Stop Guessing Cable Sizes: Learn the Professional Method
Most engineers learn cable sizing through trial and error. This course teaches a proven, step-by-step methodology based on SANS 10142 and IEC 60364, helping you size cables accurately, check voltage drop, apply derating factors, and produce professional engineering calculations with confidence.
Size Any Cable Correctly. Every Time. For Any Project.
Master the practical cable sizing methodology used on real-world mining, industrial, petrochemical, and infrastructure projects.
This comprehensive, tool-driven course teaches electrical engineers, technicians, technologists, and graduates how to confidently size LV and MV cables using a professional Excel calculator developed from industry best practices and aligned with SANS and IEC standards.
Move beyond academic theory and learn the complete engineering process—from load calculation and cable selection to documented, client-ready designs.
Many engineers learn cable sizing concepts at university but are left to develop practical skills on live projects, often through trial and error. This course bridges that gap by providing a proven, step-by-step methodology used by experienced electrical engineers in industry.
What You'll Learn
By the end of this course, you will be able to:
- Calculate cable current-carrying capacity using industry-standard design methods.
- Perform voltage drop calculations in accordance with IEC 60364 and SANS 10142 requirements.
- Apply derating factors correctly for ambient temperature, grouping, installation methods, and environmental conditions.
- Size cables for motors, including starting current considerations and protection coordination.
- Select the appropriate cable type and installation method for different applications and operating environments.
- Verify short-circuit withstand capability and protection device compliance.
- Produce professional cable schedules, calculations, and design documentation suitable for client and engineering review.
- Identify and correct undersized or oversized cables in existing installations and designs.
- Use a professional Excel Cable Sizing Calculator to complete projects faster and with greater accuracy.
- Apply the same cable sizing methodology across South African (SANS) and international (IEC) projects.
Who This Course Is For:
- Electrical Engineers
- Engineering Technologists
- Engineering Technicians
- Graduate Engineers
- EPC and Consulting Engineers
- Mining, Industrial, and Petrochemical Professionals
- Anyone involved in electrical design, construction, commissioning, or maintenance
By the end of the course, you'll have the confidence to size cables accurately, justify your design decisions, and deliver professional calculations that stand up to client, consultant, and regulatory review.
Example Curriculum
- Foundations of Cable Sizing
- Module 1 Learning Outcomes
- Why Cable Sizing Matters
- The 4 Critical Parameters
- LV vs MV — Voltage Levels in Practice
- Copper vs Aluminium — Choosing the Right Conductor
- Cable Insulation Types
- The Standards Behind the Calculator
- Reading the Calculator — Colour Coding System
- Short-Circuit Withstand Constants — Memorise These
- Your Calculator — 6 Sheets, One Workflow
- Module 1 Complete
- Inside the Excel Calculator
- Module 2 Learning Outcomes
- The Calculator: 8 Sections — A Through H
- Project Information
- Load Data — The Inputs That Drive Everything
- IFL and Istart — The Two Currents
- Cable Type Selection
- Derating Factors
- Cable Selection — Choose Size
- Voltage Drop Check
- Short-Circuit / Fault Current Check
- Results Summary — The Traffic-Light View
- The Pre-Loaded FAIL Scenario — Why It Fails
- The PRINT REPORT — Your Professional Deliverable
- Module 2 Formula Reference Card
- Module 2 Complete
- Step-by-Step Cable Sizing Workflow
- LEARNING OUTCOMES
- The 8-Step Cable Sizing Workflow
- Define Load Requirements
- Steps 2 & 3 — Set the Limits, Choose the Cable
- STEP 4 — Determine Derating Factors
- STEP 5 — Select Cable Size from Tables
- Steps 6 & 7 — Voltage Drop & Short-Circuit Checks
- STEP 8 — Compliance Review & Iteration
- WORKED EXAMPLE — 75 kW Motor Cable
- Engineering Judgement & Documentation
- Module 3 Summary
- What's Next in the Masterclass
- Where Most Engineers Make Costly Mistakes
- Module 4 Learning Outcomes
- Why Voltage Drop Matters — The Real-World Consequences
- THE FORMULA DISSECTED
- SANS 10142-1 — Voltage Drop Limits (Clause 5.3)
- THE FAIL SCENARIO
- Sensitivity Analysis — What Changes VD and By How Much?
- Upsize the Cable
- Solution 2: Add Parallel Cables (N > 1)
- Reduce the Cable Run — And the Three-Solution Comparison
- Starting Voltage Drop — The WARNING You Must Understand
- Verify the Calculator — Do the Maths by Hand
- The 6 Most Common Voltage Drop Mistakes
- QUICK ESTIMATION TOOL
- Real-World Scenarios — Where VD Failures Hurt Most
- Module 4 Complete
- Short-Circuit & Thermal Withstand
- What You Will Be Able to Do
- What Happens to a Cable During a Fault?
- PROSPECTIVE FAULT CURRENT
- WORKED EXAMPLE
- The K-Factor — What It Represents
- THERMAL WITHSTAND FORMULA
- WORKED EXAMPLE
- Effect of Clearing Time on Cable Withstand
- Using the Calculator: Section G Fault Current Check
- MV CABLE TABLES
- Three Mistakes That Cause FAIL Results
- What To Do Now — Hands-On Practice
- MODULE 5 SUMMARY
- Installation Methods & Derating
- What You'll Learn in Module 6
- Why Cables Are Derated
- The Six Derating Factors
- Solar Radiation — South African Context
- Cable Grouping — The Hidden Derating
- Combining Factors: F_total and Ir
- Calculator Section D — Derating Inputs
- LV Derating Quick Reference
- Practical Exercise — Your Turn
- Module 6 — Key Takeaways & Assessment
- Module 6 Complete
- Real-World Case Studies
- Module Purpose
- Learning Outcomes
- The 5 Case Studies at a Glance
- Case Study 1 — Industrial Motor
- Case Study 2 — Mining Long Run
- Case Study 3 — MV Substation Feeder
- Case Study 4 — Petrochemical Harsh Environment
- Case Study 5 — Aluminium Cable Sizing
- Calculator Focus — Which Check Controls the Cable?
- Practical Engineering Activities
- Resources & Downloadable Tools
- MODULE 7 — KEY TAKEAWAYS
- Common Mistakes & Design Pitfalls
- Module Purpose
- Learning Outcomes
- The 8 Mistakes at a Glance
- Mistake 1 — Ignoring Derating Factors
- Mistake 2 — Wrong K-Factor for SC Withstand
- Mistake 3 — Misreading Starting VD WARNING as a FAIL
- Mistakes 4 & 5 — Over-Design vs Under-Design
- Mistakes 6, 7 & 8 — Three Quick But Costly Errors
- Calculator Focus — Reading Section H Correctly
- Deep Dive — K-Factor Error Impact on SC Withstand
- 10-Point Design Review Checklist
- MODULE 8 — KEY TAKEAWAYS
- From Calculation to Design Documentation
- What This Module Is About
- Learning Outcomes
- The 6 Sections of a Cable Sizing Report
- PRINT REPORT Sheet Walkthrough
- The SANS Compliance Statement
- Revision Control for Engineering Calculations
- Engineering Justification Statements
- Registered Engineer Sign-Off
- Transmittal & Submission Process
- Document Control — File Naming & Version History
- Case Study: Mining Calculation Package
- Key Takeaways — Module 9
- MODULE 9 COMPLETE
- Optimising Cost, Quick Estimation & Red Flags
- Learning Outcomes
- Cable Cost Optimisation
- Copper vs Aluminium — When Does Al Make Sense?
- Parallel Cable Economics
- Rules of Thumb for Early Project Stages
- MV Cable Optimisation
- Cable Sizing Red Flags — Know When to Stop and Review
- AI & Automation in Cable Sizing
- Optimisation in Action — Calculator Exercise
- Key Takeaways
- What's Next — Capstone Project
- Full Industrial Panel Cable Sizing Exercise
- What This Module Is — and Is Not
- The Scenario: Highveld Mining Support Facility
- Every Cable Gets Three Checks
- Cable 01: 75 kW VSD Motor
- Cable 01: Key Calculations Walkthrough
- Cable 02: 22 kW DOL Motor — Buried Direct
- Cable 03: 15 kW Lighting Feeder — Conduit/Duct
- Cable 04: 100 kVA Sub-Feeder — 3 Cables Grouped
- Derating Factors: Quick Reference for This Project
- Assembling Your Calculation Package
- How Your Capstone Will Be Reviewed
- Five Common Capstone Mistakes
- Indicative Results — Use to Check Your Work
- You've Completed the Capstone Project
Meet Your Instructor
I'm M. Shezi, a consulting electrical engineer with 20 years of experience in industrial, commercial, and infrastructure electrical design. I've sized cables for projects ranging from 400V distribution systems to 11kV substations, motor control centres, and commercial buildings.
I created this course because most engineers learn cable sizing through trial and error. This course teaches the structured, practical methodology I wish I'd had when I started.
Testimonial
"This course transformed the way I approach cable sizing. Before taking it, I spent hours checking standards and tables. The calculator and step-by-step methodology gave me a clear process I can apply on every project."
— Pearl, Electrical Design Engineer
FAQ
Do I need prior experience with Excel? Basic familiarity is helpful, but the calculator is pre-built. You'll learn to use it — not build it.
Which standards does this course cover? SANS 10142-1, SANS 1507-3/4, SANS 97, and SANS 1339 — the core standards for LV and MV cable sizing in South African practice.
Is this course relevant outside South Africa? The SANS standards are South African, but the engineering principles — voltage drop, derating, short-circuit withstand — apply universally. If you work in Southern Africa or on projects aligned to IEC or similar standards, the methodology translates directly.
What do I need to get started? A computer with Microsoft Excel (2016 or later recommended) and a willingness to work through real engineering problems.
Can my team take this course? Corporate licensing options are available. Contact us directly for team pricing.
Do I need the SANS standards to follow this course?
No — the key clauses are explained and summarised in the course. Access to the standards is helpful but not required to complete the training.
Does the Calculator work on Mac?
Yes — it is an Excel file (.xlsx) compatible with both Windows and Mac versions of Microsoft Excel. It does not work in Google Sheets.
What level of engineering experience do I need?
The course starts from beginner level (Module 1 assumes no prior cable sizing knowledge) and builds to advanced. Graduates and junior engineers will benefit most, but experienced engineers will find the case studies and optimisation module valuable.
Will the calculator and tools be updated?
Yes — enrolled learners receive access to future updates of the Calculator v1.1 and all downloadable resources.
Is this course relevant outside South Africa?
Yes. While SANS 10142 is the South African standard, the methodology mirrors IEC 60364 which is used across Africa, Europe, and most of the world. The voltage drop and derating methods apply regardless of which standard governs your project.
Do I need to know advanced maths?
No. You need basic algebra — multiply, divide, square roots. Every formula is explained step by step with worked examples before you're asked to apply it.
I already know cable sizing basics. Is this too basic for me? The course starts from first principles but moves quickly into derating combinations, motor cable coordination, and professional documentation — areas where most self-taught engineers have gaps. The worked project examples alone are worth it.
What software or tools do I need?
None. All calculations are done manually in the course so you understand the method. If the Professional tier is available, you'll also receive a pre-built Excel calculator.
How is this different from reading the SANS standard myself? The standard tells you the rules. This course shows you how to apply them in sequence on a real project — which table to start with, how to combine derating factors, when to check voltage drop vs current rating first, and how to document the result professionally.
Is there a refund policy? Yes — 30-day money-back guarantee. No questions asked.
Ready to size cables with confidence?
Join electrical engineers across Africa who are applying these methods on real projects.
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