Electrical Insulation Mat IS 15652:2006 – Complete Safety Guide | SKJD India

Electrical insulation mats conforming to IS 15652:2006 are essential safety equipment designed to protect workers from electric shock in high-voltage environments. Electrical Insulation Mat IS 15652 At SKJD India (skjdindia.com), we provide premium quality electrical insulating mats that meet the stringent requirements of Indian safety standards, ensuring maximum protection for workers handling electrical installations across substations, control panels, and industrial facilities.​

Understanding IS 15652:2006 Standard for Electrical Insulation Mats

The IS 15652:2006 standard supersedes the older IS 5424:1969 specification and represents a significant advancement in electrical safety technology for industrial applications. This Indian Standard, developed by the Bureau of Indian Standards (BIS), establishes comprehensive specifications for insulating mats used as floor coverings to protect workers on AC and DC installations with system voltages up to 66 kV AC and 240 V DC. The standard aligns with international guidelines from IEC 61111-2002-06 “Matting of insulating materials for electrical purposes,” ensuring global compatibility and safety compliance.​

Classification of Electrical Insulation Mats

IS 15652:2006 categorizes insulating mats into four distinct classes based on their electrical characteristics and voltage ratings. Each class is specifically designed for different voltage applications to ensure optimal worker protection:​

Class A Insulation Mats

• Thickness: 2.0 mm (±10% tolerance)

• Maximum Use Voltage: 3.3 kV AC

• AC Proof Voltage: 10 kV

• Dielectric Strength: 30 kV

• Maximum Leakage Current: 10 mA

• Applications: Low voltage switchgear, control panels, and distribution boards​

Class B Insulation Mats

• Thickness: 2.5 mm (±10% tolerance)

• Maximum Use Voltage: 11 kV AC

• AC Proof Voltage: 22 kV

• Dielectric Strength: 45 kV

• Maximum Leakage Current: 10 mA Electrical Insulation Mat IS 15652

• Applications: Medium voltage panels and 11 kV installations​

Class C Insulation Mats

• Thickness: 3.0 mm (±10% tolerance)

• Maximum Use Voltage: 33 kV AC

• AC Proof Voltage: Higher than Class B

• Applications: High voltage electrical substations and 33 kV panels​

Class D Insulation Mats

• Thickness: 3.5 mm (±10% tolerance)

• Maximum Use Voltage: Up to 66 kV AC

• Applications: Extra high voltage installations and heavy-duty industrial applications​

Material Composition and Manufacturing Standards

Electrical insulation mats conforming to IS 15652:2006 are manufactured from high-grade elastomeric materials that exhibit exceptional dielectric properties. These mats are made from 100% virgin grade dielectric elastomer material, which is a generic term encompassing rubbers, latex, and elastomeric compounds that may be natural or synthetic, or a combination of both. The synthetic polymer blend ensures superior resistance to abrasion, moisture, oils, acids, and alkalis commonly found in industrial environments.​

Technical Specifications and Performance Requirements

Mechanical Properties

The IS 15652:2006 standard mandates specific mechanical properties for all mat classes:​

• Tensile Strength: Minimum 15 N/mm² for all thickness categories

• Elongation at Break: Minimum 250% for optimal flexibility and durability

• Surface Finish: Upper surface features small aberrations (rough surface without sharp edges) to prevent slippage, while the lower surface remains smooth or slip-resistant​

Electrical Properties

Every insulation mat must meet rigorous electrical performance criteria:​

• Insulation Resistance: Minimum 100,000 MΩ when measured with 5000V Megger or 1,000,000 MΩ with 500V Megger in wet conditions

• Leakage Current: Maximum 10 mA across all voltage classes

• Proof Voltage Test: Must withstand specified proof voltage for 3 minutes during type testing and 1 minute for routine testing without becoming appreciably warm Electrical Insulation Mat IS 15652​

Temperature Resistance

IS 15652 certified mats demonstrate excellent performance across extreme temperature ranges:​

• Normal Operating Temperature: -40°C to +55°C

• Low Temperature Resistance: Special category mats can withstand extreme cold conditions (-40°C ±3°C) without tears, breaks, or cracks when subjected to 100N force for 30 seconds

• Flame Retardance: Mats exhibit self-extinguishing properties and resistance to fire hazards​

Critical Applications and Use Cases

Industrial Substations and Switchyards

Electrical insulation mats are indispensable in high-voltage substations operating up to 66 kV AC systems. They create a protective barrier between workers and the ground, interrupting the electrical circuit path and preventing current flow through the human body during maintenance operations, equipment inspections, and emergency repairs.​

Transformer and Generator Rooms

In transformer rooms and generator facilities, insulation mats protect personnel from residual currents and ground faults. Industrial floors in these areas often become conductive due to moisture accumulation, chemical exposure, or dust particles, making insulation mats essential for worker safety.​

Control Panels and Distribution Boards

Workers operating HT/LT control panels, distribution boards, and bus bar systems require constant protection from electrical hazards. Insulation mats installed around these installations provide critical protection during routine operations, troubleshooting, and equipment maintenance.​

Workshop and Manufacturing Facilities

Assembly lines, maintenance workshops, and commercial spaces handling electrical equipment benefit significantly from strategically placed insulation mats. These mats create designated safe zones where electricians and technicians can work on live circuits with reduced risk of electrocution.​

Battery Rooms and Lift Machine Rooms

Battery charging areas and lift machine rooms present unique electrical hazards due to DC voltage systems. Insulation mats rated for DC applications up to 240V protect maintenance personnel working in these confined spaces.​

Safety Features and Protective Mechanisms

Primary Protection Against Electric Shock

The human body naturally conducts electricity, creating a dangerous pathway for current to flow from live circuits through the body to ground. Electrical insulation mats provide a high-resistance barrier that interrupts this pathway, blocking electric current from passing to ground and preventing potentially fatal electrocution.​

Slip Resistance and Surface Design

The textured upper surface of IS 15652 compliant mats incorporates small aberrations that prevent slipping while ensuring smooth trolley and equipment movement. This dual-functionality design maintains worker safety without impeding operational efficiency in busy industrial environments.​

Chemical and Oil Resistance

Premium quality insulation mats demonstrate exceptional resistance to transformer oil, diesel, acids, and alkalis commonly present in electrical installations. This chemical resistance ensures long-term performance and prevents degradation of dielectric properties even in harsh industrial conditions. Electrical Insulation Mat IS 15652​

Moisture-Proof Construction

IS 15652 certified mats maintain their insulating properties even in wet conditions, as verified through mandatory insulation resistance testing with tap water. This moisture-proof characteristic is critical in high-humidity environments and areas prone to water accumulation.​

Installation Guidelines and Best Practices

Permanent Installation Method

For maximum practical safety in adverse working conditions, insulation mats should be permanently bonded to the floor using suitable adhesives or resins that maintain stability between -40°C and +55°C. All joints and corners must be filled with insulating material of matching color, and matching colored tape should cover seams to maintain both safety and aesthetic appearance.​

Roll Dimensions and Coverage

IS 15652 recommends mats in roll format with standard dimensions of 1000 mm width and multiple lengths of 5000 mm to minimize joints and maximize continuous coverage. However, specific shapes in lengths of 1000 mm, 2000 mm, and 3000 mm can be ordered based on installation requirements.​

Floor Preparation Requirements

Before installation, porous floors should be treated with waterproofing compounds to protect the mat’s insulating and electrical properties. This preparation ensures optimal performance and extends mat lifespan by preventing moisture migration from the substrate.​

Joint Welding Technique

Butt joints between mat sections can be welded using the thermo-fusion method as per IS 8002. This technique involves making a “V” groove cut at the joint location, which is then thermally fused to create a seamless, electrically continuous surface.​

Maintenance and Inspection Protocols

Storage Recommendations

Insulation mats should be stored in their original containers or packaging, ensuring they are not compressed, folded, or exposed to direct sunlight, artificial light, or ozone sources. Optimal storage temperature ranges between 10°C and 21°C, away from steam pipes, radiators, or other heat sources.​

Pre-Use Visual Inspection

Before deployment, each mat must undergo thorough visual inspection of both top and bottom surfaces, accompanied by verification of type test reports from accredited laboratories. Any mat showing apparent damage or safety concerns should not be used and must be returned for testing.​

Periodic Cleaning Protocol

Mats should be washed periodically with soap and water at temperatures not exceeding the recommended operating temperature. Contact with petrol, paraffin, white spirit, and strong acids or alkalis must be avoided to prevent material degradation. Coal dust, cement particles, and paint marks should be removed immediately to maintain optimal performance.​

Service Life and Annual Inspection

Under normal indoor working conditions, IS 15652 compliant mats typically provide 10-15 years of reliable service unless visibly damaged through abnormal use. Annual visual inspections are recommended to identify potential issues including pinholes, cracks, blisters, cuts, conductive embedded foreign matter, creases, pinch marks, voids, and prominent ripples.​

BIS Certification and Quality Compliance

Mandatory ISI Marking Requirements

All insulating mats for electrical purposes fall under the mandatory ISI certification scheme governed by IS 15652:2006. Every roll or flat mat must be clearly marked with class designation, lot number, roll number, and manufacturer’s identity. Products may also display the Standard Mark indicating BIS certification compliance.​

Type Testing and Sampling Procedures

The standard establishes comprehensive testing protocols including type tests, sampling tests, and routine tests to ensure consistent quality. Type tests verify fundamental material properties and electrical characteristics, while sampling procedures follow specific plans based on lot size to detect both major and minor defects.​

Acceptance Testing Criteria

Acceptance testing evaluates critical parameters including tensile strength, elongation at break, insulation resistance, leakage current, dielectric strength, AC proof voltage, aging resistance, flame retardance, and low-temperature performance. Each parameter must meet or exceed specified minimum values for the mat to receive certification.​

Regulatory Compliance and Workplace Safety

OSHA and Safety Standard Adherence

Electrical insulation mats are key components of personal protective equipment (PPE) mandated by regulatory bodies worldwide. Using certified mats helps facilities maintain compliance with occupational safety regulations, avoid substantial fines, and protect against legal liability arising from workplace electrical incidents.​

Risk Mitigation in High-Voltage Environments

Electric shocks can result in severe injuries or fatalities in any work environment, particularly in high-voltage areas. Industrial floors often carry residual current or become conductive due to moisture, chemicals, or dust, making insulation mats an essential protective barrier against electrocution hazards.​

Why Choose SKJD India for Electrical Insulation Mats

SKJD India (skjdindia.com) specializes in providing high-quality electrical safety products including IS 15652:2006 certified insulation mats for diverse industrial applications. Our comprehensive product range addresses the safety needs of electrical substations, manufacturing facilities, commercial installations, and industrial complexes throughout India.​

Quality Assurance and Certification

All SKJD India electrical insulation mats undergo rigorous quality testing and carry proper BIS certification with manufacturer’s test reports. Our commitment to quality ensures that every mat meets or exceeds the stringent requirements of IS 15652:2006 for mechanical strength, electrical performance, and environmental resistance.​

Customization and Technical Support

Understanding that different installations have unique requirements, SKJD India offers customized mat dimensions, thickness options, and voltage class selections. Our technical team provides expert guidance on mat selection, installation methods, and maintenance protocols to ensure optimal safety performance.​

Comprehensive Product Portfolio

Beyond electrical insulation mats, SKJD India supplies a complete range of industrial safety and engineering materials including rubber sheets, polyurethane rods, engineering plastic rods, PTFE rods, packaging sheets, and fiberglass epoxy sheets. This comprehensive portfolio allows customers to source multiple safety products from a single trusted supplier.​

Conclusion: Investing in Electrical Safety Excellence

Electrical insulation mats conforming to IS 15652:2006 represent a critical investment in workplace safety and regulatory compliance. These specialized floor coverings provide reliable protection against electrical shock hazards, ensuring that workers can perform their duties in high-voltage environments with confidence and security. By choosing SKJD India as your supplier of certified electrical insulation mats, you partner with a company committed to delivering superior quality, comprehensive technical support, and unwavering dedication to workplace safety standards.​

For more information about our electrical insulation mats and complete range of industrial safety products, visit skjdindia.com or contact our technical sales team to discuss your specific application requirements. Electrical Insulation Mat IS 15652