centre vulnerabilities and surge mitigation Data centres house sensitive automated logic networks and vast arrays of IT equipment. Even momentary surges—often too fast or subtle for legacy grid protection— can propagate through power and data lines, causing logic errors, hardware damage, and downtime. To mitigate these risks: Equip all entry points: Install Type 1 and Type
Local protection: Use Type 3 SPDs near critical servers, network switches, and storage devices. These devices capture residual surges that bypass upstream protection. Equipotential bonding: Create a low- impedance path to earth by bonding all metallic parts—power racks, cable trays, and enclosures—to a central earthing bar. This prevents dangerous voltage differences that could disrupt sensitive electronics. Regular testing: Continuously monitor earth resistance and SPD status. Degraded Earth systems and spent SPDs reduce the effectiveness of protection. Telecom base stations: coordinated grounding for high-exposure sites Telecom towers are often sited in exposed
In today’s hyper-connected world, critical infrastructure, including data centres and telecom base stations, underpins economic activity and communications.
SPARKS ELECTRICAL NEWS
SEPTEMBER 2026
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EARTHING, LIGHTNING & SURGE PROTECTION
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Comprehensive electrical surge protection: essential strategies for modern power systems I n modern industrial, commercial, and Managing motor starting and stopping transients
residential environments, electrical installations are continually exposed to severe power-quality threats. Unpredictable weather events, power- grid switching, and heavy-machinery operations can generate damaging electrical surges, leading to catastrophic equipment failure, severe financial losses, and critical operational downtime. Implementing a robust protection strategy combining proper earthing, lightning mitigation, and surge protection is essential for any resilient power network. Why installing surge protection is vital Surge protection devices (SPDs) provide a vital barrier against transient overvoltages, which are rapid, extreme voltage spikes that propagate along power and data lines. Transients typically originate from two sources: external atmospheric events, such as direct or indirect lightning strikes, and internal utility grid switching. Without effective surge protection, these high-energy transients can easily bypass standard circuit breakers, destroying sensitive microelectronics, degrading insulation, and creating significant fire hazards. Installing SPDs extends equipment lifespan, maintains regulatory compliance, and ensures continuity of operations by clamping destructive voltage spikes and safely diverting excess energy to ground.
While lightning strikes pose a sudden external threat, internal operational switching generates a continuous stream of electrical stress. The routine starting and stopping of electric motors, widely used in HVAC systems, pump stations, conveyors, and industrial machinery, create substantial inductive voltage transients and high inrush currents. When a motor energises or abruptly shuts down, the rapid collapse or creation of magnetic fields in the motor windings generates switching surges. These micro- surges propagate through the internal distribution network, gradually degrading winding insulation and disrupting nearby delicate automation controls. Mitigating these surges requires a combination of high-grade surge suppression and specialised motor control components that absorb switching spikes and manage voltage ramps effectively. MCE Electric products for total protection To defend against both atmospheric lightning and internal switching transients, MCE Electric provides an extensive range of certified electrical protection and control gear designed for maximum reliability: Surge Protection Devices (SPDs): MCE offers comprehensive Type 1, Type 2, and Type 3 surge arresters designed for main low-voltage distribution boards down to
Surge protection devices (SPDs) provide a vital barrier against transient overvoltages, which are rapid, extreme voltage spikes that propagate along power and data lines.
mechanical wear on motor assemblies. Circuit protection: MCE’s residual current devices (RCDs), miniature circuit breakers (MCBs), and moulded case circuit breakers (MCCBs) provide reliable protection against overload, short-circuit, and earth- leakage conditions. Secure your system with MCE Electric Whether engineering protection against lightning strikes or safeguarding motor circuits from daily operational transients, MCE Electric delivers reliable hardware that meets stringent safety standards. Explore MCE’s complete product portfolio and technical specifications on its official website at https://www.mce.co.za/.
final sub-distribution networks, providing rapid response times to divert high transient currents. Earthing and lightning protection gear: Complete earthing accessories, including earth rods, bonding clamps, and conductors, establish a low- impedance path to earth—a fundamental requirement for safely discharging lightning current. Motor control and protection: For smooth motor starting and stopping, MCE provides heavy-duty contactors, Direct-On-Line (DOL) starters, Star-Delta starters, soft starters, and thermal overload relays. Pairing these control units with MCE surge modules drastically reduces electrical and
Smart grounding systems: the future of earthing, lightning, and surge protection By Minx Avrabos A s our dependence on advanced electronics and critical infrastructure grows, the need for robust earthing, lightning, and surge protection has
Earthing, or grounding, is the process of connecting electrical installations to the earth, allowing excess electrical energy—such as lightning strikes or surges—to dissipate safely.
resistance and overall system effectiveness. Traditional maintenance methods, such as periodic manual resistance testing, are often insufficient to detect sudden or gradual changes that may compromise safety. Smart grounding systems: how they work Smart grounding systems integrate IoT (Internet of Things) sensors directly into the grounding infrastructure. These sensors continuously monitor key parameters, including earth resistance and ground potential rise (GPR)—the increase in voltage between the earth and the grounding system during a fault or lightning event. The real magic happens when these sensor readings are transmitted in real time to cloud-based software platforms. There, advanced analytics and machine- learning algorithms process the data, instantly alerting maintenance teams to abnormal conditions or trends that could indicate a developing problem. For example, a sudden spike in ground resistance could signal rod corrosion or soil drying, while a gradual upward trend might suggest gradual degradation.
never been greater. Traditional grounding systems, while effective, are often static and cannot provide real-time insights into their performance. Enter smart grounding systems: a revolutionary approach that uses IoT sensors and cloud-based software to elevate safety and reliability to unprecedented levels. The importance of grounding Earthing, or grounding, is the process of connecting electrical installations to the earth, allowing excess electrical energy—such as lightning strikes or surges—to dissipate safely. A reliable grounding system is essential for protecting people, equipment, and facilities from dangerous voltages and for ensuring compliance with safety standards. However, environmental factors such as soil moisture, temperature, and corrosion can significantly affect ground
Benefits and applications With real-time monitoring, organisations can shift from reactive to proactive maintenance, reducing downtime and preventing catastrophic failures. Smart grounding systems are particularly valuable in sectors such as telecommunications, power distribution, manufacturing, and data centres—where uptime is critical and the consequences of electrical faults are severe. Additionally, integrating smart grounding with lightning and surge protection systems enables a holistic approach to safety. By correlating lightning-strike data with GPR readings and earth-resistance trends, facility managers can assess the effectiveness of their protective measures and implement data-driven improvements. Conclusion Smart grounding systems mark a paradigm shift in earthing, lightning, and surge protection. By harnessing IoT and cloud technologies, they deliver continuous, actionable insights— ensuring grounding systems remain reliable, safe, and ready to protect against unpredictable natural forces and electrical faults.
www.crown.co.za/sparks-electrical-news-magazine
SPARKS ELECTRICAL NEWS
SEPTEMBER 2026
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