Killing copper cable theft

The situation

Sabotage, vandalism and cable theft occurs in many sectors of Eskom. This entity alone loses R2 billion per year to theft, with estimated downstream losses of R78 billion.

Diversified metals producer Sibanye-Stillwater lost more than R1bn in production last year to copper cable theft.

Between January and October 2021, TRANSNET reported the theft of more than 1,000 kilometers of overhead cable. Then, in the two weeks leading up to November 10, another 55 km of cable was stolen.

As a result, Transnet has experienced significant disruptions in its services and is now contemplating replacing electric traction with diesel in the future. This potential shift would be a tremendous tragedy, not only surrendering to criminal activities but also harming the environment due to the increased emissions from numerous large diesel engines. With a considerable amount of goods now being transported by road instead of rail, hundreds of diesel trucks contribute to air pollution and road damage.

TRANSNET has now asked the state to help it remedy chronic copper cable theft that has reduced operations by up to three quarters this month. According to TRANSNET, the rampant theft on Transnet minerals corridor is beyond their ability to remedy.

The total downstream loss for South Africa is estimated at R187 per year

The Copper Export Ban is not working

The South African government has imposed a six-month ban on the export of copper and copper-alloy scrap, as well as most ferrous scrap as part of the first phase of a three-phase intervention designed to combat the rampant theft of metals used in public infrastructure. It is now proposed that the ban be extend for an additional 9 months even though there is no clear evidence that the ban has curbed theft.

Thieves are not effectively prosecuted

Only 7% of apprehended thieves are convicted due to the inability to prove the origin and ownership of the stolen cable. Syndicates employ thieves who continue stealing cables, knowing they can do so without facing consequences. While it is impossible to guard the extensive network of overhead copper cables, particularly in remote areas, there is an unique new solution.

Killing copper theft

An innovative new South African invention offers a solution to minimize cable theft. The proposed solution involves injecting microdots into insulated electrical cables and marking the top two-thirds of overhead rail cable with nickel microdots.

These microdots are exactly the same ones currently used for vehicle identification, with 18,000 officials already trained in their identification. The microdots are permanent, cannot be removed, and are resistant to burning, granulation, and being melting into ingots.

By permanently marking copper cables with these microdots, the risks associated with selling and stealing the cables become too high for scrap yards and thieves - because this technology makes effective prosecution and conviction possible. Scrap yards will refuse to purchase marked cable, significantly reducing the illegal copper resale market. Even the 250 containers of granulated copper leaving through Durban harbor for China and India each month will be identifiable, allowing for the prosecution of illegal exporters.

The road ahead

The move to net zero will require a great deal of copper - much more then we have now. We need to take drastic steps to protect our copper now.