Trafo Power Solutions’ early involvement in exploration and mining projects is helping operations avoid one of the industry’s most persistent challenges – electrical infrastructure that becomes inadequate as mines expand or evolve.

Speaking to Mining Weekly, Trafo Power Solutions MD David Claassen emphasises that far too many electrical systems are designed only for a mine’s immediate requirements, which is a short-term view that often results in costly redesigns, operational disruption and unnecessary capital expenditure as the project grows.

According to Claassen, electrical infrastructure is frequently constrained by early project assumptions. Once production ramps up or once the mine plan shifts to deeper levels or new orebodies, load demands can increase significantly.

“For almost a decade, we have focused on working with customers from the earliest concept stages to ensure their power infrastructure supports long-term growth.

“Our philosophy is about understanding the bigger picture, not simply responding to a list of equipment,” he says.

Engaging at concept and prefeasibility stage allows Trafo Power Solutions to unpack how, where and under what conditions transformers and substations will operate. This includes ventilation, ambient temperature, dust levels, mobility requirements, environmental factors and the degree to which equipment may need to be moved as the operation develops.

By integrating these variables early on, the company enables mines to anticipate future scenarios rather than become constrained by short-term design decisions.

Claassen explains that Trafo Power Solutions often provides guidance long before a formal feasibility study starts.

The company’s tender and proposals department is geared to give quick realistic budget numbers, allowing engineers and mine planners to weigh up different configurations and technologies upfront.

“We draw on a large and diverse database of past projects to ensure early estimates remain aligned with what customers see later at tender stage. This consistency is one of the reasons the market trusts us,” he says.

This consultative lifecycle- driven approach is particularly important given that transformers and substations typically operate for 20 to 30 years.

When early planning is neglected, infrastructure may need to be replaced or heavily modified just a few years into production.

Claassen notes that seemingly minor oversights, such as a modular substation base not designed for repeated relocations, can translate into significant costs down the line.

“If future expansion isn’t considered, you may find the equipment wasn’t designed to be moved or adapted. Two years later, when relocation is necessary, you suddenly face additional reinforcement work or equipment upgrades. Early planning prevents these headaches,” he points out.

A recent project in the Demo-cratic Republic of Congo highlights Trafo Power Solutions’ forward-thinking approach. Although this mine initially issued an enquiry strictly for surface-mounted miniature substations, Trafo Power Solutions recognised that substantial underground development was planned for later phases.

Drawing on its experience in similar environments, the company recommended a dual-purpose design that would suit both surface and underground applications.

“This gave the mine considerable flexibility,” says Claassen, adding that when underground demand materialised, the mine already had units capable of operating safely and reliably in those harsher conditions, without going out to tender again or incurring additional design and manufacturing lead times.

“By prioritising early engagement and designing with future expansion firmly in mind, we help mining operations reduce risk, improve cost predictability and build long-term resilience into their electrical infrastructure,” he concludes.