Silicone Composite Insulators

Single-piece silicone composite insulators for 36 kV overhead lines: K1 (40 kN) and K2 (100 kN) for suspension and tension strings, VHD-35 for conductor support. Lighter than porcelain and glass, not brittle, and the hydrophobic surface keeps insulating in polluted environments.

STRUCTURE & MATERIALS

Three materials, one body

In a composite insulator the glass-fibre rod carries the mechanical load, the silicone housing protects the rod and forms the creepage path, and forged steel fittings transfer the load to the line and cross-arm.

HTV silicone rubber housing and sheds

The hydrophobic surface keeps water in droplets and transfers this property to the pollution layer; resistant to UV and ozone. Tracking and erosion resistance is verified by the IEC 62217 salt-fog test.

ECR glass-fibre reinforced rod

Boron-free ECR glass resists acid-induced brittle fracture. Rod material passes water diffusion and dye penetration tests.

Forged steel end fittings

Hot-dip galvanised (ISO 1461) steel fittings. VHD-35 uses forged instead of cast steel, as required by TEDAŞ-MLZ/2017-067.

Sealing interface

Design preventing moisture ingress where the fitting meets the housing; interface and connection tests per IEC 62217.

STRING INSULATOR · K1

40 kN Silicone Composite Suspension & Tension Insulator

40 kN / 11B · Ball–socket coupling

Single-piece composite insulator replacing porcelain and glass disc strings on MV distribution lines. Used at suspension and tension positions; corresponds to TEDAŞ type 40 kN / 11B.

TECHNICAL DATA

Highest system voltage, Um	36 kV
Specified mechanical load, SML	40 kN
Routine test load, RTL (50% SML, 10 s)	20 kN
Coupling	Ball–socket 11 · IEC 60120
Nominal creepage distance	≥ 900 mm
Specific creepage · pollution level	25 mm/kV · III (Heavy)
Insulation level (Um 36 kV)	70 kV PF · 170 kV LI
Housing · rod · fittings	HTV silicone · ECR · HDG steel

Lighter than porcelain and glass strings; easier handling and installation
Non-puncturable body; not brittle, resistant to impact and vandalism
50% SML mechanical routine test on every unit

IEC 61109
IEC 62217
IEC 60120
IEC 60815-3

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STRING INSULATOR · K2

100 kN Silicone Composite Suspension & Tension Insulator

100 kN / 16B · Ball–socket coupling

Single-piece composite insulator for suspension and tension positions with high mechanical loads. Suitable for large conductors and long spans; corresponds to TEDAŞ type 100 kN / 16B.

TECHNICAL DATA

Highest system voltage, Um	36 kV
Specified mechanical load, SML	100 kN
Routine test load, RTL (50% SML, 10 s)	50 kN
Coupling	Ball–socket 16 · IEC 60120
Nominal creepage distance	≥ 900 mm
Specific creepage · pollution level	25 mm/kV · III (Heavy)
Insulation level (Um 36 kV)	70 kV PF · 170 kV LI
Housing · rod · fittings	HTV silicone · ECR · HDG steel

100 kN mechanical strength for large conductors and long spans
Non-puncturable body; not brittle, resistant to impact and vandalism
50% SML (50 kN) mechanical routine test on every unit

IEC 61109
IEC 62217
IEC 60120
IEC 60815-3

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LINE POST INSULATOR

VHD-35 Silicone Composite Line Post Insulator

Model KNX-36LP-R8 · TEDAŞ type R 8 ET 200 L

Line post insulator supporting the conductor on the cross-arm of 36 kV overhead lines. An original KNAOS design developed to TEDAŞ-MLZ/2017-067 and IEC 61952.

TECHNICAL DATA

Highest system voltage, Um	36 kV
Specified cantilever load, SCL	8 kN
Lightning impulse withstand, 1.2/50 µs	200 kV peak
Power-frequency withstand voltage	80 kV
Nominal creepage distance	1.215 mm
Specific creepage · pollution level	33.75 mm/kV · IV (Very heavy)
Shed profile	13 sheds · 7 large + 6 small
Rod	Ø38 mm ECR glass fibre
End fittings	Forged steel · HDG

Forged steel fittings per TEDAŞ specification; no cast iron
Alternating shed profile: long creepage in a short length
Dimensioned drawing and design report available on request

IEC 61952
IEC 62217
IEC 60815-3
TEDAŞ-MLZ/2017-067

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COMPARISON

Three insulators, side by side

Property	K1 · 40 kN	K2 · 100 kN	VHD-35
Type	Suspension / tension string	Suspension / tension string	Line post
Um	36 kV	36 kV	36 kV
Mechanical rating	SML 40 kN	SML 100 kN	SCL 8 kN
Routine test load	20 kN	50 kN	Per IEC 61952
Nominal creepage	≥ 900 mm	≥ 900 mm	1.215 mm
Pollution level	III · Heavy	III · Heavy	IV · Very heavy
Fittings	Ball–socket 11, HDG steel	Ball–socket 16, HDG steel	Forged steel, HDG
Product standard	IEC 61109	IEC 61109	IEC 61952 · TEDAŞ-MLZ/2017-067

TEST PROGRAMME

Four-stage verification from design to shipment

Stage	Standard	Scope
Design tests	IEC 62217	Interface and connection tests, 1000 h salt fog (tracking and erosion), flammability, rod water diffusion and dye penetration
Type tests	IEC 61109 · IEC 61952	Dry lightning impulse and wet power-frequency withstand tests; damage limit and interface sealing verification
Sample tests	IEC 61109 · IEC 61952 · ISO 1461	Dimensional check, locking system check, galvanising thickness, SML or SCL verification
Routine tests	IEC 61109 · IEC 61952	Mechanical routine test and visual inspection on every unit